Tanda-II Specification - Technical

NTPC Limited NTPC Limited
NTPC Limited NTPC Limited NTPC Limited

(A Government of India Enterprise)
TANDA THERMAL POWER PROJECT
STAGE-II (2X660 MW)
P PP PPAR AR AR AR ART - T - T - T - T - A AA AA
SECTION - VI
TECHNICAL SPECIFICATION
FOR
STEAM TURBINE GENERATOR PACKAGE
BIDDING DOCUMENT NO. : CS-9562-110-2
STAGE-II (2X660 MW)
P PP PPAR AR AR AR ART - T - T - T - T - A AA AA
SECTION - VI
FOR
(This document is meant for the exclusive purpose of bidding against this
Package and shall not be transferred, reproduced or otherwise used for
purposes other than that for which it is specifically issued).
SECTION-VI
STAGE - II (2X660 MW)
TABLE OF CONTENTS
PART SECTION NO. TITLE
SCOPE OF SUPPLY & SERVICES
A Project Synopsis
A A-1 Provenness
A Essential Data
A Phased Manufacturing Program
A A-2 General
A A-3 Turbine Generator and Auxiliaries
A A-4 Equipment Cooling Water System
A A-5 Condensate Polishing Unit
A A-6 Low Pressure Piping System
A A-7 (NOT USED)
A A-8 Hydrogen Generation Plant
A A-9 Service Elevators
A A-10 Power Cycle Piping
A A-11 Other Cranes and Hoists
A B-1 Electrical System/Equipment
A IIC-01 Control and Instrumentation System
A D-1 Civil Works
A Terminal Points & Exclusions
A Functional Guarantees & Liquidated Damages
A Spares
TECHNICAL REQUIREMENTS
MECHANICAL
B A-1 Operating Capability of Plant
B A-2 Layout
B A-3 Turbine Generator and Auxiliaries
SECTION-VI
B A-4 Equipment Cooling Water System
A A-5 Condensate Polishing Plant
B A-6 Low Pressure Piping System
B A-7 (NOT USED)
B A-8 Hydrogen Generation Plant
B A-9 Service Elevators
B A-10 Power Cycle Piping
B A-11 Other Cranes and Hoists
ELECTRICAL
B B-1 Generator and Auxiliaries
B B-2 Motors
B B-3 L.T. Power Cables
B B-4 L.T. Control Cables
B B-5 Cabling Earthing Lighting and Protection
B B-6 Electric Actuators with Integral Straters
B B-7 Lighting
B B-8 L.T. Switchgear
CONTROL & INSTRUMENTATION (C&I)
B IIIC-01 Basic Design Criteria
B IIIC-02 Distributed Digital Control, Monitoring & Information System
(DDCMIS)
B IIIC-03 Main Equipment Related Control and Instrumentation System
B IIIC-04 Measuring Instruments (Primary and Secondary)
B IIIC-05 Electrical Power Supply System
B IIIC-06 Process Connection and Piping
SECTION-VI
B IIIC-07 Instrumentation and Power Supply Cable
B IIIC-08 Control Valve and Actuators
B IIIC-09 Plant Auxiliary System
B IIIC-10 Type Test Requirements
CIVIL
B D-1 Civil Works
QUALITY INSURANCE (QA)
B E-1 Steam Turbine Generator & Auxiliaries
B E-2 Condenser on Line Tube Cleaning System
B E-3 Condensate Extraction Pump
B E-4 Power Cycle Heaters & De-aerator
B E-5 Boiler Feed Pump
B E-6 Turbine Hall EOT Crane
B E-7 Equipment Cooling Water System
B E-8 Condensate Polishing Unit
B E-9 Low Pressure Piping System
B E-10 (NOT USED)
B E-11 Hydrogen Generation Plant
B E-12 Service Elevators
B E-13 Power Cycle Piping
B E-14 Other Cranes and Hoists
B E-15 Generator and Auxiliaries
B E-16 Motors
B E-17 LT Switchgear
SECTION-VI
B E-18 LT Power Cables
B E-19 LT Control Cables
B E-20 Cabling
B E-21 Lighting
B E-22 Passenger/Service Elevators & Lifts
B E-23 Distributed Digital Control, Monitoring & Information System (DDCMIS)
B E-24 Main Equipment Related Control and Instrumentation System
B E-25 Measuring Instruments (Primary and Secondary)
B E-26 Power Supply System
B E-27 Process Connection and Piping
B E-28 Instrumentation Cables
B E-29 Control Valves
B E-30 Electrical Actuators
B E-31 Auxiliaries Plant Control
B Pre-Commissioning and Commissioning
C GENERAL TECHNICAL REQUIREMENT
D ERECTION CONDITIONS OF CONTRACT
E TENDER DRAWING
F NOT USED
G TECHNICAL DATA SHEET
SECTION-VI
PART - A
PART - A
SECTION-VI
PART - A
CONTENTS
PART - A
A PROJ ECT INFORMATION
A A-1 PROVENNESS
A ESSENTIAL DATA
A PHASED MANUFACTURING PROGRAM
A A-2 GENERAL
A A-3 TURBINE GENERATOR AND AUXILIARIES
A A-4 EQUIPMENT COOLING WATER SYSTEM
A A-5 CONDENSATE POLISHING UNIT
A A-6 LOW PRESSURE PIPING SYSTEM
A A-7 AIR COMPRESSORS (NOT USED)
A A-8 HYDROGEN GENERATION PLANT
A A-9 SERVICE ELEVATORS
A A-10 POWER CYCLE PIPING
A A-11 OTHER CRANES AND HOISTS
A B-1 ELECTRICAL SYSTEM/EQUIPMENT
A IIC-01 CONTROL AND INSTRUMENTATION SYSTEM
A D-1 CIVIL WORKS
A TERMINAL POINTS & EXCLUSIONS
A FUNCTIONAL GUARANTEES & LIQUIDATED DAMAGES
A MANDATORY SPARES
SECTION-VI
PART - A
PROJECT INFORMATION

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PROJECT SYNOPSIS

STAGE-II (2X660 MW)
SECTION-VI
PART- A
PROJECT SYNOPSIS PAGE 1 OF 9

INTRODUCTION
1.00.00 BACKGROUND

Tanda Thermal Power Project (Tanda TPP), Stage-II is being set up as a regional
power project for the benefit of States/UTs of Northern Region. The Stage-I (4x110
MW) of the project is under commercial operation and the Stage-II shall be a mega
project comprising of two units of 660 MW each.

1.01.00 LOCATION AND APPR0ACH

The site is located on the right bank of Main Tanda Canal near Bahadurpur village in
Ambedkar Nagar District of Utter Pradesh having latitude and longitude of 26
0
35'
30" N and 82
o
47' 35" 40 E respectively. The site is approachable from Tanda -
Faizabad State Highway. Nearest railway station Akbarpur is at a distance of 20 kms
on Faizabad-Shahganj section of Northern Central railways. The nearest airport at
Lucknow is at a distance of about 240 Kms from the project site.
Vicinity Plan is enclosed as Annexure A-I

1.02.00 Land

About 700 acres of additional land (175 acres for main plant and 525 acres for ash
disposal) is required for Stage-II (2x660 MW) of the project. In-principle land
availability clearance has been obtained from Govt. of Uttar Pradesh vide dated
06.12.07

1.03.00 Water

The make-up water requirement is estimated as 65 Cusecs for 2x660 MW. Govt. of
Uttar Pradesh vide dated 20.08.07 has given water availability commitment of 65
Cusecs of water from Tanda Pump Canal on Saryu river.

1.04.00 Capacity

Stage-I : 4 x 110 MW - Under commercial operation

Stage-II
: 2 x 660 MW - Present proposal

1.05.00 Meteorological data

Important meteorological data from nearest observatory at Faizabad is placed at
Annexure-A-II.

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STAGE-II (2X660 MW)
SECTION-VI
PART- A

1.06.00 Plant Water Scheme

The Plant water scheme is described below.

1.06.01 Condenser Cooling (CW) Water System

It is proposed to provide recirculating type CW system with induced draft type
cooling towers. For the recirculating type CW system it is proposed to supply
clarified water as make up. Raw water from the make-up water pump house shall be
pumped to a Water Pretreatment Plant (PT - CW system). The treated clarified
water shall be led to the cold water channel of CW system. CW system shall be
operated at a C.O.C of about 4.0. Chemical treatment programme (using acid dosing
and scale cum corrosion inhibitors dosing) may be employed in addition to blow
down of CW water to control the CW system chemistry in case CW system is
required to be operated beyond 4.0 COC. The expected circulating water analysis is
given in this sub-section. CW blow down shall be drawn from the discharge of CW
pumps and the same shall be led to a Service water Tank. For carrying circulating
water from CW pump house to TG-area and from TG area to cooling tower, steel
lined concrete encased duct would be provided. For interconnecting CW duct with
CW pump, condenser and cooling towers, steel pipes would be used. Cooled water
from cooling tower will be led to CW pump house through the cold water channel by
gravity.

1.06.02 Equipment Cooling Water (ECW) System (Unit Auxiliaries)

The plant auxiliaries of Steam Generator and Turbine Generator shall be cooled by
Demineralised (DM) water in a closed circuit. The primary circuit DM water shall be
cooled through plate type heat exchangers by Circulating Water tapped from CW
system in a closed secondary circuit. The hot secondary circuit cooling water shall
be cooled in the cooling towers and shall be returned back to the system. It is
proposed to provide independent primary cooling water circuit for Steam Generator
& auxiliaries and TG & its auxiliaries.

1.06.03 Station Auxiliaries Cooling Water System

The station auxiliaries such as Air compressors, Compressors of ash handling plant,
Cooling water circuit of Air Conditioning system, compressor of mill reject system
etc. shall be cooled by separate cooling water System using separate set of pumps
and cooling towers.

1.06.04 Ash Water System

a) It is proposed to operate ash water system in a closed circuit. The ash water
from the ash dyke shall be recirculated after treating a part of the quantity in
a side stream lime softening plant as the case may be. Make up to the ash

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PROJECT SYNOPSIS

STAGE-II (2X660 MW)
SECTION-VI
PART- A

water system (to compensate for the ash water system blow down and
evaporation loss in ash dyke) shall be supplied from excess CW blow down
water (Service water) and raw water supply from water source of the plant. In
addition, provision shall be kept to supply treated water from Central
Monitoring Basin of Liquid Effluent Treatment Plant.

1.06.05 Other Miscellaneous Water Systems

a) CW system blow down water shall be used for the plant service water
requirement, dust suppression system of coal handling plant, makeup to the
Ventilation system, ash slurry pumps sealing, sealing of Vacuum pumps (if
applicable) of Ash Handling plant, make-up to fire water storage tanks and
cooling water requirement of hydrogen generation plant. The service (wash
water) water collected from various areas shall be treated using oil water
separators, tube settlers, coal settling pits etc. as per requirement and
treated water from liquid effluent treatment plant shall be recycled back to the
service water system for re-use. The excess service water shall be led to
central monitoring basin for disposal.

b) Separate water Pre-treatment plants are proposed for Circulating Water (PT-
CW) system, Demineralisation Plant (PT-DM) plant and potable (PT-Pot)
water systems.

c) The drinking water requirement of the plant and colony shall be provided
from the above mentioned Water (PT-Pot ) pretreatment plant.

d) Steam Cycle make-up water, makeup to the primary circuit of ECW (unit
auxiliaries) system, boiler fill water and makeup to the hydrogen generation
plant shall be provided from Demineralising plant.

e) The quality of cooling water & DM water is given in this sub-section at
Annexure-A-III.

1.07.00 Criteria for Earthquake Resistant Design of Structures and Equipment

All power plant structures and equipment, including plant auxiliary structures and
equipment shall be designed as per the criteria specified in sub-section-D1 of
Section-VI (Part-A).

In case the acceleration criteria considered by the Bidder for the design of
anchorage bolts of Steam Turbine and Generator with TG Deck in his bid is different
with respect to above criteria, he shall indicate the same in his bid. The same will be
discussed with the Bidder and finalized considering the following:

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PROJECT SYNOPSIS

STAGE-II (2X660 MW)
SECTION-VI
PART- A

a) The earthquake design acceleration for the steam turbine and generator
acting at the centre of gravity depends upon the layout/configuration/size of
TG deck supporting columns and beams which are to be jointly decided by
NTPC and the bidder.

b) As the data regarding Foundation GA & loading data to be furnished by
Bidder may not be available at tender stage, the acceleration criteria
proposed by the bidder can not be confirmed for acceptance at the award
stage. The same can be confirmed after jointly finalizing the TG substructure
arrangement by NTPC and Bidder.

c) TG deck acceleration values will be limited to the design values adopted by
Bidder by suitably increasing the size of the TG supporting columns/beams
during detailed engineering.

Accordingly Bidder has to make equipment/piping layout clearing the TG
column/beams.

1.08.00 Criteria for Wind Resistant Design of Structures and Equipment

All structures and equipment of the power plant, including plant auxiliary structures
and equipment, shall be designed for wind forces as given as given in sub-section-
D1 of Section-VI (Part-A).

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STAGE-II (2X660 MW)
SECTION-VI
PART- A

ANNEXUREA-I

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STAGE-II (2X660 MW)
SECTION-VI
PART- A

ANNEXURE-A-II
PAGE 1 OF 2

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STAGE-II (2X660 MW)
SECTION-VI
PART- A

ANNEXURE-A-II
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STAGE-II (2X660 MW)
SECTION-VI
PART- A

ANNEXURE-A-III
COOLING WATER ANALYSIS

Sl. Constituent as mg per litre
No.

1. Calcium CaCO
3 105

2. Magnesium CaCO
3

46

3. Sodium CaCO
3

54

4. Potassium CaCO
3

12

5. Total Cations CaCO
3

217

6. Total Alkalinity CaCO
3

159

7. P-Alkalinity CaCO
3

Nil

8. Chloride CaCO
3

28

9. Sulphate CaCO
3

30

9. Total Anions CaCO
3

217

11. Silica (Reactive) SiO
2
0.01

12. Iron
Fe 0.3 mg/l

13. pH Value -
6.8 - 8.0

14. Turbidity NTU
10

Note : The C.W system is expected to operate at about 4.0 Cycles of
Concentration. As CW blow down water (Service Water) is tapped from
discharge of CW pumps, the water quality of CW Blow down water shall be
same as that above.

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PROJECT SYNOPSIS

STAGE-II (2X660 MW)
SECTION-VI
PART- A

ANNEXURE A-III

ANALYSIS OF DM WATER TO BE USED FOR
MAKE-UP WATER TO CONDENSER

Sl.No. Characteristics Value

1. Silica (Max.) 0.02 ppm as Sio2

2. Iron as Fe Nil

3. Total hardness Nil

4. pH value 6.8 -7.2

5. Conductivity Not more than 0.1micro mho/cm
excluding the effects of free CO2

SECTION-VI
PART - A
A - 1
PROVENNESS
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STAGE-II (2X660 MW)
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PART-A
A-1
PROVENNESS

PAGE
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1.0 Provenness of Turbine Set
(a) The turbine set offered shall be built up using proven modules of HP, IP and
LP turbines of the Qualified Steam Turbine Generator Manufacturer which
are in successful operation for at least one year as on the date of bid
opening. The HP turbine module offered should necessarily have operated
with supercritical steam parameters. Bidder shall furnish experience list of
individual modules offered to substantiate their provenness.
(b) The turbine to be supplied under this contract shall be manufactured,
assembled and tested in a factory where turbines of at least 500MW rating
have been manufactured in the past. Alternatively the same can also be
manufactured in the Indian Manufacturing Company under supervision of
Qualified Steam Turbine Generator Manufacturer.
2.0 Provenness of Generator
a) The generator offered shall be of proven design of the Qualified Generator
Manufacturer, of 660 MW or above rating, which is in successful operation for
a minimum period of one (1) year as on the date of bid opening.
b) The offered generator shall be similar in design and construction to the above
proven generator in respect of:
i. Cooling medium (e.g. water, Hydrogen etc) and number of shaft
mounted fans.
ii. Thermal Class of Insulation for stator and rotor windings.
iii. Core support system (e.g. spring type, rigid type etc)
iv. Type of excitation system
c) The generator to be supplied under this contract shall be manufactured,
assembled and tested in a factory where generator of at least 500MW rating
have been manufactured in the past. Alternatively the same can also be
manufactured in the Indian Manufacturing Company under supervision of
Qualified Generator Manufacturer.
3.0 Architect Engineering Firm
a) If the bidder himself has not carried out Engineering of at least one (1) no. of
fossil fuel fired reheat type steam turbine generator package, with minimum
unit rating of 500 MW, consisting of steam turbine generator sets along with
regenerative heating and pumping system which is in successful operation
for a period of not less than one (1) year as on the date of bid opening, the
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PROVENNESS

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Bidder shall get the engineering of the steam turbine generator package
done by the Qualified Steam Turbine Generator Manufacturer.
b) As an alternative to (a) above, the bidder shall employ an architect
engineering firm who is currently in the field of engineering fossil fuel fired
plants and has engineered at least one (1) no. of fossil fuel fired plant with
minimum capacity of 500MW, which is in successful operation for a period of
not less than one (1) year as on the date of bid opening. However, in such a
case, the Bidder shall get the basic engineering documents (schematics,
sizing calculations and equipment selection) prepared by such architect
engineering firm vetted either by the Qualified Steam Turbine Generator
Manufacturer or by another architect engineering firm who fully meets the
requirements stipulated at (a) above.
4.0 Provenness criteria for critical equipment(s) and bought out items
4.1 The Bidder / his sub-vendor(s) is required to meet the provenness criteria and / or
qualification requirement for critical equipment, auxiliaries, systems and bought out
items as per criteria stipulated below:
Condenser, Condensate Extraction Pumps (CEP), Condenser air evacuation pump,
Feed Water Low Pressure Heaters, Feed water High Pressure Heaters, Deaerator,
Boiler Feed Pumps (BFP), HP Bypass system, LP Bypass system and BFP Motor
offered by the Bidder shall be only from such manufacturer(s) who has previously
manufactured / got manufactured the respective equipment(s) of the type and
minimum equipment rating as stipulated below such that the respective
equipment(s) are in successful operation in at least one (1) plant for a period not
less than one (1) year as on the date of bid opening.
Sl.
No
Name of
equipment
Type of equipment Equipment rating
a) Condenser Surface type water cooled for
steam turbine generator sets
Condenser of a 500 MW
or higher size unit
b) Condensate
Extraction
Pumps (CEP)
Vertical, cannister with
double suction first stage
impeller for steam turbine
generator sets
Capacity not less than
900 Ton/ hr and total
developed Head not less
than 30 Kg/cm
2

Or
770 Ton/ hr (in case drip
pumps are used) and total
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PROVENNESS

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Sl.
No
Name of
equipment
Type of equipment Equipment rating
than 30 Kg/cm
2

c) Condenser Air
Evacuation
Pump
Liquid ring type for steam
turbine generator sets
Free dry air capacity
30SCFM at 1 of Hg (abs)
at 21.1 deg C.
d) Feed Water
Low Pressure
Heaters
Horizontal, U-tube type
having condensing and drain
cooling zones for steam
Feed Water Low Pressure
Heater of a 500 MW or
higher size unit
e) Feed water
High Pressure
Heaters
Horizontal, U-tube type
having integral
desuperheating, condensing
and drain cooling zones for
supercritical steam turbine
generator sets
800 Ton/ hour for each
string.
f) Deaerator Horizontal, direct contact,
spray or spray cum tray
design for steam turbine
generator sets
Deaerator of a 500 MW or
higher size unit
g) Boiler Feed
Pumps (BFP)
Horizontal, centrifugal,
multistage, outer casing
barrel type with end rotor
removal for supercritical
steam turbine generator sets
1100 Ton/ hr and total
than 320 Kg/cm
2

h) HP Bypass
system
HP Bypass system for
supercritical steam turbine
generator sets
Capacity of each valve
not less than 650 Ton/hr
at rated steam
parameters (i.e. pressure
& temperature)
i) LP Bypass
system
LP Bypass system for steam
Capacity of each valve
not less than 650 Ton/hr
at rated steam
parameters (i.e. pressure
& temperature)
j) BFP Motor Squirrel cage induction motor At least 10 MW.
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4.2 In case the Bidder or the proposed sub-vendor(s) is not manufacturer of proven
equipment(s) as per clause 4.1 above but is a regular manufacturer for such
equipment(s) for units of at least 200 MW rating, the Bidder or the proposed sub
vendor(s) can manufacture such equipment(s) for 660 MW supercritical units also
provided he has collaboration or valid licensing agreement for design, engineering,
manufacturing, supply of such equipment(s) in India with such manufacturer(s) who
meet the requirements stipulated at clause 4.1 above for the respective
equipment(s).
4.3 A J V Company / Subsidiary Company formed for manufacturing and supply of
equipment(s) listed at 4.1 above in India, can also manufacture such equipments
provided one of its promoters / its subsidiary(ies) / holding company meets the
requirements of clause 4.1 above. However, in such a case, the J V Company/
Subsidiary Company formed for manufacturing of equipment(s) listed under 4.1
above should have collaboration or valid licensing agreement for design,
engineering, manufacturing of such equipment(s) in India, with the J V promoter / its
subsidiary(ies) / holding company who meets the requirements stipulated at clause
4.1 above.
4.4 Before taking up the manufacturing of such equipment(s) as per clause 4.2 and 4.3
above, the Bidder / his sub vendor(s) must create (or should have created)
manufacturing and testing facilities at his works as per collaborator / licensers
design, manufacturing and quality control system for such equipments duly certified
by the collaborator / licensor.
Further, the collaborator / licenser shall provide (or should have provided) all
design, design calculation, manufacturing drawings and must provide (or should
have provided) technical and quality surveillance assistance and supervision during
manufacturing, erection, testing, commissioning of equipments.
4.5 Bidder shall offer and supply only the type of the above equipment(s) for which he
himself or the manufacturer / collaborator(s) / licenser(s) proposed by the Bidder for
the above equipment(s) is qualified.
4.6 The Employer reserves the right to fully satisfy himself regarding capability and
capacity of Bidder / his sub-vendor(s) and the proposed arrangement and may
prescribe additional requirement before allowing manufacture of the equipment
listed above for this contract.
5.0 Provenness criteria for other equipments/ systems
i) C&I Equipments / Systems
The bidder/his sub-vendor/DDCMIS supplier should have supplied,
engineered and commissioned the offered Distributed Digital Control,
Monitoring and Information (DDCMIS) based Electro-hydraulic control and
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Turbine protection systems for a Steam Turbine of rating 200 MW or above.
In addition to above, the following subsystems offered by the bidder/his sub-
vendor/DDCMIS supplier shall meet the requirements as stipulated below.
a) The offered DDCMIS based Steam Turbine Electro-hydraulic control
shall be in successful operation for a period not less than one (1) year
as on the date of Bid Opening in at least one Steam Turbine having
unit rating of 500 MW or above.
b) The offered DDCMIS based Turbine protection system, shall be in
successful operation for a period not less than one (1) year as on the
date of Bid Opening in at least one Steam Turbine having unit rating
of 500 MW or above.
or
In case the DDCMIS based Turbine protection system is from the
product range of the Steam Turbine OEM, the same should have
been in successful operation for a period not less than one (1) year
as on date of Bid Opening in at least one Steam Turbine having rating
of 200 MW or above.
ii) Design & Engineering of Power Cycle Piping:
(a) The bidder / his sub-vendor should have designed, engineered
(including static analysis, hanger engineering, stress analysis) power
cycle piping systems including at least boiler feed pump suction &
discharge, condensate pump suction & discharge, extraction steam
piping, heater drains & vents, flash tanks for at least one fossil fuel
fired thermal power unit of size 500 MW or above which is in
successful operation for at least one (1) year as on date of bid
opening.
(b) In case the bidder / his sub-vendor does not meet the requirements at
(a) above in part or full, but he is a regular piping design &
engineering firm/agency and currently carrying out the design and
engineering activity of power cycle piping systems for fossil fuel fired
thermal power unit(s), may also be considered qualified, provided he
collaborates/sub-contracts/associates with a design firm/agency, who
in turn meets the requirements of clause (a) above, for the purpose
of execution of design and engineering of power cycle piping systems
for this package. However, in such case, the bidder/ his sub-vendor
shall get the design/engineering documents as per technical
specification duly vetted by his collaborator/sub-contractor/associate
for the part of design for which he himself is not qualified
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iii) Turbine Hall EOT crane
The Bidder/ his sub-vendor should have designed, manufactured, erected
and commissioned EOT cranes of capacity 100T or more with minimum
crane span of 28 meters, which is in successful operation in at least one (1)
station for a minimum period of one (1) year as on the date of bid opening.
iv) Condenser on-load tube cleaning system (COLTCS)
The Bidder/ his sub-vendor should have designed, manufactured, erected
and commissioned COLTCS with ball collecting strainer having diameter of
not less than 2100 mm, which is in successful operation in at least one (1)
station for a minimum period of one (1) year as on the date of bid opening.
v) Hydrogen Generation Plant
The Bidder / his Sub-vendor should have designed and supplied at least one
(1) hydrogen generation plant comprising of electrolyser(s) and gas
compressors(s) to generate Hydrogen at 5 NM
3
/hr (minimum) of 99.7%
purity (minimum) at the main electrolsyer outlet which is in successful
operation for at least one (1) year as on the date of bid opening.
The sub-vendor shall propose type of design of Hydrogen generation plant,
i.e bi-polar or uni-polar, provided the same type of design were adopted in
the plants by virtue of which he is qualified as mentioned above.
vi) Condensate Polishing Plant
a) The Bidder / his Sub-vendor should have designed and supplied at
least one (1) condensate polishing plant of mixed bed, deep bed type
consisting of at least two (2) service vessels operating in parallel and
in conjunction with the main TG unit. Each of these vessels shall
have a minimum capacity of 500m
3
/hr. The plant shall have external
regeneration system, incorporating the same resin separation and
regeneration process as proposed by the Bidder for this package.
The above plant should be in successful operation for a period of at
least one (1) year as on date of bid opening.
b) In case the bidder / his sub vendor does not meet the proven
equipment as per clause no- 5.0(vi)(a) above but has supplied and
executed at least two (2) numbers Demineralised plants, each having
minimum stream capacity of 60Cu. m / hr and associates with a
supplier who in turn fully meets the requirements stipulated at
5.0(vi)(a) above.
The associate will be fully responsible for design, supply, erection
and commissioining, putting into satisfactory operation and carrying
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out guarantee test for Condensate Polishing Plant to the satisfaction
of the employer.
6.0 Balance equipments/ systems
The Bidder at his option can source the balance of plant equipment/systems not
covered in clause 4.0 & 5.0 above. However for such balance of plant
equipment/systems, the Employer reserves the rights to satisfy himself on the
provenness of the equipment and capability and capacity of the manufacturers.
7.0 Notwithstanding anything stated above, the Employer reserves the right to assess
the capabilities and capacity of the Bidder/his collaborators/ licenser/ his sub-
contractors to perform the contract, should the circumstances warrant such
assessment in the overall interest of the Employer.
8.0 To enable the approval of sub-vendors, the Bidder shall provide all necessary data
such as type, design, make, capacity, duty conditions, date of commissioning/
operation etc.

SECTION-VI
PART - A
ESSENTIAL DATA
CLAUSE NO.
ESSENTIAL DATA

STAGE-II (2X660 MW)
SECTION-VI
PART-A
ESSENTIAL DATA

PAGE
1 OF 12

The information in this chapter has been identified by the Employer as the essential,
which is to be provided by the bidders along with the bid necessarily. The
information provided by the bidder shall be the basis for Employer to design the
balance facilities of the project. Incase bidder does not fill these information, their bid
may be considered as non responsive.
Sl.N0. Description Data to be filled by Bidder
SYSTEM INTERFACE DATA
1. Steam Generator output corresponding
to BMCR flow under rated steam
condition, turbine under VWO
operation, condenser pressure of 77
mmHg (abs), 0% make up. Difference
of BMCR flow and VWO steam flow
through turbine shall be assumed to be
drawn off from Main steam line. Same
quantity of flow to be added to
condenser as additional make up.
Heat Balance Diagram
2. 105% of rated load under rated steam
conditions at condenser pressure of 77
mmHg (abs) with 0% makeup.
3. 660 MW output under rated steam
4. 660 MW output under sliding pressure
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STAGE-II (2X660 MW)
SECTION-VI
PART-A
ESSENTIAL DATA

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8. 660 MW output with all HP heaters out
of service under rated steam
9. Turbine Startup Curves for Cold, Warm
and Hot startup.
Start up Curve
10. Cooling water flow across Main Steam
Turbine Condenser at design point of
Condenser (Cu m/Hr )

11. Cooling water temperature rise across
Main Steam Turbine Condenser at
design point of Condenser (Deg C)

12. Pressure Drop on Cooling Water side
being measured between TG Package
terminal points across Main Steam
Turbine Condenser.(MWC)

13. Cooling water flow across BFP Drive
Turbine Condenser (if separate) at
design point of Condenser

BFP Drive Turbine Condenser (if
separate) design point of Condenser

terminal points across BFP Drive
Turbine Condenser (if separate)

16. Auxiliary Cooling Water(ACW) pump
design flow

POWER CYCLE PIPING DATA
A. HP TURBINE INLET
1. No. & Size (ID/OD x thk) of HP turbine
steam inlet nozzles

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ESSENTIAL DATA

STAGE-II (2X660 MW)
SECTION-VI
PART-A
ESSENTIAL DATA

PAGE
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2. Material of HP turbine steam inlet
nozzles

3. Whether piping /matching piece
material of P91/F91 or X20 can be
directly welded to the above HP
Turbine nozzles (material) at site or
shop welding is required as per
recommendation of equipment
supplier.

B. HP TURBINE OUTLET
1. No. & size (ID/OD x thk) of HP turbine
exhaust nozzle

2. Material for HP turbine exhaust nozzle
material of P22/F22 or A106Gr.C/A105
can be directly welded to the above HP
Turbine exhaust nozzles (material) at
siteor shop welding is required as per
supplier.

4. HP turbine exhaust maximum
temperature (Deg.C)

C. ESV / HP STEAM STOP VALVE &
CONTROL VALVE

1. No. of ESV/ HP steam stop valve
2. No. of HP steam control valve
3. Material of steam inlet & outlet
nozzles of ESV

nozzles of HP control valve

directly welded to the above valve
nozzles (material) at site or shop

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ESSENTIAL DATA

STAGE-II (2X660 MW)
SECTION-VI
PART-A
ESSENTIAL DATA

PAGE
4 OF 12

welding is required as per
supplier.
6. Pressure drop in MS strainer
D. IP TURBINE
1. No. & Size (ID/OD x thk) of IP turbine
steam inlet nozzles

2. Material of IP turbine steam inlet
nozzles

directly welded to the above IP Turbine
supplier.

E. IV/IP STOP VALVE & IP CONTROL
VALVE.

1. No. of IV/ IP steam stop valve
2. No. of IP steam control valve
nozzles of IV

nozzles of IP control valve

supplier.

6. Pressure drop in HRH strainer
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ESSENTIAL DATA

STAGE-II (2X660 MW)
SECTION-VI
PART-A
ESSENTIAL DATA

PAGE
5 OF 12

F. CRH NRV
1. No. ,Size & Body material of CRH NRV
site or shop welding is required as per
supplier.

3. Pressure drop in CRH NRV
G. HP BYPASS VALVE
1. No. of HP Bypass valve/unit
2. Inlet & outlet nozzle material of HP
Bypass valve

Bypass valve nozzles (material) at site
or shop welding is required as per
supplier.

H. LP BYPASS VALVE
1. No. of LP Bypass valve/unit
2. Inlet & outlet nozzle material of LP
Bypass valve

3. Whether piping of material A335
Gr.P91 or X20 or P22 can be directly
welded to the above LP Bypass
nozzles (inlet & outlet) at site or shop
supplier.

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ESSENTIAL DATA

STAGE-II (2X660 MW)
SECTION-VI
PART-A
ESSENTIAL DATA

PAGE
6 OF 12

I. No. & size of dump steam(LP
Bypass) inlet nozzles on condenser

J . Location of Spray arrangement in
LP Bypass down stream path.

K. Max. permissible dump steam
pressure & temperature at inlet to
condenser dump steam inlet
nozzles.

LAYOUT AND CIVIL DATA
1. A-B and B-C bay width for TG building,
2. Elevation of CW pit in TG building,
3. TG hall EOT crane rail elevation,
4. TG hall EOT crane clearance diagram,
5. TG hall EOT crane capacity
6. Deaerator centerline elevation,
7. TG building column spacing
8. TG top deck size and elevation
9. TG foundation GA & Loading details of
deck. Design criteria for TG deck and
suggestive location of TG columns.

10. CW Pit Loading details & Layout of
pipes

11. CEP pit GA & loading details
12. Equipment layout Drawings for various
floors of Main plant building.
i) Floor Plan
ii) Loading drawing
iii) Bracing location

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ESSENTIAL DATA

STAGE-II (2X660 MW)
SECTION-VI
PART-A
ESSENTIAL DATA

PAGE
7 OF 12

ELECTRICAL DATA
1. Generation Voltage
2. BFP Motor Rating.
Station Piping Package:
S.
N
Item Qty.
(m
3
/hr)
T.P.
Location
& Elev.
T.P.
Pressure
/ Temp.
Pipe size
OD x
thickness
Material
1 Instrument air
consumption for
TG & Auxiliaries

2 Plant air (service
air) consumption
for cleaning of
instruments /
equipment.

3 Demineralised
water for
condenser
normal make-up
& ECW O/H
tank M/U.

4 Demineralised
water for
condenser
emergency
make-up.

5 Service water
for cleaning /
washing of
equipment (if
any).

6 Circulating water
to & from
condenser

CLAUSE NO.
ESSENTIAL DATA

STAGE-II (2X660 MW)
SECTION-VI
PART-A
ESSENTIAL DATA

PAGE
8 OF 12

C&I DATA
1.00.00 DATA REQUIREMENTS FOR EMPLOYERS STATION-C&I PACKAGE
1.01.00 Bidder to furnish the quantity of drives and Input /outputs for all systems/equipments
in his scope that are being controlled through employer procured BOP-C&I DDCMIS
control system and as identified under exclusions clause no in Part-A in the below
mentioned format: For understanding the drives type refer tender drawings/ and
other relevant part of specification
1.01.00.01 Drives Table:-
Type of
control
Type of Drive
Quantity
HT
LT (AC+DC)
VARIABLE FREQUENCY DRIVE (OLCS)
MOD/MOV (MODULATING DAMPER/
VALVE)
MOVI/MODI (INCHING VALVE/DAMPER)
DSOV (DUAL SOLENOID VALVE)
OLCS
SSOV (SINGLE SOLENOID VALVE)
CLCS-1 (MODULATING CONTROL DRIVE
WITH GALVANICALLY ISOLATED
FEEDBACK)
WITHOUT GALVANICALLY ISOLATED
FEEDBACK)
CLCS
CLCS-3 (MODULATING VARIABLE
FREQUENCY DRIVE)
ANY OTHER DRIVE
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ESSENTIAL DATA

STAGE-II (2X660 MW)
SECTION-VI
PART-A
ESSENTIAL DATA

PAGE
9 OF 12

1.01.00.02 Input output signals Table:-

Note:
1) The I/O,s per drive shall be as per that indicated in the Appendix-1 to C&I
scope, Part-A
Quantity
Signal Type
AI (4-20mA)
AI (4-20mA) HART COMPATIBLE AI (Control)
AI (4-20mA) Galvanic ISOLATED
AI (4-20mA)
AI (4-20mA) HART COMPATIBLE
AI
(Information)
AO (4-20mA)
AO
AO (4-20mA) Galvanic ISOLATED
DI (COC) CHANGE OVER
CONTACT
DI
DI (NO/NC) NORMALLY OPEN/
NORMALLY CLOSED CONTACT
DO (Contact)
DO
DO (24 VDC)
SEQUENCE OF EVENTS FROM
BIDDERS CONTROL SYSTEM/
EQUIPMENTS
DI-SOE
SEQUENCE OF EVENTS FOR
BIDDERS EQUIPMENTS BEING
CONTROLLED THROUGH
EMPLOYER CONTROL SYSTEM
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ESSENTIAL DATA

STAGE-II (2X660 MW)
SECTION-VI
PART-A
ESSENTIAL DATA

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10 OF 12

1.02.00 HART SIGNAL MONITORING:-Bidder to furnish the quantity of HART compatible
signals in his scope to be monitored in Employers BOP-C&I control system
Signals Quantity
HART signals connected to BOP-C&I DDCMIS from TG-
C&I

(Note: All the HART compatible signals being connected in TG-C&I control system
shall also be monitored in HART management system being procured under
Employers Station-C&I package. Quantity of such signals shall be indicated in the
above table)
1.03.00 VIBRATION MONITORING SYSTEM:- Bidder to furnish following details for
Vibration Monitoring system to be procured under Employers Station-C&I package,
required for interlock, protection and monitoring of Bidders HT equipment(s)
Sl.
No
Name of
main HT
drive
Type of
Bearing
Type of
Vibration
Sensor
No of
Sensors
Range Remarks

1.04.00 CONTROL PANELS/OTHER PANELs Bidder to furnish details of control
panels/other panels to be placed in control equipment room as per the following
format.
Sl
No
Panel
description
Qty Dimensions Cut-out
dimensions
Heat
load
Remarks

1.05.00 UPS load requirement:- Bidder to furnish total load requirement of 230 V AC supply
for his systems/equipment, to be fed from Employers UPS system. The following
feeders have been considered under employer procured UPS system.

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ESSENTIAL DATA

STAGE-II (2X660 MW)
SECTION-VI
PART-A
ESSENTIAL DATA

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Sl.
no
Fdr
no.
Frm To Feeder Desc. KVA PDB
location
PDB
scope
1 Fdr-1 ACDB-1 PDB-
110-1
HMI Load-1 Prog.
Room
TG
vendor
2 Fdr-2 ACDB-1 PDB-
110-1
HMI Load-2 Prog.
Room
TG
vendor
3 Fdr-3 ACDB-1 PDB-
110-2
TSI & other
Loads
CER TG
vendor
4 Fdr-4 ACDB-1 PDB-
110-3
Miscellaneous
Loads
8.5m TG
vendor
Notes:
(1) Feeders from ACDB-1 are only indicated above. Identical feeders for each
PDB shall be provided from ACDB-2.
(2) Above indicated UPS feeders shall be provided from Employers ACDB.
(3) PDBs along with the necessary change over circuits (as applicable) along
with further distribution to the load shall be in the scope of the contractor.
(4) Half of the HMI Loads are to be powered through Feeder-1 and remaining
half through Feeder-2 to ensure availability of at least 50% of the HMI Loads
in event of any fault in either of the feeders.
1.06.00 SOFT/Hard wired signal exchange:-Bidder to furnish the quantity of soft/hardwired
signal Exchange between TG C&I system and Employers Station C&I system in the
following format:
Sl
No
System
(from)
System
(to)
Total Database Periodically
transmitted
Unit(U) /
Common
(C)
Soft/
Hardwired
Analog Binary Analog Binary

1.07.00 Measuring instruments:- Bidder to furnish the quantity of following measuring
instruments to be procured under employer supplied station C&I package based on
enclosed tender P&ID and bidders recommendation for the offered systems
/equipments.
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ESSENTIAL DATA

STAGE-II (2X660 MW)
SECTION-VI
PART-A
ESSENTIAL DATA

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Sl No Type of Measuring
instrument
Service Process range
1 Pressure Transmitters
2 Differential Pressure
Transmitters

3 Level Transmitters with
type( for ex
rada/ultrasonic etc)

4 Flow Transmitters with
type (DP, any other type)

5 Analytical measurement
like pH, Conductivity,
Silica etc with type

1.08.00 The above information is essentially required to be furnished along with the bid.

SECTION-VI
PART - A
PHASED MANUFACTURING PROGRAM
CLAUSE NO.

STAGE-II (2X660 MW)
SECTION-VI
PART-A
PHASED
MANUFACTURING
PROGRAM
PAGE
1 OF 3

1.00.00 CREATION / AUGMENTATION OF INDIGENOUS MANUFACTURING FACILITY
Bidders desirous of participating in this tender must ensure creation of an Indian
Manufacturing Company (registered in India as per Companies Act 1956) for
manufacturing and supply of supercritical steam turbine generator sets in India. In
case a bidder is already having a manufacturing facility for steam turbine generator
sets in India, the same shall be suitably augmented for manufacturing and supply
of supercritical steam turbine generator sets in India. The manufacturing facility
needs to be set up / augmented in a phased manner as per a phased
manufacturing program (PMP) elaborated in this chapter.
The Indian Manufacturing Company (a newly registered company or an already
existing Indian Company, as the case may be) should have a valid technology
transfer agreement, including license to manufacture and supply in India, with a
Qualified Steam Turbine Generator Manufacturer for the type, size and rating of
the steam turbine generator set specified, valid minimum up to the end of the
warranty period of the contract. The technology transfer agreement shall
necessarily cover transfer of technological know-how in the form of complete
design dossier, design softwares, drawings and documentation, quality system
manuals and imparting relevant training to concerned personnel of the Indian
Manufacturing Company. Such technology transfer agreement must have
provision that the transfer of technology to the Indian Manufacturing Company
shall be completed by the time last 660 MW supercritical unit is supplied by the
bidder under this tender.
Bidders may note that creation/development of indigenous manufacturing facility
(Indian Manufacturing Company) is a mandatory requirement which shall go in
parallel with execution of the work awarded under this contract. Therefore, it is not
mandatory that the equipments to be supplied under this contract have to be
manufactured/assembled/tested in the Indian Manufacturing Company. Bidders, at
their discretion, are allowed to source equipments from elsewhere also, subject to
meeting other provisions of the contract.
Various major milestones identified for the phased manufacturing program, their
completion schedule and the weightage factor for the purpose of levying liquidated
damages in case of delay in completion are as tabulated below:

CLAUSE NO.

STAGE-II (2X660 MW)
SECTION-VI
PART-A
PHASED
MANUFACTURING
PROGRAM
PAGE
2 OF 3

Milestones for setting up manufacturing facility of Steam Turbine Generators
(Phased Manufacturing Program for Indigenous Manufacturing)
Sl.
No.
Equipment /
Milestone
Facilities Requirement To be
established
latest by
(Months
from Date of
Award)
Weightage
factor
(%age) for
LD
1 Turbine
Casings and
Valves
machining
LP outer Casing
fabrication
HP / IP / LP Casing
Machining & blading
Heat Treatment / Stress
Relieving
Turbine valve machining
& assembly testing
36 20
2 Turbine Rotor
machining
Rotor machining including
grooves & Fir Tree
machining,
Rotor assembly and
balancing
Turbine assembly
42 20
3 Rotating blades
machining
Rotating Blade machining
& finishing
52 20
4 Generator Core
and stator
manufacturing
Core stamping, fabrication
facility, Heat Treatment /
Stress Relieving.
Generator Stator
Fabrication and Core
building facility

40 20
CLAUSE NO.

STAGE-II (2X660 MW)
SECTION-VI
PART-A
PHASED
MANUFACTURING
PROGRAM
PAGE
3 OF 3

Stator bar manufacturing
and heavy machining
facility for fabricated
items.
5 Generator
Rotor
Rotor machining including
slotting
Rotor assembly and
balancing
Exciter manufacturing &
testing
Rotor winding facility
42 15
6 Generator
Assembly
Generator assembly and
testing
48 5
A standing committee, to be appointed by Govt. of India, would be authorized
(within the ambit of the Contract) to monitor the progress of PMP. Imposition of LD
would be based on recommendations of this standing committee.
Failure to meet above identified milestones of manufacturing shall attract
liquidated damages (LD). The total LD to be levied on this account will be 5% of
the total contract value. This 5% amount will be distributed over various milestones
as per the weightage factor assigned above.
LD amount as per the assigned weightage factor for a particular milestone shall be
recovered fully if the delay is 10 weeks or more for that particular milestone. For
delays less than 10 weeks, LD rate will be 1/10
th
per week of delay or part thereof.
The bidders will be required to submit an on demand Bank Guarantee for Rs 650
Million in case of award as security for default against specified PMP. In case the
bidder does not implement the complete PMP by 52 months of award of the
contract, the Procurer will encash the bank guarantee.

SECTION-VI
PART - A
A - 2
GENERAL
CLAUSE NO.

STAGE-II (2X660 MW)
SECTION-VI
PART-A
A-2
GENERAL

PAGE
1 OF 2

1.00.00 GENERAL

The scope of work for the equipment and accessories to be furnished in accordance
with this specification shall include design, manufacture, engineering, inspection and
testing at Contractor's work(s), packing, forwarding to site, unloading, erection,
supervision, pre-commissioning, testing, commissioning and performance testing of
all equipment/systems indicated in scope of supply & services. Items though not
specifically mentioned in the specification but needed to complete the
equipment/systems to meet the intent of specification, shall also be deemed to be
included unless otherwise specifically mentioned in exclusions.

In addition to the scope of supply and services indicated in other Sub-Sections of the
scope of supply and services, the other general requirements are covered in this
sub-section as part of the scope of the Contractor.

1.01.00 Paints

The Contractor's scope of work includes supply of paints and painting of all
equipments and structures as per stipulated requirements and the Employer's
standard colour coding scheme.

1.02.00 Pre-commissioning and commissioning activities

The contractor's scope shall include all pre-commissioning and commissioning
activities, materials and services as detailed in other portion of technical
specifications including supply of all consumables (except coal and fuel oil for
firing), temporary equipment and pipings, instruments, labour / skilled manpower's
etc. The scope includes complete requirement of flushing oils including fresh oil
refilling during the pre-commissioning and commissioning activities and subsequent
initial operation.

1.03.00 First Fill of Consumable, Oils & Lubricants

All the first fill and one Year's topping requirements of consumable such as greases,
oil, lubricants, servo fluids/control fluids, gases and essential chemicals etc. which
will be required to put the equipment covered under the scope of specifications, into
successful commissioning/initial operation and to establish completion of facilities
shall be furnished by the Contractor. Suitable standard lubricants as available in
India are desired. Efforts should be made to limit the variety of lubricants to
minimum.

1.04.00 Guarantee Tests

The guarantee tests for various equipment and systems shall be carried out as
specified under chapter of Function Guarantees and Liquidated damages, this part
CLAUSE NO.

STAGE-II (2X660 MW)
SECTION-VI
PART-A
A-2
GENERAL

PAGE
2 OF 2

of technical specification. All special equipment, tools and tackles, instruments,
measuring devices required for the successful conductance of Guarantee Tests shall
be provided by the contractor, free of cost. All costs associated with the tests shall
be included in bid price.

1.05.00 Spares

The scope of supply of contractor includes supply of mandatory spares, start-up and
commissioning spares, recommended spares, consumable spares and others as
specified in this specification. The list of mandatory spares is brought out in this Part
of specification. The general requirement in respect of various type of spares is
given in separate chapter of this part.

1.06.00 Special Tools & Tackles and Test/Measuring Equipment

One set of all special tools and tackles including testing, calibrating and measuring
instruments required for erection, assembly, disassembly and maintenance and
testing of all equipment/systems covered under the scope of the contractor shall be
supplied by the Contractor as per relevant clause indicated in Part-C of Section-VI
and as specified elsewhere in Part-A of Section-VI of Technical Specifications. The
Contractor shall not use these special tools, tackles and testing/measuring
equipment for erection/commissioning purposes and shall be in an unused and new
condition, when they are handed over to the Employer. A list of all such special tools
and tackles shall be submitted along with the offer.

1.07.00 The scope of the Contractor includes complete design and engineering, technical
co-ordination (including participation and arranging technical co-ordination
meetings), finalization of drawings/documents, submission of engineering
drawing/documents and processing of their approvals by the Employer as per
requirement indicated in Part-C of Section-VI and other relevant clauses given
elsewhere in the Technical Specifications.

Further, the scope shall also include submission, in proper shape and format, of all
types of manuals, handbooks and documents in requisite numbers to the Employer
at different phases of the project as per the requirement of Employer.

Contractor shall furnish all relevant data required by the Employer, at interface
points within 45 days of notification of award.

SECTION-VI
PART - A
A - 3
TURBINE GENERATOR
AND AUXILIARIES
CLAUSE NO.

STAGE-II (2X660 MW)
SECTION-VI
PART-A
A-3
STEAM TURBINE AND
AUXILIARIES
PAGE
1 OF 8

STEAM TURBINE AND AUXILIARIES

1.00.00 GENERAL

The scope of work for the equipment and accessories to be furnished in accordance
with this specification shall include design, manufacture, engineering, inspection and
testing at Contractor's work(s), packing, forwarding to site, unloading, erection,
supervision, pre-commissioning, testing, commissioning and performance testing of
the equipment/systems indicated hereunder. Items though not specifically mentioned
in the specification but needed to complete the equipment and systems to meet the
intent of specification, shall also be deemed to be included unless otherwise
specifically mentioned under exclusions.

2.00.00 STEAM TURBINE & AUXILIARY SYSTEMS

The scope includes all equipment required for Two (2) Steam Turbine Generator
units along with auxiliaries of the type specified. Each unit will include but not be
limited to the following:

2.01.00 Steam Turbine

2.01.01 The steam turbine shall be of tandem compound construction, condensing type with
minimum seven (07) number of extractions with extraction for the top HP heater from
the HP turbine for regenerative feed heating. HP turbine shall be of double casing
design. Separate HP, separate IP and separate LP casing(s) OR combined HP-IP
and separate LP casing(s) shall be provided. HP inner cylinder, IP cylinder and LP
cylinder(s) shall be horizontally split.

2.01.02 Steam turbine shall be complete with casings, rotors, bearings, temperature
detectors, couplings, steam gland seals, rotor turning gear preferably hydraulic type
and having remote operation facility, hand barring gear, emergency stop and control
valves and reheat stop and control valves with their servomotors, removable type
steam strainers for start up and normal operation upstream of emergency stop and
reheat stop valves, cross-over/cross around piping and electric motors for all its
integral subsystems. Steam strainers integral with main steam emergency stop and
reheat stop valves are also acceptable.

2.01.03 Bidder shall provide Hydraulic / Pneumatic power operated/ Assisted Quick closing
type & ordinary NRVs for each Steam extraction line (except for extractions from LP
Turbine) including steam extraction line to BFP drive turbine. For each CRH line and
extractions from LP Turbine (except for heaters in condenser neck) minimum one
hydraulic/ Pneumatic power operated / assisted QCNRV shall be provided. The
NRVs shall be of proven design.

The type of actuation i.e. hydraulic/pneumatic shall be as per the standard proven
practice of the manufacturer.
CLAUSE NO.

STAGE-II (2X660 MW)
SECTION-VI
PART-A
A-3
STEAM TURBINE AND
AUXILIARIES
PAGE
2 OF 8

2.01.04 Turbo generator set shall be suitable for installation on spring supported Reinforced
Cement Concrete (RCC) foundation.

2.02.00 Steam Turbine Auxiliary Systems

2.02.01 Turbine gland sealing steam system shall be provided with gland steam condenser,
gland steam exhausters, all associated motors, associated piping, valves and
fittings, specialties, hangers and supports, necessary insulation and complete with
all instrumentation and control hardware including electro hydraulic/ electro
pneumatic controller, actuator, electro hydraulic / electro pneumatic converter etc. as
to make the system complete in all respects.

2.02.02 Cross over/cross around piping between IP and LP casing(s) including necessary
hangers and supports for piping and secondary structural steel shall be provided, if
required.

2.02.03 Lubricating Oil System (common for Turbine Generator Set) shall be complete with
oil tanks, oil purifying system, oil pumps and jacking oil pumps with drive motors, oil
coolers, strainers, vapour extractors with drive motors, all interconnecting piping,
valves and fittings, hangers and supports, necessary instrumentation and control
hardware to make the system complete in all respects.

Centralised oil storage and purification system shall be common for all the units
including clean oil tank, dirty oil tank, transfer pumps, purifying unit with
interconnecting piping, necessary instrumentation and control hardware to make the
system complete in all respects

2.02.04 Steam turbine control fluid and its purification system along with its conditioning
system shall be complete with control fluid tank, control fluid pumps with drive
motors, strainers, accumulator, control fluid coolers, waste fluid tank, purification
equipment including fluid circulation pumps with drive motors, associated piping,
valves, fittings and specialties, hangers and supports, Instrumentation and control
hardware to make the system complete in all respects for the 660 MW units.

2.02.05 Steam turbine governing and protection system shall be complete with electro
hydraulic governor with suitable back up as per standard practice of the
manufacturer. Electro hydraulic converter, hydraulic converter, tracking devices,
hydraulic speed governor, electrical speed sensors, speed/load adjusting gear,
motor drives shall be provided as per applicability and standard practice of the
manufacturer. The system shall be complete with remote trip solenoids and trips on
overspeed, low condenser vacuum, low lube oil pressure, high axial shift and other
trip/protection devices etc., electrical components associated with electro hydraulic
system, test devices and test panel inserts etc. and hydraulic components like
accumulator, strainers etc. alongwith associated piping, valves, fittings and
specialties, hangers and supports etc.
CLAUSE NO.

STAGE-II (2X660 MW)
SECTION-VI
PART-A
A-3
STEAM TURBINE AND
AUXILIARIES
PAGE
3 OF 8

2.02.06 Steam turbine exhaust hood spray cooling system shall be complete with spray
arrangements, associated piping, instrumentation and control devices, valves and
fittings, motor/solenoid operated valves and specialties, hangers, supports and
insulation etc.

2.02.07 Steam turbine, associated piping & equipment drain & vent system shall be
complete with turbine flash tanks, piping, valves and fittings, valve motor drives,
specialties, hangers and supports, insulation, instrumentation and control etc. The
drains under the scope of the Bidder shall be led to the Employer's drains and the
vents shall be led to atmosphere upto a suitable location outside the main plant
building.

2.02.08 Turbine preservation system consisting of adequate numbers of air driers including,
fans, motors, filters, heater drying wheel, connecting pipings, valves, fittings etc. for
preservation against corrosion of turbine during idle periods shall be provided.

2.02.09 Boroscopic inspection ports in turbine for in situ inspection of turbine internals shall
be provided as per bidder's standard practice. One set of applicable tools and plants
per station shall be provided.

2.02.10 HP/LP Bypass system shall be complete with steam and spray valves, spray control
station, throttling devices, fittings, desuperheaters, hydraulic power pack, solenoid
valves, quick acting devices, blanking devices for steam blowing, supports,
associated piping including warm up arrangements, valves, instrumentation and
control hardware, electrical devices and actuators/motors etc.

2.02.11 Clarified water cooled, divided water box, horizontal surface condensers for each
unit shall be complete with all accessories such as hotwells, valves, drains, vents,
strainers, CW line expansion joints and fittings, isolating butterfly valves with
matching flanges, associated CW piping to and from the condenser, suitable
handling arrangement(s) for water box & butterfly valves, steam throw off devices for
HP-LP bypass system, extraction steam piping routed through the condenser to low
pressure feed water heaters and heater(s) within the condenser neck and with
provision for installation of low pressure feed water heater(s) in the condenser neck,
shall be provided.

2.02.12 HP and LP flash tanks / vessels for accepting all turbine and cycle recoverable
drains including those from main steam, cold reheat, hot reheat lines, HP-LP bypass
lines, heater drains, complete with all associated spray system, piping, valves and
fittings, specialties, hangers and supports and insulation, instrumentation and
controls etc. shall be provided. In addition one atmospheric flash tank will also be
provided to accept the drains from feed water heater safety valves.

CLAUSE NO.

STAGE-II (2X660 MW)
SECTION-VI
PART-A
A-3
STEAM TURBINE AND
AUXILIARIES
PAGE
4 OF 8

2.02.13 Condenser air evacuation system shall be complete with 2 x 100% vacuum pumps,
associated motors, all accessories, associated piping, valves & fittings, specialties,
duplex filter, instrumentation and control etc.

2.03.00 TG Integral and Other Miscellaneous Piping

The scope of work for TG integral and miscellaneous piping covered under this
specification shall include but not be limited to the following systems:

(a.) Condenser air evacuation system

(b.) Condenser cooling water system

(c.) Cycle make-up system

(d.) Control fluid system

(e.) Gland steam sealing system

(f.) Lube Oil system

(g.) Central oil storage and purification system

(h.) Exhaust hood spray system

(i.) Gland sealing (of valves and pumps) system

(j.) Equipment cooling water system

(k.) Compressed air system (Service Air and Instrument Air)

(l.) Steam evacuation line (HPT exhaust) from CRH piping system.

Piping shall be complete with fittings / accessories and specialties, expansion joints,
valves, insulation, hangers, supports, restraints / guides, snubbers and auxiliary
steel etc. The design and engineering of the piping system shall include but not be
limited to pipe sizing, hanger / snubber engineering, engineering of thermal
insulation etc.

3.00.00 CONDENSER ON LOAD TUBE CLEANING SYSTEM

Sponge rubber ball type condenser on load tube cleaning system separately for
each half of the condenser. Each Condenser on load tube cleaning system shall be
complete with one number Ball recirculation pump, one number Ball separator, one
number Ball collecting vessel, differential pressure measuring system, Ball
CLAUSE NO.

STAGE-II (2X660 MW)
SECTION-VI
PART-A
A-3
STEAM TURBINE AND
AUXILIARIES
PAGE
5 OF 8

monitoring system (comprising of ball recirculation monitor and ball oversize
monitor), associated piping, valves and accessories, instrumentation and controls,
all drives, power and control cables, motors and accessories, etc.

4.00.00 CONDENSATE EXTRACTION PUMPS

3 x 50% capacity motor driven condensate extraction pumps for each unit along with
all accessories, drives, suction strainers, associated piping, and valves,
instrumentation and control etc. including one number cannister drainage pump per
station shall be provided.

5.00.00 FEED WATER HEATING PLANT

5.01.00 Complete regenerative feed heating system including full capacity drain cooler,
minimum three (03) nos. of low pressure heaters, deaerator and feed storage tank,
minimum three (03) nos. of high pressure heaters, all accessories, associated
piping, valves, Nitrogen gas filling arrangement, instrumentation and controls etc.
shall be provided for each unit. One set of test kit for measuring oxygen content at
deaerator outlet shall also be provided for the station.

6.00.00 BOILER FEED PUMPS

6.01.01 Two thirty percent capacity (2x30%) motor driven boiler feed pump for each unit
complete with booster pump along with it's drives, mechanical seals, flexible
couplings, hydraulic coupling, gear box, base plate(s), forced oil lubricating system
(including oil pumps, oil tank, lube oil coolers, working oil coolers, duplex oil filters
etc.), ON/OFF type low load recirculation flow control valve, mobile cradle, integral
piping and valves, temporary and permanent strainers, local instrument
racks/enclosures, instrumentation and control etc. shall be provided. One (1) number
portable centrifuge of adequate capacity shall also be provided.

6.01.02 Two half capacity (2x50%) steam turbine driven boiler feed pumps for each unit
complete with booster pump, step down gear box, flexible couplings, mechanical
seals, foundation base plates, ON/OFF type low load recirculation flow control valve,
mobile cradle, integral piping and valves, local gauge boards, instrumentation and
control etc. shall be provided.

6.01.03 Two (2) steam turbine drives for the turbine driven boiler feed pump per unit
complete with ESV, control valves, non return valves for single admission drives,
permanent & temporary steam strainers, preferably hydraulic turning gear, hand
barring device, atmospheric relief diaphragm and it's vent piping, all inter connecting
piping, foundation base plates, integral gland seal system, complete lube oil and
control oil system including oil tank, oil coolers, duplex oil filters, vapour exhausters,
100% capacity centrifuge for each steam turbine driven pump, jacking oil system (if
required), Electro-hydraulic governing system, Turbine Supervisory system along
with all control and accessories as specified elsewhere in the specification shall be
CLAUSE NO.

STAGE-II (2X660 MW)
SECTION-VI
PART-A
A-3
STEAM TURBINE AND
AUXILIARIES
PAGE
6 OF 8

provided. If bidder offers separate condenser for each drive turbine then separate
2x100% vacuum pumps, COLTCS system for each half of the condenser, 2x100%
CEP for each drive turbine condenser (if required), associated piping fittings,
instruments etc. shall be provided by the bidder. The design and sizing of these
equipments shall be in line with the requirement for main turbine condenser.

6.01.04 Boiler feed pump sets shall be suitable for installation on spring supported
Reinforced Cement Concrete (RCC) foundation.

6.02.00 Feed regulating station (FRS) for feed water flow control during unit startup,
consisting of the following for each unit:

(1) One pneumatically operated (0 to 30% BMCR capacity range) feed control
valve

(2) Two numbers motor operated gate valves with motor operated integral
bypass valve, one each on upstream and downstream of feed control valve.

(3) Two motor operated gate valve (each 50% BMCR capacity) with motor
operated integral bypass valve in parallel to the feed control valve to bypass
the feed control valve in the unit operation range of 30 to 100% BMCR.
alternatively bidder can offer one motor operated gate valve of 100% BMCR
capacity with motor operated integral bypass valve in parallel to the feed
control valve.

7.00.00 MAKE UP SYSTEM

Normal and emergency cycle make-up to condenser hot well for each unit consisting
of piping, valves, flow elements with flow transmitter and indicators, hot well make-
up control station (normal and emergency) including control valves, drain, vents, etc.
are in the scope of this contract upto A-row.

Like wise, condensate spill pipe line consisting of piping, valves, control station etc.
are in the scope of this contract upto A-row near the condenser for further routing by
the employer.

8.00.00 TURBINE HALL EOT CRANES

8.01.00 Two (2) number of Electrically operated overhead travelling cranes with associated
auxiliaries, along with electrical equipment, control & instrumentation as required
and specified shall be provided in the turbine hall for erection and maintenance of
turbo-generators and their auxiliaries.

Each crane shall be capable of lifting at least 105% of the weight of single heaviest
component/ equipment, including lifting beam and slings etc. (as applicable) to be
handled in TG hall for erection as well as maintenance of the equipment provided in
AB bay. The auxiliary hook capacity shall not be less than 20 Ton.

CLAUSE NO.

STAGE-II (2X660 MW)
SECTION-VI
PART-A
A-3
STEAM TURBINE AND
AUXILIARIES
PAGE
7 OF 8

In addition, it shall also be possible to handle Generator Stator with tandem
operation of two Turbine hall EOT cranes for which necessary arrangements shall
be provided. In such case, the combined capacity of two EOT cranes shall not be
less than the 105% of weight of Generator Stator, including the weight of lifting beam
with swiveling arrangement and slings.

9.00.00 PERFORMANCE GUARANTEE TEST

Performance tests of all the equipments/systems in the contractor test facilities and
performance guarantee tests at Employer's site as specified elsewhere in the
specification are included in the scope of this specification.

Performance guarantee/acceptance test for each turbine-generator unit shall be
carried out as per ASME-PTC-6 (Latest Edition).

10.00.00 OTHER MISCELLANEOUS ITEMS:

The scope of work for the equipment covered under this specification shall include
but not be limited to the following systems:

10.01.01 All weld neck counter flanges shall be supplied by bidder wherever nozzle ends on
any equipment such as strainer, flow nozzles etc. are flanged.

10.01.02 All fixtures, embedded parts, steel embedments including fixing lugs and welding
between them, foundation plates, nuts, bolts etc. for fixing all the equipments, piping
on civil works shall be included in scope work of this package.

10.01.03 All structures which would be required by the Bidder for supporting the piping shall
be included in scope of work of this package.

10.01.04 Initial charge of all the lubricants and fluids including one year topping up
requirement.

10.01.05 Paints and painting of all equipments as per approval of the Employer.

10.01.06 Chemical cleaning of all equipment and systems after their erection shall be in
Bidder's scope.

10.01.07 All the environmentally clear waste shall be suitably routed to the Employer's storm
water drainage system through drains by the Bidder. All the vents to atmosphere
shall be suitably led to outside the main plant building.

10.01.08 Thermal insulation and removable metal cladding shall be provided for all the
equipments, piping and piping support frames as required.

10.01.09 Necessary blanking arrangements required to protect the valves and turbine
internals and other auxiliaries during steam blowing shall be provided.

CLAUSE NO.

STAGE-II (2X660 MW)
SECTION-VI
PART-A
A-3
STEAM TURBINE AND
AUXILIARIES
PAGE
8 OF 8

10.01.10 All oils, chemicals etc. to waste shall be routed to a common collection tank (to be
supplied by the Bidder) individually identified by the Employer for oil or any such
obnoxious material which cannot be put into the plant drainage.

10.01.11 The oil drains from the Lube oil system in TG area which are collected in a common
collection tank, will be transferred to drums for further disposal/reuse.

10.01.12 Similar arrangement will be provided for the oil drains in control fluid system also.

10.01.13 Suitable HOT/Electric Monorail hoist cranes along with runway/monorails beams and
approach ladders and/ or platform of adequate capacity to meet the need for
erection, operation and maintenance.

10.01.14 Operating platform around the deaerator, GSC, flash tanks, lube oil/ control oil tanks,
HP/LP bypass valves, Emergency Stop Valves / Intercept valves, local platforms for
various inaccessible valves and equipments etc. shall be in contractor's scope.

11.00.00 TOOLS AND TACKLES

11.01.00 One set of all special tools and tackles required for the maintenance of
equipments/system have to be supplied by the Bidder. These tools and tackles shall
be separately packed and brought to site. These shall not be used for
erection/commissioning purposes and shall be in an unused and new condition,
when they are handed over to the Employer. A list of all such special tools and
tackles shall be submitted along with the offer.

11.02.00 One set of maintenance and repair tools including all special tools and tackles
required for the installation and maintenance of equipments/system for
commissioning, testing, calibration, modification and maintenance.

12.00.00 ERECTION MATERIALS

All the erection materials and consumables like shims, welding rods, soldering and
brazing alloys, insulating tapes, compounds, chemicals etc. required for the erection
and commissioning work shall be included in the Bidder's scope of work.

13.00.00 SPARES

The offer shall cover all the mandatory spares, start-up spares, commissioning
spares, consumable spares and others as specified in the specification. The list of
mandatory spares is attached in this Part of the specification.

SECTION-VI
PART - A
A - 4
EQUIPMENT COOLING WATER SYSTEM
CLAUSE NO.

STAGE-II (2X660 MW)
SECTION-VI
PART-A
A-4
EQUIPMENT
COOLING WATER
SYSTEM
PAGE
1 OF 1


1.00.00 SCOPE

1.01.00 Equipment Cooling Water System for Unit auxiliaries

Each unit shall be provided with a closed circuit cooling system for cooling of the
various auxiliaries of Turbogenerator by the Bidder. The equipment cooling system
for each unit shall include the following and as detailed out in relevant sub section of
Part-B of Technical Specification.

(a) One cold water header tapped from intake cold water CW pipes to the
condenser.

(b) One hot water header discharging into the hot water CW pipes from the
condenser.

(c) 2x100% capacity self cleaning type filters on the secondary side.

(d) 3x50% capacity plate type heat exchangers.

(e) 3x50% capacity auxiliary circulating water booster pumps, alongwith drives.

(f) 3x50% capacity, DM cooling water pumps alongwith drives.

(g) Overhead DM water tank (ECW O/H tank).

(h) Alkali (Sodium Hydroxide) preparation tank, agitator and motor, piping,
valves etc.

(i) Complete piping, fittings, supports, valves and specialties including
instrumentation and electrical equipment as required and as specified for the
system.

SECTION-VI
PART - A
A - 5
CONDENSATE POLISHING UNIT
CLAUSE NO.

STAGE-II (2X660 MW)
SECTION-VI
PART-A
A-5
CONDENSATE
POLISHING
UNITS
PAGE
1 OF 2

CONDENSATE POLISHING UNITS

1.00.00 SCOPE

1.01.00 The proposed Condensate Polishing Plant (CPP) shall treat the condensate of the
Turbine-Generator (TG) Units of the power station. Two (2) numbers of identical,
separate Condensate Polishing Plants (CPP) for TG (Turbine-Generator) unit, along
with complete external regeneration system common for all the Condensate
polishing plants shall be provided as detailed out in relevant sub-section of Part-B of
Technical Specification.

1.02.00 Each Condensate Polishing unit shall consist of three (3) service vessels (3 x
33.33% capacity) for each TG Unit alongwith emergency system, resins, blowers,
panels, instrumentations, valves and pipings etc.

1.03.00 Inclusion of plant adequate resins for all the condensate polisher service vessels,
resin storage vessel (2 nos.) in regeneration area and one addiational charge for use
during commissioning stage of unit. Therefore, total number of charges supplied by
bidder shall be nine (9).

1.04.00 For regeneration, resin from the exhausted exchanger vessel will be transferred
hydraulically through resin transfer pipe line to the regeneration system. The
exhausted resin charge will be cleaned, separated, regenerated, mixed and rinsed
before being stored for the next use. Regeneration facilities shall consisting of :-

a) Resin transfer & DM water pipe lines & valves,

b) Resin separation vessel, cation/anion regeneration vessel(s) resin makeup
hopper, mixed resin storage vessel,

c) Air blowers & drives,

d) One set of alkali solution preparation & dosing facility

e) One set of acid solution preparation & dosing skid

f) Two (2) numbers of DM water Pumps for chemical preparation & dilution

g) Two (2) numbers of DM Water Pumps for resin transfer operation.

h) Effluent system upto N.pit alongwith piping, valves, fittings, agitation
systems; Lime dosing system including lime solution preparation facilities for
neutralisation; primimg and effluent transfer system from N. pit to employers
ash slurry sump.
CLAUSE NO.

STAGE-II (2X660 MW)
SECTION-VI
PART-A
A-5
CONDENSATE
POLISHING
UNITS
PAGE
2 OF 2

i) One number of tank for collection of water used for resin transfer operation
and two numbers (2 x 100% capacity) of recycle pumps for pumping the
water to Employers cooling water channel near CW Pump House.

j) Complete Piping, Valves, fittings etc, associated instrumentation, controls,
control panels etc. as required and detailed out in Part-B of Technical
Specification.

k) Any other equipments, devices to meet the system requirement.

l) DM water storage tanks for regeneration system.

m) Bulk acid and alkali storage tanks and acid/alkali unloading facilities for
regeneration system.

SECTION-VI
PART - A
A - 6
LOW PRESSURE PIPING SYSTEM
CLAUSE NO.

STAGE-II (2X660 MW)
TECHNICAL SPECIFICATIONS
SECTION-VI
PART-A
A-6
LOW PRESSURE PIPING
SYSTEM
PAGE
1 OF 5

1.00.00 LOW PRESSURE PIPING
1.01.00 The Scope of Low Pressure (LP) piping systems for the following services shall be
as defined in various tender drawings & the sub section pertaining to Terminal
points and exclusions and shall include the following systems:
(a.) Circulating water system.
(b.) DM water normal make-up system (condenser makeup, ECW makeup etc.)
(c.) Condenser emergency make up / condensate storage and transfer system.
(d.) Boiler and Deaerator fill system.
(e.) Equipment Cooling Water (ECW) system including its chemical dosing
system for primary circuit
(f.) Service water system
(g.) Instrument Air System.
(h.) Service (plant) Air System.
(i.) Drain piping system for the piping\equipment etc. under the bidders scope.
(j.) Tanks as described elsewhere in the specification for the above systems..
(k.) Re-circulation pipes along with valves, break-down orifices etc., wherever
required/specified elsewhere in Technical Specification.
(l.) Any other piping system required making the Low Pressure (LP) piping
systems in the bidders scope complete.
1.02.00 The scope covers the following for the complete LP piping systems mentioned
above:
a) Design, engineering, manufacturing, supply, fabrication, testing packaging,
transportation to site, storage, taking delivery of Employer supplied
equipment from site stores, in plant transportation, erection, cleaning, testing
and commissioning of all items i.e., piping fittings, supports/ hangers, valves,
actuators, motors, specialties, tanks, chemical dosing system for Equipment
Cooling Water System (Primary circuit), instruments, drains, vent including
drain/ vent valves ,air release valves etc.
The items though not specifically mentioned or indicated here in but are
needed to make the system / equipment complete shall also be furnished
and treated as if included in the specification unless otherwise specifically
excluded.
CLAUSE NO.

STAGE-II (2X660 MW)
SECTION-VI
PART-A
A-6
LOW PRESSURE PIPING
SYSTEM
PAGE
2 OF 5

b) Surface preparation, priming and painting of all non-insulated above ground
piping and equipment except galvanized steel piping & surfaces , stainless
steel piping & surfaces and gun metal surfaces.
Paints and varnishes, primers, thinners etc. as required for anti-corrosive
protection of piping & equipment above ground.
c) Bidder shall provide anti-corrosive protection (coating & wrapping or
anticorrosive tape) on the external surfaces of pipes to all directly buried
piping including galvanized carbon steel piping.
On the internal surface of all pipes 1000 mm and above, a coat of primer followed by
a hot coat of coal tar enamel paint or coal tar epoxy paint shall be applied.
Bidder's scope of supply/ work shall include but not be limited to items such as,
Pipes, headers and manifolds, bends, elbows, returns, tees, laterals, crosses,
reducers/ expanders, caps and closures, couplings, plugs, sleeves, and saddles,
stubs and bosses, unions and other similar fittings, flanges, gaskets, fasteners and
sealants, ring joints, backing rings, all types of valves including drain/ vent/ air
release valves, 3-way valves(where applicable) with test connection for instruments/
manifolds etc.actuators, specialties, orifices, flow nozzles, etc. as per finalized single
line flow diagrams and layout drawings/ isometric drawings.
1.03.00 The scope also covers the following:
a) Complete assemblies of hangers, supports anchor, guides, restraints, etc.
including welded attachments, clamps, devices tie-rods, turn-buckles, springs
and spring cages, shoes, rollers, trapezes etc.
b) Weather hoods for pipes crossing ceilings and walls.
c) Instrument tapping and stub connections, root valves, 3-way valves (where
applicable) with test connections, drains and vent valves & expanders /
reducers as required and instruments as indicated else where for instruments
supplied by the Contractor..
d) Drain funnels, drip pans, moisture traps etc. where ever required shall be
provided.
e) Instrument tapping, stub connections, root valves and instrument tubing up to
root valves for instruments supplied by the Employer for onward connections
by the Employer. Contractor shall furnish the list of all such tapping with their
X, Y, Z co-ordinates.

CLAUSE NO.

STAGE-II (2X660 MW)
SECTION-VI
PART-A
A-6
LOW PRESSURE PIPING
SYSTEM
PAGE
3 OF 5

f) All supporting attachments like plates, saddles, stools, shoes, base plate,
saddle plates, angles, channels, I-beams, trapeze, cantilevers, brackets,
sways, braces, nuts, bolts, cleats, clamps, needed to complete the erection
of piping system covered under this specification.
Anchor bolts, bed & foundation plates, pipe sleeves and Nuts to be
embedded in concrete for piping where ever indicated in the drawing. All
grouting and chipping work (including supply of cement, sand and stone
chips) for equipment foundations, pipe supporting etc.
Reinforced concrete valve chambers wherever required for underground
piping.
g) Excavation, preparation of bed, backfilling with compaction of soil and
removal of extra-earth to designated places in case of pipes to be buried.
h) Bidder shall also design, supply, fabricate, erect, set and commission all
hangers, tie-rods, turn-buckles, supports, guides, restraints, anchors, etc. as
required for the, piping system. This includes the provision of all associated
steel work including brackets, cradle supports, duck foots, channels, angles,
etc. It is Bidder's responsibility to estimate these requirements and include
them in their offer price. Whenever, straight run of the yard pipes are more
than 300 meters, flexibility analysis shall be conducted by the contractor to
identify the requirement of loops, type of supports etc.
i) In covered concrete trenches bidder shall supply necessary supporting
materials such as stools, saddles, base plates, clamps, U-bolts, angles, clips
etc.
j) Bidder shall supply all necessary drains and vents with drain & vent valves
including anti-flash funnels and moisture traps for compressed air system as
required for the safe and effective draining-venting of the piping systems
based on the approved flow scheme / single line diagram. It is bidder's
responsibility to identify the requirements of drains, vents, and supply the
necessary pipe work, fittings, hangers and supports etc. for the same.
k) Bidder shall supply and install necessary matching pieces as may be needed
for connection of piping systems with equipment terminals, valves and
specialties.
l) Bidder shall erect all instrument impulse piping and fittings from the tap-off
point of the last root valve including the root valve and instruments.
m) Bidder shall perform necessary internal machining of pipe for installing
orifices, flow nozzles, straightening vanes etc.
CLAUSE NO.

STAGE-II (2X660 MW)
SECTION-VI
PART-A
A-6
LOW PRESSURE PIPING
SYSTEM
PAGE
4 OF 5

n) The Bidder shall prepare the flow diagrams, detailed dimensional piping
layout/ Isometric/ fabrication/ As built drawings of all the systems along with
Cross sectional drawings, showing all supports and equipment as required.
o) In addition to submission of drawings as stipulated above bidder
shall also furnish the data/ documents with respect to following:
1) Thickness calculation of CW duct/large diameter buried pipes as per
AWWA-M-11.
p) Bidder's scope of supply for fabrication, erection, cleaning, testing and
commissioning of the piping systems installed by him shall include the
following:-
All welding consumables like welding electrodes, filler rods and wires; gases
like oxygen, acetylenes, argon, carbon-dioxide, propane, backing rings etc.
Films for radiographic examination of welds.
X-ray and Gamma -ray equipment including isotopes, dye penetrants, and
other required non-destructive testing materials and equipment (all to be
taken back by the Bidder after completion of work).
All heating and stress relieving equipment, thermocouples asbestos blankets,
cables, temperature recorders, charts heat sensitive chalks and crayons etc.
(All to be taken back by bidder after completion of work).
All machinery, equipment tools and tackles as required for transportation
handling, fabrication and erection (All to be taken back by Bidder after
completion of work).
All equipment/ materials as required for cleaning, flushing, blowing out and
hydro testing of the piping systems; these shall include but not be limited to
pumps and compressors with prime movers, instruments, pipe work with
supports, valves, strainers and other specialties, blanks, plugs, spool pieces,
dummy plates, electrical accessories, etc. (All to be taken back by Bidder
after completion of work).
All scaffolding materials and false work (To be taken back by Bidder after
completion of work).
1.04.00 The Contractor shall provide Services of erection superintendent and foremen, fitters
and riggers, welders, transport and crane operators and other skilled and unskilled
labour.

CLAUSE NO.

STAGE-II (2X660 MW)
SECTION-VI
PART-A
A-6
LOW PRESSURE PIPING
SYSTEM
PAGE
5 OF 5

The design engineering and providing all temporary pipe work as required for
erection, cleaning, flushing, blowing out, testing and commissioning of the piping
system is the responsibility of the Bidder.
The Bidder's scope shall include design, supply of required structural steel (except
those which are specifically excluded), their fabrication and erection where ever
required.
The Bidder shall include in his offer a complete set of special tools and tackles
required for handling the various equipment / piping system during maintenance.
Bidder scope of services shall include the following also.
i) Obtaining approval from Chief Inspector of Boiler as per Indian Boiler
Regulation, (IBR - 1950) for design/ fabrication/ erection / testing of piping /
fittings / valves and specialties coming under the purview of IBR, if any.
ii) The bidder shall also identify and satisfy all other statutory code requirement
as may be necessary for the piping systems covered in this specification.
iii) Certified copies of test reports for all tests and examinations specified in the
specification shall be furnished to the Project Manager. Cost of meeting all
statutory requirements and furnishing the required certificates shall be
deemed included in the proposal price.

SECTION-VI
PART - A
A - 7
(NOT USED)
SECTION-VI
PART - A
A - 8
HYDROGEN GENERATION PLANT
CLAUSE NO.

STAGE-II (2X660 MW)
SECTION-VI
PART-A
A-8
HYDROGEN
GENERATION PLANT
PAGE
1 OF 1

1.00.00 HYDROGEN GENERATION PLANT

A hydrogen generation plant has been envisaged in order to fill up high pressure
hydrogen cylinders which are required for generator initial fill up and regular make
up required for generator rotor cooling. Hydrogen generation is accomplished by
water electrolysis process. It is proposed to provide a hydrogen generation plant of
12 NM/hr with two streams of electrolysers each of capacity 6 NM/hr with three
hydrogen compressors each of capacity 7.5 NM/hr along with auxiliaries. The plant
shall be designed as per the regulations of the Explosives Authority with all the
required safety aspects, instrumentation control, including online hydrogen purity
analyser system and control panel.

2.00.00 Special tools and tackles and handling arrangement for maintenance shall be
supplied by vendor.

SECTION-VI
PART - A
A - 9
SERVICE ELEVATORS
CLAUSE NO.

STAGE-II (2X660 MW)
SECTION-VI
PART-A
A-9
SERVICE
ELEVATORS
PAGE
1 OF 1

SERVICE ELEVATORS

1.00.00 ELEVATOR

1.01.00 Passenger Elevators for TG Building, Service Building and Administration
Building

The Passenger elevators for TG Building, Service Building and Administration
Building shall be as under.

(i) Two (2) nos. panoramic type elevator with five glass panels on rear side
having capacity of 13 persons (884 kg.), for Administration building.

(ii) Two (2) nos. conventional type elevator having capacity of 13 persons for TG
Building.

(iii) Two (2) nos. conventional type elevator having capacity of 13 persons for
Service Building.

1.01.01 The scope shall include all items / accessories, service along with all electrical
equipment etc. required to meet all design, installation, operation, safety, protection
and other requirements of IS: 14665 (latest edition) (all parts), 'Lift' and service lifts'.
This scope shall include all items / devices needed to comply with the requirements
indicated elsewhere in the specification. The scope shall include but not limited to
the following:

(a) 1 No. fireman's switch for each elevator.

(b) Machinery supporting Beam.

1.01.02 The location of Elevators shall be as per tender drawings enclosed with the
specification.

1.01.03 Complete erection, testing and commissioning including all testing and
commissioning materials, consumables and other tools and tackles required for
erection.

1.01.04 To obtain necessary local administration permits / approvals and make
arrangements for inspection and tests required thereby.

SECTION-VI
PART - A
A - 10
POWER CYCLE PIPING
CLAUSE NO.

STAGE-II (2X660 MW)
SECTION-VI
PART-A
A-10
POWER CYCLE PIPING
PAGE
1 OF 9

POWER CYCLE PIPING
1.00.00 GENERAL
1.01.00 Scope of supply and works for Power Cycle piping system shall include the piping
systems as listed below.
(a.) Auxiliary steam piping from auxiliary steam header upto user point.
(b.) All extraction steam piping
(c.) Complete Feed water piping including booster pumps suction, boiler feed
suction & discharge piping upto inlet of NRV (in Boiler envelope) at
economiser upstream, re-circulation, BFP warm up (if applicable) and leak
off.
(d.) BFP turbine exhausts piping to condenser.
(e.) Spray piping system for the following , as per the scope indicated in tender
drawings:
(1.) Reheater attemperation,
(2.) HP Bypass and LP Bypass system
(f.) Condensate piping system
(g.) Heater drains and vents piping system
(h.) Steam drains from piping / equipment(s) in the scope of bidder to flash
Tank(s) / flash tank manifold(s) as per the scope indicated in the tender
drawings.
(i.) Flash tanks including drain and vent piping.
(j.) Valve gland sealing piping system
(k.) Miscellaneous line drains and vents.
(l.) Complete safety valve exhaust piping for SVs / SRVs on piping/equipment in
Bidders scope.
(m.) HP Bypass warm-up line
(n.) LP Bypass warm-up line
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STAGE-II (2X660 MW)
SECTION-VI
PART-A
A-10
POWER CYCLE PIPING
PAGE
2 OF 9

(o.) Complete chemical cleaning piping system (Temporary).
(p) Complete steam blowing piping system (Temporary)
(q) Any other piping system required to make the power cycle piping, in the
bidders scope, complete.
1.02.00 Design, manufacture, supply, erection, testing and commissioning of complete
piping /fittings / accessories, valves and specialties, strainers, expansion joints,
restraints, hangers/ snubbers / shock absorbers/ supports with all components &
attachments, thermal insulation etc. for the above piping systems in bidders scope.
1.03.00 All auxiliary steel structures (including structures in C-D Bay, boiler envelope etc.)
required for providing proper supporting arrangement for the piping systems in
bidders scope.
1.04.00 For the above piping systems scope shall include complete design and engineering
including but not limited to pipe sizing, flexibility analysis, hanger support
engineering, engineering of thermal insulation etc. and shall be to Employer's review
and approval.
1.05.00 Steam blowing of piping systems, as specified elsewhere in the technical
specification, after complete erection is to be carried out, which includes supply,
erection and dismantling of temporary piping, pipe spools, supports, valves, fittings,
blanking plates etc.
1.06.00 Chemical cleaning of piping systems, as specified elsewhere in the technical
specification, after complete erection is to be carried out, which also includes
complete supply, erection and dismantling of temporary piping, valves and fittings
etc.
1.07.00 In case the steam to the turbine enters from the top casing, flange(s) shall be
supplied for the piping connected to the steam inlet nozzle on turbine top casing.
This is to facilitate dismantling of turbine top casing during maintenance without
cutting the pipe.
1.08.00 Providing other necessary services for making the piping systems in bidders scope
complete.
1.09.00 All paints and primer as required and suitable for environment / conditions prevailing
at site.
1.10.00 All supplies, works, services shall comply with the detailed scope given in the
subsequent clauses of this Sub-section.
CLAUSE NO.

STAGE-II (2X660 MW)
SECTION-VI
PART-A
A-10
POWER CYCLE PIPING
PAGE
3 OF 9

2.00.00 SCOPE OF SUPPLY
2.01.00 Pipes and fittings
(a.) Piping, fittings, stubs, plugs, flanges, caps, steam traps, break-down orifice,
drip pan and other accessories for the piping systems identified above and
as per approved schemes.
(b.) The Contractor shall supply all standard and non-standard matching pieces
as may be needed for the piping systems (in contractors scope) and for
connection of these piping systems at terminal points.
(c.) Pipe stubs for mounting thermowells and other instrumentation, including for
the instruments supplied by others, along with necessary root valves,
reducers / matching pieces and instrument tubing
(d.) Thermal insulation and cladding alongwith all necessary accessories for all
piping systems, etc. in bidders scope
(e.) Thermal insulation and cladding alongwith all necessary accessories for all
the equipment and tanks in the bidders scope.
(f.) The contractor shall also design and provide for additional guides/
stops/restraints etc. alongwith auxiliary steel for control of pipe line vibration
within allowable/ acceptable limits
2.02.00 Valves and Specialties
Valves, actuators and specialties including expansion joints, orifice plate assemblies,
steam traps, strainers, instrument root valves, etc. for the systems specified
The Contractor shall also supply special accessories like floor stands, chain
operator, extended spindle etc. as required. Valve, especially for which approach
from existing floors are not possible for O&M, bidder shall provide appropriate
platforms with the access ladders for the same.
2.03.00 Hangers and Supports
All pipe supporting elements such as constant load spring hangers, variable spring
hangers, supports, guides, restraints, stops, etc. and all associated auxiliary steel
and hardware such as beams, channels, insert plates section attachments to pipe
supports, pipe and beam clamps, straps, slings, stools, shoes, saddles, devices,
rods, turn buckles, graphite /steel plate / Teflon sheet etc. for all the systems
specified.
CLAUSE NO.

STAGE-II (2X660 MW)
SECTION-VI
PART-A
A-10
POWER CYCLE PIPING
PAGE
4 OF 9

2.04.00 Miscellaneous Erection ,Testing and cleaning Materials
(a.) All erection material such as bolts, nuts, washers, gaskets, electrodes, filler
materials, welding gas, consumable inserts and backing rings, accessories
and miscellaneous specialties required for the proper installation of piping
systems.
(b.) All temporary piping, supports, valves, blanking plates, caps, pumps,
pressure gauges, plugs, gaskets, bolts & nuts, spools, tools & tackles,
special devices (as applicable) for stop valves/control valves and other
accessories required to complete the Hydrostatic testing of piping systems in
bidders scope .
(c.) The bidders scope shall also include supply of necessary blanks, blanking
inserts/hydraulic kit or other special devices and accessories (as applicable)
for the Stop valves/control valves supplied by the TG package contractor and
installed on SG Package contractors scope of piping (i.e. MS,HRH, CRH,
HP&LP Bypass) for carrying out hydrostatic testing of these piping systems
with the Stop valves/control valves in circuit, as per the scheme/procedure
for hydrostatic testing approved by employer.
(d.) All temporary piping, supports, valves, blanking plates, caps, pressure
gauges, plugs, gaskets, bolts & nuts, tools & tackles, spool pieces for
valves/control valves/ flow nozzles & specialties etc., tanks and other
accessories as required to complete chemical cleaning operation of piping
systems in bidders scope as specified elsewhere in the technical
specification.
(e) Blow out tools, blow through tools, temporary valve heads/valve blow down
cover plate/ flanges, blanking inserts, strainers, gaskets, bolts & nuts, special
tools & tackles, etc. as required for HPT stop & control valves, IPT stop &
control valves, CRH NRVs & HP & LP By Pass valves & overload valve as
per the scheme & procedure prepared by SG contractor and approved by
employer during detailed engineering stage for the steam blowing operation
(SG scope) of MS,HRH,CRH,HP&LP By Pass piping systems.
3.00.00 SCOPE OF OTHER SERVICES
3.01.00 Complete design, engineering, etc. for the power cycle piping systems and other
piping systems included in this specification shall be the responsibility of the
Contractor. Employer's responsibility/ function in this connection shall be limited to
review and approval of Bidder's design/ calculation, engineering, drawings, and
documents. Bidder's scope of services for complete engineering of the power cycle
piping systems shall include but not be limited to the following :
CLAUSE NO.

STAGE-II (2X660 MW)
SECTION-VI
PART-A
A-10
POWER CYCLE PIPING
PAGE
5 OF 9

(a.) Preparation of Engineering piping diagram indicating flow schematic, flow
parameter, pipe sizes, line designations and tag nos. of various components
etc. and submission of same to Employer for review.
(b.) Design parameter selection, pipe sizing calculation, pipe schedule, valve
schedule, insulation schedule, specialties schedule and hanger schedule for
the systems included in the Bidder's scope.
(c.) Preparation of preliminary as well as final composite piping layout drawings
and isometric drawing of pipe size 65mm NB & above and submission of
same to Employer for review and approval.
(d.) Preparation of isometric drawings, fabrication and erection isometric (with
material take off) drawings for shop fabricated piping which are of size 65
mm NB and above and submission of the same to the Employer for review
and approval.
(e.) Preparation of layout drawings & isometric drawings for site routed piping
and submission of the same to the Employer for records.
(f.) AS BUILT" drawing of the piping layout shall also be prepared by the
Contractor based on any layout modifications made at site and submitted to
Employer for records.
(g.) Approval from Statutory Authorities
(1.) It is the sole responsibility of the contractor to identify and obtain all
necessary approvals from various Government
agencies/board/statutory authorities/IBR etc., as applicable for the
design, manufacture and testing of pipes, valves, fittings, specialties
etc.
(2.) The contractor shall also identify and obtain all necessary approvals
from the IBR authority in the state where the plant is being installed,
for the erection/testing/commissioning/registration and any other
requirement as required by IBR.
(3.) In order to obtain the above approvals, all necessary documentation
etc. required shall be arranged and furnished by the Contractor to the
statutory authorities.
(h) In case any localized modifications/re-routing/re-erection etc. are required for
the piping systems (in contractors scope) & its supporting arrangement even
after approval of drawings/during erection, then the same shall be carried out
by the contractor under his scope of supply & services in consultation with
employer.
CLAUSE NO.

STAGE-II (2X660 MW)
SECTION-VI
PART-A
A-10
POWER CYCLE PIPING
PAGE
6 OF 9

3.02.00 The Contractor shall design in detail all piping supports including restraints, guides,
stops etc., after deciding the final location of hangers and supports and based on
final stress analysis and hanger/ support load data originated by him. Bidder shall
submit to Employer for review his hanger design documents in the form of hanger
GA drawings and hanger schedule.
3.03.00 The Contractor shall furnish separate sketches for each hanger/ support, restraint,
anchor, etc. These sketches shall include the location with reference to column co-
ordinates, identification number, bills of material, design loads, operating load, spring
stiffness, amount of spring pre-compression etc., the method of attachment to the
pipe and steel structure. Additionally the sketches shall show a key plan referenced
to plant north and centre line elevation of the pipe at the point of attachment for cold
and hot conditions.
3.04.00 In order to ensure that all supporting elements, anchor and restraints have been
installed and adjusted in accordance with design documentation, the Contractor
shall inspect and log the hanger readings for the hangers associated with the power
cycle piping system as follows:
(a.) After hydrostatic test with the piping in the cold position, with all travel stops
removed, with the pipe completely insulated and in all respect ready for
startup.
(b.) Piping in hot position, with the unit operating at rated parameters
(c.) Piping in hot position (rated parameter condition) after six (6) months of
operation
(d.) Piping in cold position during the first complete shutdown after at least six (6)
months of operation.
(e.) After steam blowing, in case steam blowing is applicable for the line
3.05.00 At the time of each inspection, the Contractor will determine the necessity for
revision, adjustment or replacement of pipe supporting elements, restraints and
anchors. Any changes proposed shall be subject to the concurrence of the
Employer. The changes shall be incorporated by the Bidder after Employer's
concurrence. A written record shall be furnished to the Employer.
3.06.00 Design and engineering of all temporary piping that are required for the
commissioning activities of power cycle piping system shall be as specified herein.
3.07.00 All shop tests as required by the applicable codes, ANSI Standards, IBR and other
standards enumerated or specified.
CLAUSE NO.

STAGE-II (2X660 MW)
SECTION-VI
PART-A
A-10
POWER CYCLE PIPING
PAGE
7 OF 9

(a.) Obtaining approval from Chief Inspector of Boiler as per Indian Boiler
Regulations (IBR - 1950). This shall include furnishing all necessary
certificates for design, manufacture and testing for pipe, valves, fittings,
specialties, certificate of manufacture and test for each erected piping in the
relevant formats to the Chief Inspector of Boilers, obtaining his approval and
furnishing the same to the Employer.
(b.) The Contractor shall also identify and satisfy all other statutory code
requirements as may be required for the piping systems covered in this
specification.
3.08.00 Certified copies of test reports for all tests and examinations specified in the
specification and for the mandatory test and analysis required by ASME/ ASTM
material specification, for the materials used for piping, shall be furnished to
Employer.
3.09.00 Drawings, data and design calculations as specified in this Sub-section and
elsewhere in the specification shall be furnished by the Contractor to the Employer
for review.
3.10.00 Cleaning including chemical cleaning of all systems as specified herein and
installation of temporary pipe work for the same.
3.11.00 Making temporary closures on piping system as required for performing hydrostatic
test on all piping.
3.12.00 Steam blowing of all piping systems as specified elsewhere in the technical
specifications including temporary pipe work, making temporary closures on piping
systems etc. as required.
3.13.00 Interface Connections:
(a) Making interface connections, as applicable, for the piping systems in TG
package contractors scope at Terminal points with valves/equipment/Piping
etc. supplied by employer/others.
(b) However, in the following cases, interface weld joints at SG/TG terminal
points in MS,HRH,CRH,HP&LP By Pass piping systems (SG scope) shall be
done by TG package contractor , as part of TG package scope, at TG
contractors works/ TG equipment manufacturers works:
(i) If the nozzle material of TG equipment/ valves in TG package
contractors scope (i.e., HPT nozzles, HPT stop & control valves, IPT
nozzles, IPT stop & control valves, CRH NRVs & HP & LP By Pass
valves/over load valves), to which piping/matching piece in SG
CLAUSE NO.

STAGE-II (2X660 MW)
SECTION-VI
PART-A
A-10
POWER CYCLE PIPING
PAGE
8 OF 9

package contractors scope is to be welded, is of dissimilar material
and the TG equipment manufacturer/ valve supplier recommends
only for shop welding at equipment manufacturers works for such
joints SG package contractor shall supply & deliver the required
matching pieces, upon employers advice, at TG manufacturers/ TG
contractors works and all expenses on account of supply/delivery of
matching pieces to TG contractors/ TG manufacturers works shall be
in the scope of SG contractor.
(c.) In the event of (b) above, TG contractor/TG equipment manufacturer shall
provide the following:
(i) furnish the details of matching pieces required (Viz, dia, thickness,
length & quantity) to be supplied by SG contractor for shop welding
to respective equipment/valves in TG contractor/TG equipment
manufacturers works and
(ii) carry out edge preparation as per the EP details furnished by SG
contractor during detailed engineering at the pipe end/open end of
the matching pieces supplied & delivered by SG package contractor,
before dispatch of the equipment/valves to site (after welding them
with matching pieces).
3.14.00 TG contractor shall provide necessary works/services, wherever applicable, for
assembling & dismantling of HPT stop & control valves, IPT stop & control valves,
CRH NRVs, HP & LP Bypass valves etc.
3.15.00 Installation/mounting of pipe mounted items, supplied by employer/others, on the
piping system.
3.16.00 Performing all tests and implementing all quality control procedures as specified
herein including provision of testing equipment, stress relieving equipment,
radiography equipment and any other equipment necessary to meet the
requirements of the specification.
3.17.00 Apart from carrying out chemical cleaning, the work shall include disposal of water,
clean up, reinstatement of the cleaned piping system, dismantling and removal all
temporary piping, equipment and materials from site.
3.18.00 Painting of piping system shall be in accordance with the stipulations laid down
elsewhere in this specification.
3.19.00 Weather hood for pipes crossing ceilings and walls.
CLAUSE NO.

STAGE-II (2X660 MW)
SECTION-VI
PART-A
A-10
POWER CYCLE PIPING
PAGE
9 OF 9

3.20.00 Providing complete interface engineering with the suppliers of other equipment &
piping with which the piping systems in contractors scope is to be connected or
have interface in any other way.
3.21.00 Stress Analysis
The Contractor shall carryout stress analysis of piping system and submits for
Employers approval. .
(a.) A write-up on the stress analysis including codes used and design conditions
considered.
(b.) A copy of the computer print out for input data for the various design
conditions considered for stress analysis along with the stress diagram
(piping isometric marked with node points marked.)
(c.) Analysis results in tabular form giving calculated and allowable
reactions/forces/moments on equipment nozzles/terminals for the various
design conditions considered for analysis.
(d.) Allowable and calculated code stresses at various node points in the piping
for the design conditions considered based on code requirements for
analysis.
(e.) Analysis results giving calculated forces and moments and movements at
various hanger/support/restraint/anchor points from the static analysis
corresponding to various thermal / operating conditions, sustained load case,
hydro load case (other than water lines) and occasional loads ,as applicable,
for each piping system analysed .

SECTION-VI
PART - A
A - 11
OTHER CRANES AND HOISTS
CLAUSE NO.

STAGE-II (2X660 MW)
SECTION-VI
PART-A
A-11
OTHER CRANES AND
HOISTS
PAGE
1 OF 1


CRANES/ HOISTS / MONORAIL

1.00.00 CRANE, HOIST

1.01.00 Suitable EOT Crane/HOT crane/monorail beams with hoists/chain pulley blocks of
adequate capacity, to meet the erection and maintenance requirements are to be
provided by the vendors for the various equipment/areas. Some of the
areas/equipment not covered by TG hall EOT crane are indicated below. For
balance areas/equipment, not listed herein after the requirements of Specification
shall be followed.

(a) Feed water heaters & deaerators.

(b) Various pumps & Heat Exchangers.

(c) Condenser water boxes (front & rear), vacuum pumps, CW butterfly valves,
control fluid room etc.

(d) Auxiliary cooling water pumps and DM cooling water pumps of ECW systems
and Plate heat exchangers.

(e) Central lube oil system room.

(f) Any other equipment.

The above requirement is indicative only, the requirement given in the respective
chapter is to be adhered to.

SECTION-VI
PART - A
B - 1
ELECTRICAL SYSTEM / EQUIPMENT
CLAUSE NO.

STAGE-II (2X660 MW)
SECTION-VI
PART-A
B-1
ELECTRICAL SYSTEM
/ EQUIPMENT

PAGE
1 OF 3

ELECTRICAL SYSTEM / EQUIPMENT
1.00.00 GENERAL

The Bidder scope shall include design, manufacture, engineering, inspection &
testing at supplier's works, packing, forwarding to site, unloading, erection , testing ,
commissioning and performance testing of the Electrical equipment / system and
works indicated in this chapter. Unless explicitily stated to be common for all the
units, the Bidder shall provide all system/equipment for each of the units. The
electrical scope shall be described briefly in the following clauses, but not limited to
it.

2.00.00 GENERATOR AND AUXILIARY SYSTEM

2.01.00 Generator complete in all respects including stator, rotor, bearings, couplings,
terminal pads with palms and all its associated supervisory and instrumentation
system.

2.02.00 Complete hydrogen cooling, carbon dioxide and nitrogen gas systems as applicable
including the necessary piping and pipe supports, valves, measuring system
alongwith the control panel and gas cylinders.

2.03.00 Complete seal oil system including the necessary tanks, pumps, motors, coolers,
strainers, piping and pipe supports, valves, measuring system alongwith control
panel.

2.04.00 Complete water cooling system where applicable including the necessary tanks,
pumps, motors, heat exchangers, strainers, piping and pipe supports, valves,
measuring system alongwith control panel.

2.05.00 Complete excitation system (static type) with excitation transformer, thyristor, and
field flashing equipment etc. as applicable along with the Voltage regulator,
deexcitation equipment, cables/bus duct and all necessary control, annunciation and
monitoring equipment mounted on suitable panel

3.00.00 MOTORS

3.01.00 Motors along with couplings and coupling guards for all rotating auxiliaries covered
under this package.

4.00.00 LT SWITCH GEAR

i) Hydrogen Generation plant MCC

ii) DC motor starter panels including starting resistors

CLAUSE NO.

STAGE-II (2X660 MW)
SECTION-VI
PART-A
B-1
ELECTRICAL SYSTEM
/ EQUIPMENT

PAGE
2 OF 3

iii) Starter panels for the following

a) Oil purification system of each TG unit

b) Central oil purification system for TG

c) Condenser on load tube cleaning system

iv) Local Emergency push button (PB) stations for all drives energised from
MCC's under contractor scope.

5.00.00 CABLES

5.01.00 All LT power & control cables required for connection between contractor's
equipment/devices.

5.02.00 CABLING

1) Employer will supply and erect the cable trays and its supporting structure in
the Main cable routes both for employer's cable and contractor's cable
covered in Electrical and C&I section. Contractor shall provide tray and
support arrangements for his cables in the branch routes (i.e the route to
each equipment, instruments, J B's etc from the nearest main route).
However , in case of hydrogen generation plant , Contractor shall supply and
erect complete galvanised cable trays and its prefabricated bolted type
flexible galvanised supporting structure for his cables as well as for
employer's incoming cables within hydrogen plant building. Contractor shall
also provide cable tray structure up to the terminal point (near the building)
for employer's incoming cable.

2) Contractor will lay and terminate the cables under his scope of supply on the
main tray route( provided by the employer) and branch routes (to be provided
by the contractor).

3) Contractor shall furnish the complete main cable route drawing (tentative),
and cable tray routing upto the drives / equipments / panels, indicating the
contractor's tray requirement / location of equipment.

4) Employer shall prepare main cable tray routing based on the contractor's
input as mentioned above and shall submit the same to contractor for review
and clearance.

5) The contractor shall furnish the complete and final feeder list for LT system
and HT system for all loads and drives under the scope of supply of
contractor to employer in advance and as per mutually agreed schedule.
Contractor shall indicate the location of his equipments in feeder load list.
CLAUSE NO.

STAGE-II (2X660 MW)
SECTION-VI
PART-A
B-1
ELECTRICAL SYSTEM
/ EQUIPMENT

PAGE
3 OF 3

6) Contractor shall furnish the cable list as per mutually agreed format for all the
cables under his scope of supply under electrical and C&I section to facilitate
preparation of cable schedule.

7) Interconnection diagram for cables between contractor's equipments shall be
prepared by the contractor.

8) Contractor shall provide all accessories such as rigid/ flexible conduits,
fittings, junction boxes, tying materials, cable tags, markers etc. for the
cables under his scope.

9) Contractor shall provide cable glands and lugs for all equipments in his
scope.

6.00.00 LIGHTING

6.01.00 Complete lighting for internal and external areas of hydrogen generation plant
building.

7.00.00 EARTHING AND LIGHTNING PROTECTION

7.01.00 Complete overground earthing and lightning protection for hydrogen generation plant
equipment and building.

8.00.00 ELECTRICAL ACTUATORS

8.01.00 Electric actuators with integral starters along with associated accessories etc shall
be supplied on as required basis for Valves / Dampers to meet the functional and the
other specification requirements.

9.00.00 PAINTING FOR ELECTRICAL EQUIPMENT

9.01.00 The painting of all electrical equipment shall be epoxy based with suitable additives.
The thickness of finish coat shall be minimum 50 microns (minimum total DFT shall
be 100 microns). However in case electrostatic process of painting is offered for any
electrical equipment, minimum paint thickness of 50 microns shall be acceptable for
finish coat. The Contractor shall furnish the complete painting details during detailed
engineering stage.
10.00.00 Type test
Contractor shall carry out/ submit all type tests on electrical equipments as stipulated
in relevant chapters of Part-B of technical specifications.

SECTION-VI
PART - A
IIC - 01
CONTROL AND
INSTRUMENTATION SYSTEM
CLAUSE NO.

STAGE-II (2X660 MW)
SECTION-VI
PART-A
IIC-01
CONTROL AND
INSTRUMENTATION
SYSTEM
PAGE
1 OF 15

CONTROL AND INSTRUMENTATION SYSTEM
FOR STEAM TURBINE, GENERATOR AND AUXILIARIES
1.00.00 GENERAL
1.01.00 The Contractor shall provide Control & Instrumentation system for control,
monitoring and operation of the systems, equipment etc. covered under these
specifications, in all regimes of operation in safe and most efficient manner. The
scope of work for the equipment, material and system to be furnished in
accordance with this specification shall include design, engineering, manufacture,
fabrication, assembly, pre-shipment testing at manufacturer's works, proper
packing for transportation, delivery at plant site, unloading, storage, installation,
interconnection with related plant and equipment, calibration, testing,
commissioning and putting the Control and Instrumentation System together with
all accessories, auxiliaries and associated equipment as specified hereinafter in a
fully operational condition and in the manner acceptable to the Employer as
covered under this specification. The Contractor shall also provide all material,
equipment and services which may not be specifically stated in the specifications
but are required for completeness of the equipment/systems furnished by the
Contractor and for meeting the intent and requirements of these specifications.
The work shall be consistent with modern power plant practices and shall be in
compliance with all applicable codes, standards, guidelines and safety
requirements in force on the date of award of the contract. The requirements of
statutory Authorities (e.g. MOEF, Inspector of Factories, IBR, TAC,
CPCB/SPCB/CERC etc with regard to various plant areas like main plant etc.)
shall be complied even if not actually spelt out. It shall be the responsibility of the
Contractor to coordinate with Employer and offer Control and Instrumentation
System to meet the actual requirements of the plant and furnish a complete
system as per clause 1.01.00 above, and also to coordinate with other system
vendors for proper interfacing of Control and Instrumentation system vendors with
all other related equipment and systems.
1.02.00 SCOPE OF SUPPLY & SERVICES :
1.02.01 The following clauses describe the brief scope of supplies only. The detailed
technical specifications are stipulated under various Control and Instrumentation
Sub-sections, Part - B, Section-VI of the specification as well as in various other
Parts of the Technical Specifications. Also refer to Appendix-1 to Part-A, Section-
VI of the specification for general requirements and contract quantities.
1.02.02 Where-ever in the specification ,Bidders offering as per his standard and
proven practices are identified to be acceptable, The same shall be accepted
(with project/plant specific customisation as necessary) based on the
documentary evidence of the reference project/plant indicated in the Bid
CLAUSE NO.

STAGE-II (2X660 MW)
SECTION-VI
PART-A
IIC-01
CONTROL AND
INSTRUMENTATION
SYSTEM
PAGE
2 OF 15

document. Any other reference project, if proposed by the bidder during detailed
engineering, shall be strictly as agreed by the employer during detailed
engineering.
1.02.03 Where-ever in the specification ,Bidders offering as per his standard and
proven practices are identified to be acceptable, the bidder is required to provide
the detailed explanation / concepts , if required by employer, of such
implementation along with the standard documentation. The list of such minimum
documentation is as identified in the technical specification.
1.03.00 Unless explicitly stated to be common for all the unit(s), the Contractor shall
provide all system/equipment described in this specification for each of the unit(s).
1.04.00 NOT USED.

2.00.00 DISTRIBUTED DIGITAL CONTROL, MONITORING & INFORMATION SYSTEM
(DDCMIS)
2.01.00 Latest state of the art microprocessor based Distributed Digital Control, Monitoring
& Information System (DDCMIS) shall be provided comprising of the following as
a minimum and meeting all requirements specified under Sub-section IIIC-02
DDCMIS of Part -B, Section-VI of Technical Specification and the following
annexure of this subsection:
(a.) IIIC-02G: HMI Hardware
(b.) IIIC-02J : Security Policies and Procedures

2.02.00 Control system (Including its Measurement system)
2.02.01 The control system shall generally consist of the following system(s):-
2.02.02 Steam Turbine and Generator (STG) C&I system comprising of the following :-
(a) Steam Turbine and Generator (TG) C&I system comprising of Turbine
Protection System Function (TPS) including Generator Mechanical
Protection, Turbine Electro-hydraulic Governing system, Turbine Stress
Control System (TSCS)/ Turbine Stress Evaluation System (TSES) and
turbine supervisory system Gland steam pressure control and turbine oil
temperature control for main and BFP turbine, Automatic Turbine Testing
(ATT) for main turbine etc.
(b) Turbine supervisory system
(c) Turbine Electro-hydraulic Governing system
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(d) Automatic Turbine Run up System (ATRS) including
(1.) Oil System
(2.) Vacuum system.
(3.) Gland steam pressure control
(e) HP/LP Bypass Control System
(f) Turbine -Generator control system for Seal oil, primary water, Generator
gas temperature control etc.
(g) BFP Drive Turbine and its auxiliaries OLCS and CLCS control
(h) Miscelleonous controls like
(1.) Condenser on load tube cleaning & SCS controls
(2.) Turbine lub oil purification control
(3.) central lub oil purification control
(i) Hydrogen system control
(j) CPU controls.
The functional grouping of the above system(s) shall be as per Appendix-1 to C&I
(contract quantities) Part-A, Section-VI.
2.02.03 The above system(s) shall include their respective measurement system for signal
acquisition, conditioning and signal distribution of various types of inputs/outputs,
meeting specification requirements including respective Hardware requirements
as stipulated in Sub-section -DDCMIS, Part-B, Section-VI of Technical
Specification.
2.03.00 Human - Machine Interface & Plant Information System (HMIPIS)
2.03.01 HMIPIS shall be as detailed out in Sub-section DDCMIS of part -B, Section-VI of
Technical Specification. The quantities of HMIPIS items/equipments shall be as
per Appendix-1 to C&I(contract quantities) Part-A, Section-VI and relevant tender
drawings.
2.03.02 State of the art computer furniture shall be provided in the Control Equipment
Room for HMIPIS items/equipments as indicated as per Appendix-1 to C&I
(contract quantities) Part-A, Section-VI and relevant tender drawings.
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2.03.03 Information Stations (Servers/Workstations) in redundant configuration to be used
for applications like historical storage and retrieval of long-term storage and
retrieval of data, generation of reports, logs etc. Servers/Work station which are
located in programmers room will be multiplexed with the help of Matrix KVM
switcher for 6 users(Refer Drawing No 0000-110-POI-A-014.)
2.04.00 Data Communication System
Data Communication System shall be as detailed out in Sub-section DDCMIS of
part -B, Section-VI of Technical Specification.
2.05.00 System programming, diagnostics & documentation facility.
2.05.01 The programmer station, system documentation facility for automatic generation
of system documentation and the diagnostic system shall be as detailed out in
Sub-section DDCMIS of part -B, Section-VI of Technical Specification. The
quantities shall be as per Appendix-1 to C&I(contract quantities) Part-A, Section-
VI and relevant tender drawings.
2.05.02 Power Supplies
2.05.03 Redundant power packs/ supplies for powering the control systems described
above in system cabinets with necessary auctioneering and distribution.
2.06.00 Cabinets
(a.) System cabinets as detailed out in Sub-section DDCMIS of part -B,
Section-VI of Technical Specification..
(b.) Marshalling cabinets separate from system cabinets for terminating inputs
from field/swgr etc., for further wiring to control system and for terminating
outputs from MCC/SWGR etc. In case Bidders system design requires the
termination cabinet independent from system cabinet, the marshalling
cabinets can be combined with the termination cabinet.
(c.) In case it is bidders standard and proven practice not to have separate
marshalling cabinets, then the system cabinet can be suitably partitioned
to create separate marshalling area on the rear side of the system
cabinet to ensure segregation of the electronics module area from the
marshalling area.
(d.) Relay cabinet-housing relays for providing contact outputs by control
system to other system wherever contacts are used in circuit/scheme of
Control supply/power supply of more than 24 V and in cases where the VA
burden is more than the VA burden the Output module can drive.
Alternatively, these relays can also be mounted in termination/marshalling
cabinets also. It may be noted that relays can not be mounted in system
cabinets.
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2.07.00 Signal Exchange: The bidder shall provide all the signal exchange between TG
control system and Employers Station C&I package & SG packages as per
subsection IIIC-02, Part-B, Section-VI of Technical Specification.
2.08.00 Warranty and Annual Maintenance Contract
2.08.01 Warranty and Annual Maintenance Contract (AMC) for DDCMIS, as per Sub-
section DDCMIS, Part -B, Section-VI of Technical Specification.
3.00.00 MAIN EQUIPMENT RELATED CONTROL & INSTRUMENTATION SYSTEM
Other special C&I systems shall be provided by bidder including but not limited to
the following as a minimum as per the requirement of Sub-section Main Eqpt Inst.
Sys., Part -B, Section-VI of Technical Specification.
(a.) Turbine supervisory system (TSS) including vibration analyser, vibration
monitoring system, turbovisory instrumentation for Main Turbine and BFP
Turbine. Also provision for interfacing 100 raw buffer vibration signals from
plant auxiliary to be kept for vibration analysis and diagnostic.
(b.) The vibration analysis system shall be connected to Employer procured
SACS system at Corporate Centre for remote analysis of the turbine
vibrations by experts at Employers SACS center. For connectivity of the
turbine vibration system to Corporate Centre, a 2 mbps line is envisaged,
by the employer. The required bandwidth will be allocated for Bidders
system. Remote monitoring at SACS center shall not affect in any way the
turbine vibration system at site including the vibration analysis system at
site. It shall be possible to do vibration analysis simultaneously at site as
well as corporate centre. Entire vibration analysis functionality shall be
made available in the system at SACS center also, including all the types
of plots & alerts. The required Software Licenses shall be provided
accordingly to meet this requirement.
(c.) Auto synchronizer for Turbo-Generator.
4.00.00 MEASURING INSTRUMENTS (PRIMARY & SECONDARY)
The following shall be provided as minimum meeting specification requirements of
Sub-section MEAS INST of Part-B, Section-VI of Technical Specification.
4.01.00 For the instruments that are in the scope of the bidder as identified in the
subsequent clauses the specifcation applicability shall be as follows:-
(a) The instruments that are envisaged to be wired to Employers procured
BOP C&I/station C&I DDCMIS system ,these shall be provided meeting
specification requirements of Sub-section IIIC-04 ,MEAS INST of Part-B,
Section-VI of Technical Specification.
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(b) The instruments that are proposed to be connected to the DDCMIS system
in Bidders scope, Bidders standard instrumentation specification are also
acceptable if the instruments offered are as per the Bidders standard and
proven practice.
4.02.00 Unless stated other wise ,the contractor shall supply instruments like
Microprocessor based transmitters, thermocouples & RTDs, pressure/diff.
Pressure/temperature/flow switches & gauges, flow sensing elements (orifice
plates, flow nozzles, impact head type elements etc.) Ultrasonic, positive
displacement type flow transmitters, radar type level transmitters etc. for :
(a) Main plant and auxiliary plant on as required basis to meet the
control/interlock/protection/monitoring requirement, redundancy and other
requirement specified under technical specifications of this package
subject to minimum quantity as indicated in the tender PID. However, PT,
DPT, FT & LT which have been indicated in the tender PID as connected
to BOP-C&I/SG-C&I (being procured by employer under separate
package) are excluded from bidders scope of supply.
(b) Integral equipments which are not indicated in the tender drawings, but are
required for control, monitoring and operation of the equipment / plant
systems for which no P&IDs are enclosed. All the instruments shall be
provided to meet the actual system requirements and other requirements
specified under technical specifications subject to Employers approval.
(c) All temperature elements along with associated temperature transmitters
in the TG scope piping/ducts/equipments shall be provided by the
contractor (unless indicated otherwise) whether wired to Contractors
control system or Employers BOP C&I (Station C&I) control system . In
addition to temperature elements indicated in the tender P&ID, any other
temperature elements and temperature transmitters which are required for
control, interlocks, protection and monitoring of Contractor supplied
equipments/ systems shall be in the scope of the Contractor.
(d) How-ever for the temperature measurements that are proposed to be
connected to the control system in Bidders scope, direct connectivity of
these temperature elements(i.e. without Temperature Transmitters) to
Bidders control system is acceptable if it is a standard and proven
practice of the bidder.
(e) Generally, electronic transmitters shall be provided for the process
measurement that are in the scope of the bidder and connected to bidders
control system. How-ever the use of process actuated switches are also
acceptable if it is a standard and proven practice of the bidder.
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4.03.00 Rail mounted/ Rack mounted temperature transmitters for temperature elements
are to be provided by the contractor for the signals that are envisaged to be
connected to Employer procured DDCMIS system ,as per the followings.
(a) In case of multiple measurements of temperature for any application,
resulting in trip / protection, where logic implementation tolerates failure of
one TE (e.g. 2v3, 2v4 etc.), for only one of the TE, dual TT is to be
provided. In case of other applications, wherever single TE causing trip /
protection (either part of the single measurement or part of the multiple
measurement not tolerating for failure of one TE, e.g. 1v2, 1v3, 1v4 etc.),
for each of such TEs, dual input TT shall be provided.
(b) For other applications, if usages of dual input TTs is recommended by the
equipment manufacturers, the same shall also be acceptable. The exact
applications for which this type of transmitter to be provided shall be
finalised during detail engineering.
(c) Bidder shall provide enclosures/racks/J Bs for mounting the dual-input TTs
on as required basis. The number of Temperature Transmitters in
enclosures/ racks/ J Bs and the internal arrangement of the same shall be
subject to Employers approval during detailed engineering.
Remaining temperature transmitter are to be DIN rail mounting type
5.00.00 ELECTRIC POWER SUPPLY SYSTEM
(a.) Sets of Microprocessor based modular 24VDC power supply system shall
be used for powering the control systems including its network devices.
For number of sets, refer Appendix-1 to C&I contract quantities Part-A,
Section-VI.
(b.) Contractor shall provide power supply distribution panels/cabinets/boxes
for sub-distribution of DC/Main UPS/utility feeders on as required basis.
The power supply distribution box shall include change over circuitry
switch fuse units, MCBs, terminal blocks etc. suitable for application.
6.00.00 PROCESS CONNECTION & PIPING
6.01.00 For temperature transmitters following sub clauses are not applicable .For
mounting arrangements of temperature transmitters refer Section-VI, Part-A ,sub
section II-C-01 of the specification.
6.02.00 For all the local instruments and remote instruments that are skid mounted and
for instruments that are proposed to be connected to the STG integral controls
(i.e. Close loop control (CLC) ,Open loop Control(OLC) and protection pertaining
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to steam turbine and generator), Bidders standard and proven practice of Hook
up installation/Process connection & piping is acceptable.
6.03.00 How-ever for the instruments that are in the scope of the bidder as identified in the
tender P&IDs and that are not skid mounted, Process connection & piping
including all impulse piping, sample piping, pneumatic piping/tubing, valves, valve
manifolds, fittings and all other accessories required for proper installation &
completeness of impulse piping system, sampling piping system and air supply
system shall be as stipulated under Sub-section PCP, Part-B, Section-VI of
Technical Specification. The contractor shall provide Local Instrument racks
(LIRs)/J Bs for housing the transmitters and process activated switches in his
scope of supply on as required basis.
6.04.00 Bidder shall provide the necessary stubs, reducer after root valves, for Employers
furnished instruments to be mounted on Contractors equipments/ piping.
Connections/ welding of Employers impulse piping to the Contractors root valve
shall be done by the Employer.

7.00.00 INSTRUMENTATION CABLES, CONTROL & POWER SUPPLY CABLES &
CABLES SUB-TRAYS
7.01.00 All instrumentation cables twisted & shielded, FRLS PVC insulated, including
thermocouple extension cables and prefabricated cables, Power Supply cables,
optical fiber cables other than shown in exclusion, as applicable for
interconnection of all equipment/system/devices in Contractors scope as well as
for connection of signals from/to systems like MCC/LT SWGR/HT SWGR
/Temperature Transmitter etc. along with necessary laying & termination
accessories, hardware etc. shall be in the scope of the contractor.
7.01.01 The requirements specified under Sub-section INST CABLE, Part -B, Section-VI
of Technical Specification shall be applicable excpet for the following:-
For STG integral controls (i.e. Close loop control (CLC) ,Open loop Control (OLC)
and protection pertaining to steam turbine and generator) following is accepted

1. Fibre Optic cable, T/C cables and other special instrumentation cables as
per Bidders standard and proven practice.

2. Internal Panel Wiring as per Bidders standard and proven practice.

3. Termination philosophy of Instrumentation & Power Supply Cables (Refer
Table-A of Sub-section INST CABLE, Part -B, Section-VI of specifications)

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(a) For all devices/equipment identified at end A under Table A plug in
connector/screwed connection shall be offered as per standard &
proven practice of Bidder for :-

i) STG (Steam Turbine Generator)integral mounted J Bs

ii) Skid/equipment mounted J Bs for balance equipments

(b) For end B the cable termination philosophy for various equipment
shall be as follows:-

Marshalling cabinets/other cabinets-instrumentation cable
termination cage-clamp termination shall be offered. However, for
power and control cable, Bidders standard and proven practice
would be accepted.
7.02.00 All the instruments in the scope of the bidder and connected to the employers
control system shall be wired upto the input terminal of the J B by the bidder. The
contractor shall provide J unction boxes and all sub trays along with supporting,
connecting hardware etc. required for laying of instrumentation, control, power
and other cables etc. up to main cable trays on as required basis.
7.03.00 The cable interconnection philosophy to be adopted shall be such that extensive
grouping of signals by large scale use of field mounted Group J unction boxes
(J Bs) at strategic locations (where large concentration of signals are available,
e.g. valves limit & torque switches, switchgear) is done and consequently cable
with higher number of pairs are extensively used. However it shall be ensured that
any fault in any one cable shall not result in trip of TG and important auxiliaries.
8.00.00 CONTROL VALVES & ACTUATORS
8.01.00 For the pneumatic operated control valves that are in the scope of the bidder as
identified in the subsequent clauses the specification applicability shall be as
follows:-
(a) The Pneumatic operated control valves, actuators and accessories shall
be provided meeting requirements specified under Sub-section: IIIC-08
(CONTROL VALVE AND ACTUATORS), Part-B, Section-VI of Technical
Specification. Specially designed valves/trims to prevent cavitation and
limit noise and control outlet velocity, shall be provided.
(b) The Pneumatic operated control valves that are proposed to be connected
to the DDCMIS system in Bidders scope, Bidders standard control valve
specification are also acceptable if the control valve offered are as per the
Bidders standard and proven practice.
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8.02.00 Microprocessor based electronic positioner is to be provided with all the
pneumatic Control valves being provided by the contractor. How-ever for
requirement as indicated at 8.01.00 (b) Bidders standard and proven practice
shall also be acceptable.
9.00.00 CONTROL AND INSTRUMENTATION FOR PLANT AUXILIARY SYSTEMS
9.01.00 Instrumentation and Control System with interlocks, protection and annunciation
of the mechanical common auxiliary systems as mentioned below shall be
provided. Instrumentation for this system shall meet the requirement stipulated
under Sub-section Aux. Plant. Ctrl, Part -B, Section-VI of Technical Specification.
All necessary equipments / system for control, monitoring and operations of the
plants as well as the incomers and bus couplers shall be provided.
9.02.00 For certain plants, control systems shall be provided as indicated below:

Sl No Auxiliary Plant Control System HMIPIS etc.
01 Hydrogen Plant Independent Microprocessor
based / PLC based control
system as per vendors
standard practice with
redundant cold standby
processor.(Refer relevant
Tender Drawing for the
configuration)
Microprocessor
based / PLC based
with Two number
Operator
Workstations cum
programming
station, one
number A4 size
Color Laser printer.
Dual two way
Ethernet
Connectivity
utilising OPC to
employer Station
LAN for
information.
02 Lub oil
purification
system(Main
Turbine and
Central Lub oil
purification
system)
Local control panel for local
operation and interface to
TG control system controls

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10.00.00 TYPE TEST REQUIREMENT
10.01.00 The type tests to be conducted for C&I systems & equipments shall be as detailed
out in Sub-Section C&I TYPE TEST, Part-B, Section-VI of Technical Specification.
11.00.00 OTHER INTERFACING REQUIRMENT TO/FROM EMPLOYERS PROCURED
Sl
No
Employer
procured
system
Brief Description of
the system
Interfacing
Requirement
Specific
requirements
01 PLANT
PERFORMA
NCE
ANALYSIS,
DIAGNOSIS
&
OPTIMIZATI
ON
SOFTWARE
A PC based On-line
Plant Performance
Analysis, Diagnosis &
Optimization system
(PADO) for the station
is being procured by
Employer in a
separate package
which will carry out the
following functions as
detailed below. The
PADO system shall
provide the following
functions in a modular
and seamlessly
integrated
environment, using a
common plant model
and a dynamically
shared database
Performance
analysis and
monitoring of
systems and
components.
Emission Analysis
and monitoring.
System and
performance
diagnosis.
The
Contractor
shall be
required to
furnish all the
P&IDs in his
scope ,Heat
Balance
diagrams,
Heat Rate
correction
curves, Data
sheets of
equipments
e.g Heaters,
Condenser,
Pumps,
Generator
etc.. for proper
development
and
improvements
of PADO.
The system
shall use
the
measured
data from
the
Bidders
DDCMIS
through
appropriate
The no of analog
signals and Binary
signals required
from contractor
supplied DDCMIS
system are
approximately 250
Analog(including
calculated) and 50
Binary signals.
How-ever any other
signal if required
during detailed
engineering shall
also be supplied on
as required basis.
The individual
signal data transfer
rate shall not
exceed 1 minute .
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System and
performance
optimization.
Boiler performance
optimizations
including optimized
operation of soot
Blowing system.
Boiler stress
condition
analysers.
Interactive water
and gas chemistry
management
system.
Regenerative cycle
performance
optimization
system.
interface to
be provided
by the
bidder
through
employers
procured
station
LAN/ Unit
LAN

02 TG-Soft link
to employer
DDCMIS
(a) Redundant signal
exchange to
employer
HMIPIS utilizing
Ethernet/ OPC
based
communication
system for
Alarms, analysis
softwares, Logs,
MIMICS, ERP
interfaces
(b) LVS
annunciation
system
Redundant
Ethernet based
OPC link
(a) All Analog
signal transfer
at 1 second
except for
temperature
points ,which
shall be as per
the process
update rate.
(b) All drives
status
(c) In case LVS
based
annunciation
are not offered
by the Bidder
,then all the
time stamped
alarms and
critical
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DDCMIS
diagnostics
events
generated in
Bidders
DDCMIS
system shall
be transferred
to Employers
DDCMIS
system utilizing
OPC
communication
links.
03 SOE
system
Integrated SOE is
being procured by the
employer
Potential free
Signals
contacts from
the Bidders
supplied
DDCMIS
system
Quantity of SOE
signal shall be
approximately 100
Nos
How-ever these are
the minimum
quantities to be
considered. Bidder
to supply the same
as on required
basis.
04 HART
instruments/
Device
Connectivity
HART management
System is Employers
Scope
Terminations
for connecting
instruments/D
evice to
connect with
employers
procured
HART
Management
System.
In case online
programming by
employer procured
HART
management
system is not
allowed for the
instruments/device
s, that are being
offered as a part of
standard and
proven
instrumentation for
STG integral
controls and
TDBFP integral
Controls, the
transmitters/DDCM
IS system would be
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provided with the
necessary capabilty
to be interfaced
with the employer
procured HART
Management
system after the
system is handed
over to the
employer.
05 H/W signal
exchange
for
employer
procured
control
system
Open Loop Control
system, Closed loop
Control system (CMC
etc), Protection system
(such as RH
protection) are being
implemented in a
employer procured
control system
All the
standard
hardwired
signals to/from
the bidders
/employer
control system
required for
implementing
the control and
protection
strategies shall
be provided
For quantity
estimation of these
signal following
minimum
quantities/types to
be considered.
30-AO
5-AI
50- DI
75-DO

How-ever these are
the minimum
quantities to be
considered.

Bidder to supply
the same
on as required
basis.

12.00.00 OTHER SCOPE OF ENGG SERVICES
12.01.00 All control ,monitoring and operations of all equipments/systems that are defined
under Terminal Point and exclusions chapter in Part-A of this specification are
being controlled through microprocessor based Distributed Digital Control
Monitoring and Information System (DDCMIS) being procured by Employer under
separate package (Station C&I Package). This DDCMIS system shall perform all
functions such as auto / manual operation of valves, pumps, drives, local / remote
selection of operation, status indication, annunciation, interlock and protection of
pumps/drives etc.
12.02.00 For successful implementation of the same, the Contractor shall furnish all the
required details/drawings/data/information like list of drives to be controlled, write-
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ups for controls, interlock and protection of Contractors equipment, recommended
control loops, External connection diagrams or any other data etc as might be
required by Employer during detailed Engineering stage without any cost
repercussion.
12.03.00 The logics diagram for the above shall also be provided by the bidder to the
employer, for implementing the control schemes in employers procured control
system.
12.04.00 The Contractor shall provide the comprehensive engineering documents such as
Input/Output list, Drive list, Instrument Schedule, List of instruments/devices for
HART, J B grouping document, Annunciation list, SOE list etc. in the reusable
database format like MS-Excel, MS-Access etc for all instruments/devices/drives/
equipments/systems/signals under this scope of piping/ducting (including Station
C&I scope of supply/control). The typical contents /fields for these documents are
indicated in tender drawing No: 9562-999-POI-G-001.
12.05.00 NOT USED
12.06.00 The Contractors representative shall be present at the time of Factory
Acceptance test of the above mentioned Control System being procured by
Employer at finally selected Employer Vendors works.
12.07.00 Contractor shall provide all necessary supervision/assistance for proper
commissioning of his equipment to Control System Supplier through Employer.
12.08.00 The Contractor shall provide KKS codes for all instruments and drives in the
scope of work.The list of kks codes to be adopted by the bidder are also being
provided along with this specification.
12.09.00 Contractor shall provide their recommendation for Unit control philosophy / Logic
comprising of CMC and Automatic Plant Start-up logic under all regimes of
operation (from cold/warm/hot start-up to full load) as per their standard and
proven practice for implementation of these logics under Employers Station C&I
Package.
13.00.00 TOOLS & TACKLES
13.01.00 The Contractor shall furnish a complete new set of all special tools and tackles of
reputed make and model which are required for erection, ease in maintenance to
have minimum down time, testing and calibration of all the equipments and
systems to be provided by the Contractor under this specification for C&I systems.

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APPENDIX-1 TO C&I (CONTRACT QUANTITY FOR STG C&I SYSTEM)
1.00.00 GENERAL REQUIREMENTS OF CONTRACT QUANTITIES
The scope of C&I systems under this specification Steam Turbine and Generator
(STG) C&I system is covered in Part-A and Part-B of this specification. The
purpose of this appendix is to supplement the scope given in Part-A and the
specification requirements given in Part-B of technical specification and is not
intended to give total Scope. The Contract quantities of many subsystems covered
under Part-A and Part-B of technical specification are generally not reproduced
here to avoid duplication. However, in case of any conflict or repetition, the more
stringent requirements among them are to be complied with.
2.00.00 NOT USED
3.00.00 Contractor should note that he has to supply system complete in all respects with
all software, hardware, accessories, interfacing equipment required, etc., whether
specifically stated herein or not, to make the system operational and fully meeting
the functional, parametric, hardware, software, interfacing, quality assurance &
testing requirements within the quoted lumpsum price.
3.01.00 The Contractor shall provide functional groups as per the following guidelines.
(I) STG integral controls (i.e. Close loop control (CLC) ,Open loop
Control(OLC) and protection pertaining to steam turbine and generator)
block:- The contractor shall provide functional group(s) for the Turbine
protection and Turbine EHTC block, Automatic Turbine Testing, TSEs,
Gland steam system controls, Turbine and Generator Auxiliaries including
ATRS, Oil System, Vacuum system, seal oil system, stator water system
etc., The functional group(s) consist of set(s) of controllers, I/O modules,
communication controllers, power packs/modules. The configuration of this
function group shall be as per standard & proven practice of the Bidder.
(II) Over and above the STG integral controls block envisaged above, the
Contractor shall also provide functional groups as per the following
guidelines. The TG control system is divided into different process blocks.
For different process blocks, separate sets of FG(s) are to be provided. For
definition and requirements of function groups (FGs), refer Section VI,part-
B,IIIC-02,clause 4.00.00. The process blocks of the TG control system are
defined below. It may be noted that the process areas, equipment, logic,
loops given below cover major areas of control. The exact areas/control
shall be subject to employers approval during detailed engineering stage.
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a. BFP Drive Turbine-A block: This block will consist of BFP Drive
Turbine-A OLCS and CLCS controls, including EHTC of Drive
Turbine-A and auxiliaries of Drive Turbine-A.
b. BFP Drive Turbine-B block: This block will consist of BFP Drive
Turbine-B OLCS and CLCS controls, including EHTC of Drive
Turbine-B and auxiliaries of Drive Turbine-B.
c. Balance control implementation :- The remaining controls envisaged
in the scope of the work such as HP/LP bypass system, condenser
on load tube cleaning system, SCS, CPU Controls, Turbine lube oil
purification control, central lub oil purification control etc. can be
implemented in any of the above process blocks or separately as
per the Bidders standard and proven practice. The exact
implementation methodology ,how-ever shall be strictly as approved
by Employer during detailed engineering.
d. If it is a standard and proven practice of the bidder to offer
proprietary integral controls for the systems/equipments listed at a)
b) and c) ,the same shall also be acceptable how-ever these
systems shall be interfaced suitably with the offered DDCMIS
system so as to realize a unified HMIPIS for plant, operation
monitoring and controls. For each such proprietary control suitable
programming kit/device/station shall also be supplied. The exact
interfacing details shall be as finalised during detailed engineering
and subject to employer approval.
3.02.00 Input/output signal multiplication, and distribution of process, system and software
generate points, etc. required within the system are to be provided by the
Contractor on as required basis.
3.03.00 For signal exchange with BOP C&I systems, Contractor shall provide suitable data
link/interface as specified in item Signal Exchange, Subsection DDCMIS, Part B,
Section VI. of the specification. The no of such signals shall be as identified under
Section-VI, Part-A .However signals required to be exchanged between SG/BOP
C&I systems for protection of Turbine, Boiler and other HT drives as well as for
CMC shall be hardwired. The same shall be provided on as required basis.
3.04.00 The spare capacity for the system as indicated under item System Spare capacity,
Subsection DDCMIS, Part B, Section VI shall be included and provided by the
Contractor.
3.05.00 The contact rating of DO (contact) type outputs from control system shall be as
follows. The contact rating for such outputs for Unit DDCMIS shall be minimum
60VA, and shall be suitable for contact interrogation at 24 V DC. For such outputs
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for other DDCMIS systems relays shall be provided for each of such outputs, and
the rating of contacts of the relays shall be as specified in Part-B of specification.
4.00.00 The following back-up instrumentation and Secondary instruments shall be
provided by the Employer as a minimum for TG applications. Contractor has to
supply all the required input output modules in TG C&I part of DDCMIS for
interface of these modules without any cost implication to the employer. The
quantity indicated here is for each unit.
(i) 2 PB +3 LED 5
(ii) TRIP PB 1
(iii) RECESSED
PB(Release)
1
5.00.00
6.00.00 LIST OF AREAS FOR WHICH SOFT SIGNALS IS TO BE CONNECTED TO
STEAM TURBINE AND GENERATOR (STG) C&I SYSTEM
Sl
No.
Area Connected
to the
DDCMIS
System
Minimum
Qty of
links/
Location
Type Qty of
signals
1. TG Charger in
each unit
TG C&I of
respective
unit
04 Nos. /
Charger
Room per
unit
RS 485 /
RS232
40 per
charger
7.00.00 PLC based Control Systems
Sl
No.
Area Description of
Control system
Quatity
1. Hydrogen
Generation
Plant
Microprocessor/PLC
based Control
system as per
manufacturers
standard practice
with redundant cold
stand-by processor.
I Set (as per the configuration
drawing)
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8.00.00 The quantities of other equipment related to Control System, HMIPIS etc is as
follows.
Sl.
No.
Item Name Unit DDCMIS Remarks
1.0 Control System Qty./Unit
1.1 Functional groups Nos. As per the
guidelines indicated
in Appendix-1 to C&I
contract quantities
part-A.

1.2 Control Cabinets for
housing Control
system hardware
Nos. On as required
basis

1.3 (a) Control Cabinets
for housing
Remote I/Os
hardware for
Service
vessel/unit and
CPU
Regeneration
system.
(b) Control Cabinets
for housing
Remote I/O
hardware
(wherever
specified/applicabl
e)
Nos. On as required
basis

On as required
basis

1.4 Marshalling Cabinets,
Termination cabinets,
Relay Cabinets
Nos. On as required
basis as per the
applicability of these
cabinets in line with
specification
requirement

1.5 Relays Nos. On as required
basis

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1.6 Cubicles for mounting
network components
& power supply
distribution equipment
Nos. On as required
basis

2.0 Human Machine
Interface

2.1 Redundant Servers
(Only for Alternative 1)
Sets 1 1 set is Two
Nos. servers
minimum.
2.2 Operator Work
Stations
Nos. 2 *The function of
OWS can be
implemented in
the server itself
for Alternate-1
2.3 Programming station Nos. 1 If system
documentation
facility is not
part of this
station,
separate
workstations
shall be
provided for the
same.
2.4 Information Work
Stations (only for
Alternative-II)
Nos. 2 *The function of
information
Workstations
can be merged
with each of the
OWS.
2.5 Large Video
Screens(LVS)
Nos. Nil Screens are
being procured
by Employer
under Station
C&I package
2.6 Work Station for LVS Nos. 2
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2.7 Suitable redundant
interfaces and
redundant links for
connectivity between
Unit LAN/ station wide
LAN, and DDCMIS
sub systems,
unit/station PLCs, PC
stations, PADO,
Remote Service
Centre as applicable.
Sets 1 Each set will
include
components for
respective
remote I/O &
FGs.
2.8 Control System
Programming device
including EPROM
Writer/eraser etc. (if
applicable)
Nos. 2 This item is not
required in case
not applicable.
2.9 Data Communication
System
As required basis
2.10 Remote Service
centre hardware
As required basis
3.0 Printers
3.1 NOT USED
3.2 Laser jet colour printer
(A4 size)
Nos. 1
4.0 Software
Software for DDCMIS
meeting requirements
specified under item
SYSTEM
SOFTWARE
REQUIREMENTS,
sub section DDCMIS,
Part-B, Section-VI of
Technical
Specifications.
As required basis
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PART-A
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9.00.00 24 V DC POWER SUPPLY SYSTEM
24 V DC Power Supply systems shall be of continuous duty for the following
estimated loads:-
Description of
Loads
Contra
ctors
load
Power supply
Configuration
Employ
ers
load
Total
Rating
(Amp)
Quantity
per
unit
Co
mm
on
1. UNIT TG C&I:-
24 V DC for all
Contractors
load including
a. TG-C&I
system
(see
notes
below);
b. Any other
load of
Contract
or
supplied
system/e
quipment
requiring
24 V DC
supply
* 1. As per cl
1.03.00(A),
Subsection-
IIIC-05

2
sets

2. Hydrogen
Generation
Plant (see
notes below)
2. As per cl
1.03.00(D),
Subsection-
IIIC-05
1
set
3. CPU Remote
I/O panels(For
common
Regeneration
area)
*

3. As per cl
1.03.00(B),
Subsection-
IIIC-05

2
sets
The rating marked * are for instrument/equipment/system being supplied by
Contractor. The Bidder shall estimate the requirement of these and provide
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additional capacity margin of 5% of the estimated Contractors load for all the
items and thereafter add the Employers loads to get the load for the entire
system.
Note:-
1. Control system would cover as a minimum, controllers, I/Os, associated
modules etc. as well as, data communication system & Network devices
(like LAN Switches), related to control system associated relays and
solenoid valves driven by 24 V DC system, etc;. Any other loads of
Contractor requiring 24 V DC supply shall also be included in this
calculation.
2. One set of manual discharge resistance bank of adequate capacity shall be
Provided Per unit for the main plant 24VDC TG(C&I) control system.
10.00.00 UPS
10.01.00 Uninterrupted Power Supply of required capacity shall be provided by Contractor
for HMI and other relevant equipment of Hydrogen Generation Plant and CPU
System
10.02.00 Employer shall provide following single phase, 230 V AC UPS feeders for
powering various Main Plant TG loads under the scope of this work through PDBs
with redundant inputs from both ACDBs. Further distribution from ACDB
downwards including the PDBs shall be in the scope of Bidder.
Sl.
no
Fdr
no.
Frm To Feeder Desc. KVA PDB
location
PDB
scope
1 Fdr-1 ACDB-
1
PDB-
110-1
HMI Load-1 6 Prog.
Room
TG
vendor
2 Fdr-2 ACDB-
1
PDB-
110-1
HMI Load-2 6 Prog.
Room
TG
vendor
3 Fdr-3 ACDB-
1
PDB-
110-2
TSI & other
Loads
3 CER TG
vendor
4 Fdr-4 ACDB-
1
PDB-
110-3
Miscellaneous
Loads
5 8.5m TG
vendor

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Notes:
half through Feeder-2 to ensure availability of at least 50% of the HMI
Loads in event of any fault in either of the feeders.
11.00.00 PROCESS CONNECTION AND PIPING
11.01.00 The Contractor shall provide, install and test all required material which is
necessary for proper installation and interconnection of the equipment/systems
furnished by the Contractor as per this specification and their integration with
Employer's main equipment/systems as per Technical Specification requirements
and its sub-clauses, enclosed installation drawings and other applicable clauses on
as required basis. The Contractor shall furnish, within his quoted lump sum price,
all hardware and accessories to ensure that the equipment/systems furnished
against this specification form a complete and operational system meeting the
intent and requirement of this specification.
11.02.00 The Bidder shall note that no price adjustments shall be applicable for the
equipment and services furnished as per this sub-section since the Contractor has
to furnish these equipment/services on as required basis.
11.03.00 Local Instrument Enclosures (LIEs) and Local Instrument Racks (LIRs)
a) Local Instrument Enclosures (LIEs) complete with all fittings, mountings &
accessories etc for each unit on as required basis.
b) Local Instrument Racks (LIRs) complete with all fittings, mountings &
accessories etc. for each unit on as required basis.
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12.00.00 The following contract quantities of equipments for local operation shall be
furnished for the following systems.

Sl
No.
Item Description Qty Application and
location
Unit Common
1. Operator Work
stations
As per
PLC
configura
tion
drawing
At Hydrogen
Generation Plant
Control room
2. Operator Work
stations

1 No

CPU
regenera
tion
control
room
Operator Work
stations

3. Graphical Interface
unit of 10
1 no/unit
plus +2
nos for
common
regenera
tion area
CPU
service
vessel
remote
I/O
room+
CPU
regenera
tion local
control
area
Graphical Interface
unit of 10
13.00.00 One set of related furniture, as defined below :
Sl
No.
Area Item description Qty
(unit)
Qty
(Comm
on)
a. Chair 2 nos
b. Key pad 1 nos
1. Hydrogen
Generation
Plant
c. Locker set 1 nos
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a. Chair 2 nos
b. Key pad 1 nos
2. CPU Remote
I/O
Room(Regene
ration)
c. Locker set

1 nos
a. Chair 1 nos
b. Key pad 1 nos
3. CPU Remote
I/O
Room(service
vessel)
c. Locker set 1 nos
14.00.00 For the items like Measuring Instruments, Process Connection and piping, Control
Valves and Actuators, Other TG C&I systems, and Instrumentation and Power
supply cables, contract quantities shall be governed by corresponding Sub-
sections in Part-B.

SECTION-VI
PART - A
D - 1
CIVIL WORKS
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CIVIL WORKS FOR STEAM TURBINE GENERATOR PACKAGE

1.00.00 SCOPE OF CIVIL WORKS

1.01.00 Scope of Bidder for Civil Works shall include but not be limited to the design, supply
and erection of the following:

1.01.01 All supporting steel structures (excluding foundation which shall be provided by
Employer) for the areas, plants, systems and facilities (including all
piping/cables/ducts therein) as covered under Bidder's scope of supply elsewhere in
this specification.

1.01.02 All operating / maintenance platforms and interconnecting platforms required for
equipment valves, etc., at any elevations other than main floor levels, with
associated ladders / stairs to and / or from the main floor levels, gratings, handrails,
etc.

1.01.03 All anchor fasteners, foundation bolts along with composite templates (connecting all
the foundation bolts of particular column/ base plate / bearing), inserts and
embedments along with lugs, plates, strips, etc., pipe sleeves with lugs, monorail
beams, crane rails, etc., complete whatsoever required for supporting / mounting of
equipment / piping / cable / ducts and structure.

1.01.04 All miscellaneous steel structures such as gratings, handrails, ladders, platforms,
edge protection angles / tees on equipment foundations, etc.

1.01.05 Dressing of foundations, grouting works of pockets including underpinning of base
plates and grouting of any holes / blockouts required in pedestals for supporting the
equipment / structures.

1.01.06 Furnishing of foundation loading data, foundation anchor bolts location plans, pocket
details, equipment mounting details, opening details on floor / walls / cladding / roof,
embedments and inserts details, etc., in the form of input drawings to the Employer,
for the Employer's engineering work.
Furnishing the acceptable tolerances (deviation limits) of foundation and structures
which are in the scope of supply of Owner, which can be reasonably achieved at site
based on the construction practice followed, like
a) Tolerances in finished dimension & top level of foundation / structures
b) Tolerances in location, size, level of foundation pockets
c) Tolerances in location and level of embedment
d) Tolerances in location and alignment of pipe sleeve for foundation bolt
e) Tolerances in location & top level of foundation bolts
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The deviation limits furnished by the contractor shall be reviewed by the Employer
before taking up the execution. If in the view of the Owner, the deviation limits
proposed by the contractor are stringent and difficult to achieve at site, then the
same shall be discussed & finalized with contractor.

1.01.07 Fixing supports, filling and finishing of openings for pipes/cables/ducts in
floors/walls/cladding/roof, etc.

1.01.08 PTFE bearings for supporting of Bidder's structures on Employer structure

1.01.09 Corrosion protection painting for structures

1.01.10 Painting of portions of Employer structures wherever connection/welding is carried
out by Bidder for supporting his structures

1.01.11 All rectification including painting of Employer structures which are damaged by
Bidder during his work.

1.01.12 Placement of the embedments / foundation bolts supplied by the Bidder, shall be
done by the Employer. However, the accuracy of fixing of the embedments /
foundation bolts shall be checked and ensured by the Bidder during the placement
of the same. Any modification required on these embedments / anchor bolts
subsequent to their placement shall be done by the Bidder.

1.01.13 All modifications including making cut outs / pockets etc. in the RCC floor or RCC /
Masonry wall or metal cladding for installing equipment in bidders scope which
become necessary either due to the change in design input by the bidder or due to
additional requirements which bidder did not indicate at the time of furnishing the
initial design input.

1.01.14 Supply, testing, installation and erection of Steel helical springs and Viscous
dampers for Turbine generator (TG), TDBFPs and MDBFPs shall be in Bidders
scope.

1.01.15 Any other facilities / structures that would be required, as per the system
requirements covered under various sections / chapters of this specification but not
covered here above.

1.01.16 Detailed technical requirements for Civil Works are covered elsewhere in the
specification

2.00.00 CONSTRUCTION FACILITIES
The following are also in the Bidder's scope of work:
1. Providing drinking and service water for Bidder's labour, staff and other
personnel working for Bidder at the work site and in his staff/labour colony.
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He shall install necessary borewells with associated pumping or water
tankers and treatment facilities to supply quality water as per standards.

2. Developing temporary staff colony and labour colony alongwith fencing etc.
land if required shall be arranged by Bidder himself.
However space required for contractors office, storage, pre assembly and
fabrication areas shall be provided by owner free of charge within the plant
premises.
The area to be allocated to the bidder shall be discussed & finalized with the
bidder after the award, keeping in view the availability of free space & similar
requirement of other agencies.

3. Providing all arrangements for distribution of construction power at various
locations as per his requirements from the supply point of Employer.

4. Providing all arrangements for the supply of construction water including
bore-wells, water tankers etc.

5. Providing temporary construction office, construction stores (open / covered),
workshops, material / field testing laboratory, any other temporary buildings

6. Providing all construction equipment, labour and materials. The Bidder shall
provide all the tools and tackles required for the work.

7. Development of the pre-assembly and storage yard with fencing, drainage,
internal roads, boulder soling, etc.
However owner shall provide leveled ground. The ground shall be natural
ground or filled up ground with controlled compaction.

8. Owner intends to construct approach road to project site from the nearest
existing road network. However, the same may not be available to the bidder
for his use in the initial stage of the project. Further, Owner intends to
construct the roads as per the layout shown in the General Layout plan in a
progressive manner. Some of these roads may not be available to the bidder
for his use. Similarly the drainage network for the plant site being constructed
by the owner may not be available to full extent. The bidder shall plan his
work within the plant area considering the above constraints of roads and
drains. Access roads to his work sites, offices, stores, preassembly /
fabrication yard, etc. as required for providing approach/access for men,
materials, equipment, cranes, trailor, construction/erection activities etc.,
what so ever are required by the bidder, shall be constructed and maintained
by the bidder.
In case the nearest road as per proposed road layout is not available /
constructed by NTPC meeting the access requirement of the bidder, NTPC
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shall construct a temporary WBM road to provide at least one access to
bidders storage, preassembly area, site office area and for erection of STG
& Aux. The details of such temporary road access shall be discussed and
finalised in consultation with the bidder as per site requirement.
Further till such time permanent approach road to plant site is ready, owner
will provide temporary WBM approach road from the nearest existing road
network.

9. Area lighting at the construction / erection site, pre-assembly and storage
yard, office areas and labour / staff colony.

10. Providing all necessary fire fighting devices / equipment / fire tender etc.
required during the project execution stage. He shall maintain all such
equipment / devices in proper working conditions throughout the period of
work.

11. Providing first aid facilities at the construction / erection sites, workshops,
laboratories, pre-assembly and storage yard and other places of work as per
the requirement.

12. The Contractor shall arrange skilled / semiskilled / unskilled manpower from
local source(s) as far as available in this country. He shall also arrange
supervisory staff for quality execution of all works in his scope.

13. Contractor's office, store, workshop, laboratory or any other temporary
buildings:

The Contractor shall adopt pre-engineered/ pre-fabricated constructions
made of steel with single / double skin, insulated for un-insulated roof and
wall coverings (fabricated out of permanently color coated metal sheets) for
his site office, covered store workshop, laboratory or any other temporary
buildings. Alternatively, bidder can adop readymade `Portacabin' or similar
construction. Bidder shall ensure that all such constructions are well-
engineered, neatly constructed and overall present a pleasing look. The
above requirements shall be applicable to his sub-vendors also and bidder
shall be responsible for enforcing the same on his sub-vendors.
Any other type of construction if proposed by the bidder shall be subject to
approval of the owner. However, such construction shall be based on proper
design and shall have aesthetic look.

14. Use of ash and ash based products:

In line with Gazette Notification on Ash Utilization issued by MOEF and its
amendment thereafter, Bidder shall use ash and ash based products in
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construction of his offices, stores, staff quarters and labour huts etc. He shall
furnish a compliance report along with all details of use of ahs and ash based
products along with each bill. The above requirements shall be applicable to
his sub-vendors also and Contractor shall be responsible for enforcing the
same on his sub-vendors.

15. Repair & Maintenance Facilities by the Bidder:

Bidder shall establish/set up at site suitable repair facilities for construction
plant, equipment and machinery (like cranes, hydra, forklifts, welding
equipments, etc.) He will also make arrangements/tie up with manufacturers/
suppliers of such construction plant, equipment & machinery, for periodic
overhaul/maintenance and for major breakdown, if any. He shall also keep
adequate stock of spares at site for various construction plant, equipment
and machinery to meet day to day requirements as recommended by the
equipment manufacturer/suppliers or as instructed by the Engineer. Bidder
shall deploy dedicated qualified, full time mechanical/electrical
foreman/supervisors for manning the repair facilities as specified above.

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ANNEXURE-WL
CRITERIA FOR WIND RESISTANT DESIGN OF STRUCTURES AND
EQUIPMENT

All structures shall be designed for wind forces in accordance with IS:875 (Part-3)
and as specified in this document. See Annexure-B for site specific information.

Along wind forces shall generally be computed by the Peak (i.e. 3 second gust)
Wind Speed method as defined in the standard.

Along wind forces on slender and wind sensitive structures and structural elements
shall also be computed, for dynamic effects, using the Gust Factor or Gust
Effectiveness Factor Method as defined in the standard. The structures shall be
designed for the higher of the forces obtained from Gust Factor method and the
Peak Wind Speed method.

Analysis for dynamic effects of wind must be undertaken for any structure which has
a height to minimum lateral dimension ratio greater than 5 and/or if the
fundamental frequency of the structure is less than 1 Hz.

Susceptibility of structures to across-wind forces, galloping, flutter, ovalling etc.
should be examined and designed/detailed accordingly following the
recommendations of IS:875(Part-3) and other relevant Indian standards.

It should be estimated if size and relative position of other structures are likely to
enhance the wind loading on the structure under consideration. Enhancement factor,
if necessary, shall suitably be estimated and applied to the wind loading to account
for the interference effects.

1.02.00 Damping in Structures

The damping factor (as a percentage of critical damping) to be adopted shall not be
more than as indicated below for:

a) Welded steel structures 1.0%

b) Bolted steel structures 2.0%

c) Reinforced concrete structures 1.6%

d) Steel stacks As per IS:6533 & CICIND Model
Code whichever is more critical.

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ANNEXURE-B

SITE SPECIFIC DESIGN PARAMETERS

The various design parameters, as defined in IS: 875 (Part-3), to be adopted for the
project site shall be as follows:

a) The basic wind speed V
b
at ten meters
above the mean ground level : 47 meters/second

b) The risk coefficient K
1
: 1.07

c) Category of terrain : Category-2

Note: Notwithstanding the values of the above mentioned parameters, the design
wind pressure so computed at any point shall not be taken less than 1500 N/Sq.
metre for all classes of structures, i.e. A, B & C, as defined in IS: 875 (Part-3).

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ANNEXURE-EQ

CRITERIA FOR EARTHQUAKE RESISTANT DESIGN OF STRUCTURES AND
EQUIPMENT

All structures and equipment shall be designed for seismic forces adopting the site
specific seismic information provided in this document and using the other provisions
in accordance with IS:1893 (Part 1):2002 and IS:1893 (Part 4):2005. Pending
finalisation of Parts 2, 3 and 5 of IS:1893, provisions of part 1 shall be read along
with the relevant clauses of IS:1893:1984, for structures other than the buildings and
industrial structures including stack-like structures.

A site specific seismic study has been conducted for the project site. The peak
ground horizontal acceleration for the project site, the site specific acceleration
spectral coefficients (in units of gravity acceleration g) in the horizontal direction for
the various damping values and the multiplying factor (to be used over the spectral
coefficients) for evaluating the design acceleration spectra are as given at
Annexure-A-V.

Vertical acceleration spectral values shall be taken as 2/3rd of the corresponding
horizontal values.

The site specific design acceleration spectra shall be used in place of the response
acceleration spectra, given at figure-2 in IS:1893 (Part 1) and Annex B of IS:1893
(Part 4). The site specific acceleration spectra along with multiplying factors
specified in Annexure-I includes the effect of the seismic environment of the site, the
importance factor related to the structures and the response reduction factor.
Hence, the design spectra do not require any further consideration of the zone factor
(Z), the importance factor (I) and response reduction factor (R) as used in the
IS:1893 (Part 1 and Part 4).

Damping in Structures

The damping factor (as a percentage of critical damping) to be adopted shall not be
more than as indicated below for:

a) Steel structures : 2%

b) Reinforced Concrete structures : 5%

c) Reinforced Concrete Stacks : 3%

d)

Steel stacks : 2%
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Method of Analysis

Since most structures in a power plant are irregular in shape and have irregular
distribution of mass and stiffness, dynamic analysis for obtaining the design seismic
forces shall be carried out using the response spectrum method. The number of
vibration modes used in the analysis should be such that the sum total of modal
masses of all modes considered is at least 90 percent of the total seismic mass and
shall also meet requirements of IS:1893 (Part 1). Modal combination of the peak
response quantities shall be performed as per Complete Quadratic Combination
(CQC) method or by an acceptable alternative as per IS:1893 (Part 1).

In general, seismic analysis shall be performed for the three orthogonal (two
principal horizontal and one vertical) components of earthquake motion. The seismic
response from the three components shall be combined as specified in IS:1893 (Part
1).

For buildings, if the design base shear (V
B
) obtained from modal combination is less
than the base shear (V
B
) computed using the approximate fundamental period (T
a
)
given in IS:1893:Part 1 and using site specific acceleration spectra with appropriate
multiplying factor, the response quantities (e.g. member forces, displacements,
storey forces, storey shears and base reactions) shall be enhanced in the ratio of
V
B
/ V
B.
However, no reduction is permitted if V
B
is less than V
B
.

For regular buildings less than 12m in height, design seismic base shear and its
distribution to different floor levels along the height of the building may be carried out
as specified under clause 7.5, 7.6 & 7.7 of IS:1893 (Part 1) and using site specific
design acceleration spectra. The design horizontal acceleration spectrum value (Ah)
shall be computed for the fundamental natural period as per clause 7.6 of IS:1893
(Part 1) using site specific spectral acceleration coefficients with appropriate
multiplying factor given in Annexure-A-V. Further, the spectral acceleration
coefficient shall get restricted to the peak spectral value if the fundamental natural
period of the building falls to the left of the peak in the spectral acceleration curve.

Design/Detailing for Ductility for Structures

The site specific design acceleration spectra is a reduced spectra and has an in-built
allowance for ductility. Structures shall be engineered and detailed in accordance
with relevant Indian/International standards to achieve ductility.

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ANNEXURE A-V
SITE SPECIFIC SEISMIC PARAMETERS FOR DESIGN OF STRUCTURES AND
EQUIPMENT

The various site specific seismic parameters for the project site shall be as follows:

1) Peak ground horizontal acceleration (MCE)

: 0.16g
2) Multiplying factor to be applied to the site specific horizontal
acceleration spectral coefficients (in units of gravity
acceleration g) to obtain the design acceleration spectra

a) for ordinary moment resisting steel frames designed
and detailed as per IS:800

: 0.047
b) for braced steel frames designed and detailed as per
IS:800

: 0.035
c) For special moment resisting RC frames designed
and detailed as per IS:456 and IS:13920

: 0.028
d) for steel chimney

: 0.070
e) for design of structures not covered under 2 (a) to 2
(d) above and under 3 below

: 0.047
3) Multiplying factor to be applied to the site specific horizontal
acceleration spectral coefficients (in units of gravity
acceleration g) for design of equipment and structures
where inelastic action is not relevant or not permitted

: 0.093

Note: g =Acceleration due to gravity

The horizontal seismic acceleration spectral coefficients are furnished in subsequent
pages.

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ANNEXURE A-V

HORIZONTAL SEISMIC ACCELERATION SPECTRAL COEFFICIENTS
(In units of g)

Time Period
Damping Factor (as a percentage of critical damping)

(Sec) 2% 3% 5%
0.000 1.000 1.000 1.000
0.030 1.000 1.000 1.000
0.040 1.319 1.260 1.201
0.050 1.635 1.508 1.385
0.060 1.948 1.746 1.555
0.070 2.259 1.976 1.716
0.080 2.569 2.200 1.868
0.090 2.877 2.419 2.013
0.100 3.184 2.633 2.153
0.110 3.490 2.842 2.288
0.108 3.429 2.801 2.261
0.110 3.490 2.842 2.288
0.115 3.643 2.946 2.354
0.120 3.795 3.048 2.418
0.125 3.947 3.150 2.482
0.130 4.098 3.251 2.545
0.134 4.220 3.331 2.594
0.141 4.220 3.470 2.680
0.147 4.220 3.470 2.750
0.150 4.220 3.470 2.750
0.200 4.220 3.470 2.750
0.250 4.220 3.470 2.750
0.300 4.220 3.470 2.750
0.350 4.220 3.470 2.750
0.400 4.220 3.470 2.750
0.450 4.220 3.470 2.750
0.500 4.220 3.470 2.750
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ANNEXURE A-V

(In units of g)

Time Period

(Sec) 2% 3% 5%
0.550 4.220 3.470 2.750
0.555 4.182 3.470 2.750
0.560 4.145 3.470 2.750
0.565 4.108 3.470 2.750
0.570 4.072 3.470 2.750
0.575 4.037 3.470 2.750
0.580 4.002 3.470 2.750
0.585 3.968 3.470 2.750
0.590 3.934 3.470 2.750
0.595 3.901 3.470 2.750
0.600 3.868 3.470 2.750
0.650 3.571 3.203 2.538
0.700 3.316 2.974 2.357
0.750 3.095 2.776 2.200
0.800 2.901 2.603 2.063
0.850 2.731 2.449 1.941
0.900 2.579 2.313 1.833
0.950 2.443 2.192 1.737
1.000 2.321 2.082 1.650
1.050 2.210 1.983 1.571
1.100 2.110 1.893 1.500
1.150 2.018 1.810 1.435
1.200 1.934 1.735 1.375
1.250 1.857 1.666 1.320
1.300 1.785 1.602 1.269
1.350 1.719 1.542 1.222
1.400 1.658 1.487 1.179
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ANNEXURE A-V

(In units of g)

Time Period

(Sec) 2% 3% 5%
1.450 1.601 1.436 1.138
1.500 1.547 1.388 1.100
1.550 1.497 1.343 1.065
1.600 1.451 1.301 1.031
1.650 1.407 1.262 1.000
1.700 1.365 1.225 0.971
1.750 1.326 1.190 0.943
1.800 1.289 1.157 0.917
1.850 1.255 1.125 0.892
1.900 1.222 1.096 0.868
1.950 1.190 1.068 0.846
2.000 1.161 1.041 0.825
2.050 1.132 1.016 0.805
2.100 1.105 0.991 0.786
2.150 1.080 0.968 0.767
2.200 1.055 0.946 0.750
2.250 1.032 0.925 0.733
2.300 1.009 0.905 0.717
2.350 0.988 0.886 0.702
2.400 0.967 0.868 0.688
2.450 0.947 0.850 0.673
2.500 0.928 0.833 0.660
2.550 0.910 0.816 0.647
2.600 0.893 0.801 0.635
2.650 0.876 0.786 0.623
2.700 0.860 0.771 0.611
2.750 0.844 0.757 0.600
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ANNEXURE A-V

(In units of g)

Time Period

(Sec) 2% 3% 5%
2.800 0.829 0.744 0.589
2.850 0.814 0.731 0.579
2.900 0.800 0.718 0.569
2.950 0.787 0.706 0.559
3.000 0.774 0.694 0.550
3.050 0.761 0.683 0.541
3.100 0.749 0.672 0.532
3.150 0.737 0.661 0.524
3.200 0.725 0.651 0.516
3.250 0.714 0.641 0.508
3.300 0.703 0.631 0.500
3.350 0.693 0.621 0.493
3.400 0.683 0.612 0.485
3.450 0.673 0.603 0.478
3.500 0.663 0.595 0.471
3.550 0.654 0.586 0.465
3.600 0.645 0.578 0.458
3.650 0.636 0.570 0.452
3.700 0.627 0.563 0.446
3.750 0.619 0.555 0.440
3.800 0.611 0.548 0.434
3.850 0.603 0.541 0.429
3.900 0.595 0.534 0.423
3.950 0.588 0.527 0.418
4.000 0.580 0.521 0.413

SECTION-VI
PART - A
TERMINAL POINTS AND EXCLUSIONS
CLAUSE NO.

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SECTION-VI
PART-A
TERMINAL POINTS
AND EXCLUSIONS
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A. TERMINAL POINTS

The following terminal points are ot be read in conjunction with the tender drawings,
scope of supply and technical specifications of various systems covered under this
package. At interface points counter flanges where required shall be supplied by the
TG Contractor.

1.00.00 STEAM SERVICE

1.01.00 Main Steam : Main Steam Inlet nozzle on HP Turbine

1.02.00 Cold Reheat : Steam Outlet nozzle of HP Turbine

1.03.00 Hot Reheat: Steam inlet nozzles on the IP Steam Turbine

1.04.00 HP Bypass: (1) Steam inlet and outlet nozzles of HPBP Valve

(2) Inlet and outlet ends of Breakdown orifice plate assembly.

1.05.00 HP Bypass warm-up line: Stubs provided on HP Bypass Line

1.06.00 LP Bypass : Inlet and outlet nozzles of LPBP Valve and inlet to condenser
nozzles.

LP Bypass warm-up line: Stubs provided on HRH Piping

1.07.00 Extraction to HP Heater-6, BFPTs, Deaerator & Tee-off/ stubs provided on CRH
Piping.

1.08.00 HPT exhaust steam evacuation line: Stub provided on CRH line

Note: For TP of BFP DT steam supply, please refer the notes on P&ID for "P&ID for
Extraction Steam to BFP Turbine".

2.00.00 FEED WATER:

2.01.00 Inlet to NRV at upstream of economiser inlet.

2.02.00 RH Spray: Inlet to block valve(s) (located inside the Steam generator envelope) at
upstream of respective spray control station.

2.03.00 Spray to Aux PRDS: Stub(s) provided on Boiler Feed Water Discharge / Condensate
discharge piping system in BC Bay.

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3.00.00 AUX. STEAM SYSTEM

3.01.00 Isolation valve(s) outlet end of tap off provisions (stub connections with isolation
valve provided by others) on the auxiliary steam header(s) for the TG user points.

4.00.00 CIRCULATING WATER SYSTEM

4.01.00 Circulating water piping- intake and discharge C.W. water piping upto 2.5 metres
beyond A-row columns.

5.00.00 PLANT WATER SYSTEM

5.01.00 DM Water Make up System

5.01.01 For each unit, Employer shall terminate one DM water make up connection to near
A-row, at suitable location at about 4 meters above local grade level for further
connection by the Contractor to supply water for condenser hotwell makeup (normal
supply) & overhead tank of Bidder's ECW system. The terminal pressure shall be
about 4 Kg/Sqcm(g) at the terminal point.

5.01.02 For each unit, Employer shall terminate one emergency DM water make up
connection to condenser hotwell and overhead tank of bidder's ECW system, near
A-row, at suitable location at about 4 meters above local grade level for further
connection by the Contractor. The terminal pressure shall be about 4 Kg/Sqcm(g) at
the terminal point.

5.01.03 Employer shall terminate one DM water connection with an isolation valve at 5
meters from the Hydrogen generation building for further interconnection by the
contractor.

5.02.00 Equipment Cooling Water (ECW) System

5.02.01 For each unit, Bidder to tap off Secondary circuit cooling water from the Circulating
water System pipe (the terminal point of the same is defined under Circulating Water
System above) at the upstream of condenser and terminate the hot water into the
CW system discharge pipe at the downstream of condenser.

5.02.02 Secondary cooling water circuit for SG cooling: -

For each unit, Bidder shall terminate one secondary circuit cold water (from the
discharge of Auxiliary cooling water pumps at the downstream of self cleaning filters)
at a suitable location along 'C' row for cooling of primary DM cooling water of ECW
system of SG Auxiliaries in separate set of Plate type Heat (PHE's) exchangers to
be provided by Employer. The cooling water flow shall be about 750 Cu.M/hr.
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Employer shall terminate the secondary circuit hot water (from the discharge of
Employer's Plate type heat exchangers of SG Auxiliaries) at suitable location along
'C' row to enable the Bidder to interconnect the same to their discharge header. The
return hot secondary cooling water circuit flow of 750 Cu.M/hr shall be limited to a
temperature rise of 7 deg.C across the Employer's cooling system and the pressure
drop across the secondary circuit shall be limited to 19 MWC between the terminal
points.

5.03.00 Service Water System

5.03.01 For each TG unit, Employer shall provide one service water (which is of CW blow
down quality) connection with an isolation valve at a pressure of about 4 Kg/sqcm
(g) near C-row, at suitable location at about 4 meters above local grade level for
further interconnection by Contractor to meet the service water network of respective
TG & their auxiliaries.

5.03.02 Employer shall terminate one cooling water connection (from the service water
network) with an isolation valve at 5 meters from the Hydrogen generation plant for
further interconnection by the Contractor and hot water shall be drained to the
nearest drainage network by Bidder.

5.04.00 Deaerator Fill Water System

For each unit, Employer shall provide one deaerator fill connection with an isolation
valve from the boiler fill system, at C-row, at about 4 meters above local grade level
for further interconnection by Contractor.

5.05.00 LP Dosing & Oxygenated Treatment

Bidder to provide required Stub connections in condensate and feed water pipelines
for connection of Boiler Feed water chemical dosing (both AVT & Oxygenated
treatment) system piping by SG vendor.

5.06.00 Liquid Effluents

The Contractor shall terminate condensate drains if any to the nearest drainage
network

5.07.00 Condensate Polishing Plant

5.07.01 Bidder to refer the relevant tender drawing.

5.07.02 The DM water used for resin transfer operations from the Regeneration building to
the Condensate Polisher vessels and from the Condensate Polisher vessels to the
Regeneration building shall be collected in a tank (MSRL construction) of adequete
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capacity in Condensate Polishing Plant regeneration building and the same shall be
pumped to Employer's CW channel near CW Pump House for recycle/re-use. Bidder
to terminate the water at 10 meters from the discharge of pump header.
5.07.03 The rinse water outlet from the Condensate Polisher vessels shall be led into the
Condenser hotwell.
5.08.00 Boiler Fill System: Bidder shall terminate a tap-off from condensate system at C-
Row at a suitable location for filling of SG (Boiler) circuit of Employer.
6.00.00 COMPRESSED AIR SYSTEM
6.01.00 Instrument Air System
6.01.01 For TG of each unit, Employer shall provide instrument air connection(s) from the
instrument air ring main of the respective unit within power house, at about 9 meters
above local grade level for further interconnection by the Bidder to meet the
instrument air requirements. The pressure at terminal point(s) shall be about 6
Kg/Sq.cm(g).
6.01.02 Employer shall terminate one instrument air connection with an isolation valve at 5
meters from the Hydrogen generation building.
6.01.03 Employer shall terminate one instrument air connection with an isolation valve at 5
meters from the Condensate Polishing Plant regeneration building.
6.02.00 Service Air System
6.02.01 For main TG each unit, Employer shall provide service air connection(s) from the
service air ring main of the respective unit within power house, at about 9 meters
above local grade level for further interconnection by the Bidder to meet the service
air requirements. The pressure at terminal point shall be about 6 Kg/Sq. cm.(g).
6.02.02 Employer shall terminate one service air connection with an isolation valve at 5
meters from the Hydrogen generation building and from condensate polishing plant
regeneration building.
7.00.00 CONTROL AND INSTRUMENTATION
7.01.00 NOT USED.
1.02.00 Upto and including the out-put/input(as applicable) TB's of the following
panels/cabinets/J Bs/LIE/LIR/descks etc the signals of which are being connected to
/from the employer's systems/equipment.
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(a) Local junction boxes or integral junction box of LIE/LIR for primary
instruments including temperature transmitters for all the instruments in the
Scope of Bidder
(b) Local control panels (wherever provided). For terminating employers
instrumentation/control/power cables.
(c) J B provided on the valves for manually operated valves Limit switches
where-ever specified
(d) Contractors DDCMIS Marshalling cabinets for hardwired signal exchange to
SG C&I and BOP C&I control systems.
(e) Employers DDCMIS Marshalling cabinets for hardwired signal exchange
from SG C&I and BOP C&I control systems.
(f) Employer's Main PDB's for 230 V AC Uninterrupted Power Supply (UPS).
(g) Employers Vibration Monitoring system cabinet TBs for connecting raw
buffer signals of BOP C&I to vibration diagnostics and analysis system
(h) Unit control desk and Electrical control panel in control room/CER
1.03.00 Earthing grounding requirement
(a) Contractor's DCDB earthing strip/bolts and terminals for connecting the
system / shield earth cable to employer's earthing strip / earthing pit at 0.0M
level.
1.04.00 Reducer after shutoff valves for sample tapping points for Employers SWAS
(connection/welding of Employers sample piping to be done by Employer).
1.05.00 Upto & including root valves in the contractor provided equipment/piping for
Employers procured instruments
1.06.00 Contractor's Switch/Hub/Terminal/port.
(a) For communication with Station LAN
(b) For communication with Employers procured DDCMIS LAN

8.00.00 ELECTRICAL

8.01.00 Terminal pads of the Generator.

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PART-A
TERMINAL POINTS
AND EXCLUSIONS
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8.02.00 Incoming power supply terminals of all contractors equipments (like LT MCCs, DC
starter boxes, distribution boards, integral starters for actuators) which are directly
fed from Employers switchgear.

8.03.00 Terminals of incoming isolating switch of EOT / cranes /hoists and elevators.

8.04.00 Terminal block for HT motors

NOTE: All terminal connections shall be made by the Contractor unless
otherwise stated in this specification.

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PART-A
TERMINAL POINTS
AND EXCLUSIONS
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9.00.00 B. EXCLUSIONS

9.01.00 All civil works other than operating / maintenance platforms and interconnection
platforms (at levels other than main floor levels) with ladders / stairs & handrails,
structural supports and hangers for pipes / cables / ducts, crane rails, all
embedments and inserts with lugs including anchor fasteners, bolts etc., dressing of
foundations, 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.

9.02.00 ELECTRICAL

9.02.01 HT cables (11 KV, 3.3 KV).

9.02.02 Underground Earthmat

9.02.03 Over ground earthing and equipment earthing (except for areas where over ground
earthing is specifically mentioned elsewhere in the specification to be in Bidder
scope).

9.02.04 Complete lighting system and lighting protection (except for Hydrogen Generation
system)

9.03.00 Plant make-up Raw water system.

9.04.00 Cooling Tower, CW pumps, CW pump house and CW channel.

9.05.00 Ventilation system makeup pumps, CW system makeup pumps, Air pre-heater
wash water pumps, Boiler fill pumps, DM water make up pumps and Condensate
transfer pumps.

9.06.00 Air Conditioning System.

9.07.00 Ventilation System

9.08.00 Common Fire fighting system and Equipment (unless specifically included in scope).

9.09.00 Water Pre-treatment, DM Plant, Chlorination plant, CW side stream filtration plant
and CW chemical treatment system, Liquid effluent treatment plant, Ash water
recirculation system and Ash water treatment plant.

9.10.00 Chemicals required for Conditioning of DM water of ECW system

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PART-A
TERMINAL POINTS
AND EXCLUSIONS
PAGE
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9.11.00 Bulk acid and alkali tanks, DM water Storage tanks, Final Effluent disposal pumps
and chemicals (such as alkali, acid and lime)) associated with Condensate Polishing
Plant.
9.12.01 Distributed Digital Control Monitoring and Information System (DDCMIS) , covering
the following
(a) NOT USED
(b) BOP (C&I) system including the control of the following drives/systems.
(1.) Binary control of CEPs, MDBFPs, HP/LP Heaters, ECW, ACW and its
associated drives.
(2.) Modulating controls of LPH/HPH level control, Deaerator
level/pressure control, CEP minimum recirculation, drum level control,
LP dosing control, DMCW DP control, Gland Seal Pressure Control
for condensate, BFP minimum recirculation and Coordinated Master
Control etc.
(c) NOT USED
(d) NOT USED.
9.12.02 Unit control Desk and unit control panel in control room.
9.12.03 Large Video Screens (LVS).
9.12.04 Centralised steam and water analysis system including sample piping for the same
from shut off valves onwards.
9.12.05 Impulse piping connection from root valves onwards for Employers procured
instruments
9.12.06 Uninterruptible Power Supply System (230 V single phase AC for TG System).
9.12.07 Maintenance and calibration equipment required for routine maintenance and
calibration of general instrumentation which are not in Contractors scope.
9.12.08 Following control instrumentation and power cables
(a) Instrumentation cables between the bidder's J B to the employer's control
system for the instruments provided by the bidder & connected to employer
control system.
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PART-A
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AND EXCLUSIONS
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(b) Instrumentation cables between Contractors local control panels and
Employers DDCMIS to be done by Employer.
(c) NOT USED.
(d) Vibration monitoring system including field sensors for TG HT Auxiliaries
other than Turbine supervisory system for main turbine and BFP drive
turbine and vibration monitoring system for Turbine Driven BFP as
indicated in sub section IIIC-03,section VI, Part-B of specification
9.12.09 Employers earthing Pit at 0.00 M Level in the plant

SECTION-VI
PART - A
FUNCTIONAL GUARANTEES
&
LIQUIDATED DAMAGES
CLAUSE NO.
FUNCTIONAL GUARANTEES & LIQUIDATED DAMAGES

STAGE-II (2X660 MW)
SECTION-VI
PART-A
FUNCTIONAL
GUARANTEES &
LIQUIDATED DAMAGES
PAGE
1 OF 16

FUNCTIONAL GUARANTEES, LIQUIDATED DAMAGES
FOR
SHORTFALL IN PERFORMANCE AND GUARANTEE TESTS
(The term "Performance Guarantees" wherever appears in this Sub-Section shall
have the same meaning and shall be synonymous to "Functional Guarantees".
Similarly the term "Performance Tests" wherever appears in this Sub-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 sub-section) under 0%
cycle make-up and 77 mm Hg (abs) condenser pressure unless used in conjunction
with a different cycle make-up and/or a different condenser pressure.
1.00.00 PERFORMANCE GUARANTEES
1.00.01 General Requirements
(a) The Contractor shall guarantee that the equipment offered shall meet the
ratings and performance requirements stipulated for various equipment
covered in these specifications.
(b) 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.
(c) The Contractor shall demonstrate all the guarantees covered herein during
functional guarantee / acceptance test. The various tests which are to be
carried out during performance guarantee/acceptance test are listed in this
Sub-section. The guarantee tests shall be conducted by the Contractor at
site in presence of Employer on each unit individually.
(d) All costs associated with the tests shall be included in the bid price.
(e) In case during performance guarantee test(s) it is found that the
equipment/system has failed to meet the guarantees, the Contractor 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 Employer and re-conduct the performance guarantee test(s) with
Employer's consent. However if the specified performance guarantee(s) are
still not met but are achieved within the Acceptable Shortfall Limit specified
at clause 1.01.02 of this sub-section, Employer will accept the
equipment/system/plant after levying liquidated damages as per clause
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1.01.02 of this sub-section. 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 Employer, after the tests have been
completed, the Employer will have the right to either of the following :
(i) For Category-I Guarantees
Reject the equipment / system / plant and recover from the
Contractor the payments already made
OR
Accept the equipment /system/ plant after levying Liquidated
Damages as specified hereunder. The liquidated damages for
shortfall in performance indicated in clause 1.01.02 of this sub-
section shall be levied separately for each unit. The rates indicated
in clause 1.01.02 of this sub-section are on per unit basis. 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.
(ii) For Category-II Guarantees
Reject the equipment / system/ plant and recover from the
Contractor the payments already made. The performance
guarantees under this category shall be called 'Category-II'
Guarantees. Conformance to the performance requirements under
Category-II is mandatory.
(iii) For Category-III Guarantees
Reject the equipment /system / plant and recover from the
Contractor the payments already made.
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 Employer. Such
damages shall, however be limited to the cost of replacement of the
equipment(s) / system(s), replacement of which shall remove the
deficiency so as to achieve the guaranteed performance. These
parameters/capacities shall be termed as Category-III Guarantees.

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1.01.00 Guarantees under Category-I
1.01.01 The performance guarantees which attract liquidated damages are as follows:
(i) Turbine Cycle Heat rate in kcal/kWhr under rated steam conditions at 77
mmHg(abs) design condenser pressure with 0% make up at 693 MW unit
load (i.e. 105% of rated load).
(ii) Turbine Cycle Heat rate in kcal/kWhr under rated steam conditions at 77
mmHg(abs) design condenser pressure with 0% make up at 660 MW unit
load (i.e. 100% of rated load).
(iii) Continuous TG output of 693MW unit load (i.e. 105% of rated load) under
rated steam conditions at 77mmHg(abs) design condenser pressure with
0% make-up.
(iv) Condenser pressure in mm Hg (abs) measured at 300 mm above the top
row of condenser tubes under VWO conditions, 3% make up, design CW
temperature and CW flow.
Note: The condenser pressure measurement while conducting the
guarantee tests from (i) to (iv) above shall be measured at 300 mm
above the top row of condenser tubes.
(v) CW pumping power in KW for design CW flow and the pressure drop on
CW side being measured between Bidder's terminal points. (Power
consumption shall be computed based on overall efficiency of 83% of CW
pump and drive set).
(vi) Auxiliary Power Consumption
Auxiliary Power Consumption at 100% TMCR (660 MW) Unit Load.
The total auxiliary power consumption for all the Turbine Generator
auxiliaries and turbine cycle equipments and other common auxiliaries
required for continuous unit operation at 660 MW (i.e 100% rated load)
under rated steam conditions and at condenser pressure of 77 mm Hg (abs)
with 0% make-up shall be guaranteed in line with the requirements
stipulated in Clause 1.01.03 of this Sub-Section.
Note: Power consumption of each of the pump/fan/compressors etc.
wherever mentioned shall be measured with its own drive.

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1.01.02 AMOUNT OF LIQUIDATED DAMAGES APPLICABLE FOR CATEGORY-I
GUARANTEES
If the performance guarantee(s) specified at clause 1.01.01 are not met by the
Contractor even after the modifications and/or replacements mentioned at clause
1.00.01 (e) of this Sub-section but are achieved within the stipulated Acceptable
Shortfall Limit as indicated in this clause, Employer will accept the
equipment/system/plant after levying liquidated damages as indicated here under,
however, if the demonstrated guarantee(s) continue to be more than the stipulated
Acceptable Shortfall Limit, the Employer may at his discretion reject the
equipment/system and recover the payment already made or accept the
equipment/system only after levying liquidated damages against the Contractor, at
the rates listed herein, and such liquidated damages shall be deducted from the
Contract Price:
Sl.
No.
Guarantee Rate of Liquidated
Damage (LD)
Acceptable
Shortfall Limit with
LD
i) For increase in the
guaranteed turbine
cycle heat rate

a) At 105%
TMCR
(693MW) Unit
Load
US $ 273,810 (US dollar
Two hundred seventy
three thousand and eight
hundred ten only) per 1
Kcal/Kwhr increase in heat
rate.
(+) 2.5 % of the
guaranteed turbine
cycle heat rate.
b) At 100%
TMCR
(660MW) Unit
Load
US $ 1,043,087 (US
dollar One million forty
three thousand and eighty
seven only) per 1
Kcal/Kwhr increase in heat
rate.
(+) 2.5 % of the
guaranteed turbine
cycle heat rate
subject to maximum
of 1850 kcal/kwhr.
ii) For deficiency in
Turbine Generator
output
US $ 642 (US dollar Six
hundred forty two only) per
1 KW short fall in TG
output.
(-) 2% of guaranteed
Turbine Generator
output.
iii) For deficiency in
condenser pressure
US $ 1,510,482 (US
dollar One million five
hundred ten thousand and
four hundred eighty two
only) per 1 mmHg
increase in condenser
pressure.
(+) 2.5% of the
guaranteed
condenser pressure.
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iv) For increase in
C.W. pumping
power for pressure
drop and C.W. flow
in condenser
(Power
consumption shall
be computed based
on overall efficiency
of 83% for the CW
pump and drive set)
Four thousand and eight
hundred thirty one only)
per 1 KW increase in CW
pumping power.
(+) 1% of the
guaranteed C.W.
pumping power.
v) Auxiliary Power
Consumption

Auxiliary Power
Consumption at
100% TMCR (660
MW) unit load for
increase in the
auxiliary power
consumption in KW
guar-anteed as per
the requirements of
Cl.1.01.01(vi) of this
Sub Section.
Four thousand and eight
hundred thirty one only)
per 1 KW increase in Aux.
Power consumption.
(+) 1% of the
guaranteed auxiliary
power consumption.
NOTE :
i) Each of the liquidated damages specified above shall be independent and
these liquidated damages shall be levied concurrently as applicable.
ii) If the contract currency is other than US dollars, then the liquidated damages
shall be in equivalent amount in contract currency based on Bill selling
exchange rate of State Bank of India prevailing on the date of award of
contract.
iii) All these liquidated damages for short fall in performance shall be deducted
from the contract price as detailed in accompanying General Conditions of
Contract (GCC)/ Special Conditions of Contract (SCC)
iv) Contractor's aggregate liability to pay liquidated damages for failure to attain
the functional guarantee shall not exceed twenty five percent (25%) of the
Contract Price.

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1.01.03 Auxiliary Power Consumption
The unit auxiliary power consumption shall be calculated using the following
relationship.
Pa = Pu + TL
Pa = Guaranteed Auxiliary Power Consumption.
Pu = Power consumed by the auxiliaries of the unit under test.
TL = Losses of the transformers supplied by bidder based on works test
reports.
While guaranteeing the auxiliary power consumption the bidder shall necessarily
include all continuously operating unit auxiliaries. The auxiliaries to be considered
shall include but not be limited to the following :
UNIT AUXILIARIES (to be considered for calculating Pu)
(a) Turbine Unit Oil purifier.
(b) Turbine Unit control oil purifier.
(c) Electric oil heater for turbine lube oil.
(d) Feed and discharge pumps of turbine oil purification system.
(e) Main turbine Condenser air evacuation pumps.
(f) BFP drive turbine Condenser air evacuation pumps (if envisaged).
(g) Main turbine Condenser tube cleaning system pumps.
(h) BFP drive turbine Condenser tube cleaning system pumps (if envisaged).
(i) Condensate extraction pumps.
(j) Drip pump (if envisaged).
(k) BFP drive turbine Condensate extraction pumps (if envisaged).
(l) Hydrazine dosing pumps.
(m) Ammonia dosing pumps.
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(n) Oil purifiers of 2x50% TDBFPs and their feed and discharge pumps.
(o) Lube oil pumps of 2x50% TDBFPs and the electrical oil heater for lube oil.
(p) Auxiliary oil pump for MDBFP.
(q) Oil pumps for HP-LP bypass system.
(r) Motor Driven Boiler Feed Pump
(For this purpose only 15% of the deemed power consumed by both the
MDBFPs at 100% TMCR unit load shall be considered).
(s) DM Cooling (normally working) Water pumps to supply cooling water on the
secondary (DM) side of the plate type heat exchangers in the closed loop
Equipment cooling (Unit auxliaries) water system.
(t) Auxiliary Cooling (normally working) water pumps to supply cooling water on
the secondary side of the plate type heat exchangers in the closed loop
Equipment cooling (unit auxiliary) water system.
(u) One third (33%) of power consumption of one stream of hydrogen generation
plant.
(v) Power consumption of any other continuously operating auxiliaries for unit
operation at different guarantee point loads.
Note :
1. The bidder shall furnish a list of equipments to be covered under auxilliary
power consumption, which shall be subject to Employer's approval.
2. Power consumption at rated duty point sl. no- (s) and (t) to be arrived at
based on shop test.
3. Power consumption for hydrogen generation plant at its rated capacity shall
be arrived at based on site test.
1.01.04 HEAT RATE
Turbine Cycle Heat Rate shall be calculated as follows & indicated in all computed
heat balance diagrams :
M1 (H1-h1) +M2 (H3-H2) +Mis (h1-his)+Mir (H3 - hir)
HEAT RATE = ---------------------------------------------------------------------------------
Pg
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The expression "Mis (h1-his)" in the numerator of the formula is not applicable if
spray water to superheater is completely internal to the boiler (i.e. tapped from a
location downstream of economizer inlet).
Where,
M1 - Quantity of live steam entering the turbine stop valve including any live
steam supplied to valve stems, or glands etc. in Kg/hr.
M2 - Quantity of steam from turbine to reheater in Kg/hr.
Mir - Quantity of desuperheating water flowing into reheater system for
regulation of steam temperature in Kg/hr.
Mis - Superheater desuperheating spray flow in Kg/hr.
H1 - Enthalpy in kcal/kg of live steam.
H2 - Enthalpy in kcal/kg of steam to reheat.
H3 - Enthalpy in kcal/kg of reheated steam.
h1 - Enthalpy of feed water in kcal/kg at the downstream of the junction of feed
flow and bypass flow of HP heaters.
hir - Enthalpy of desuperheating water flowing into reheat system in Kcal/Kg.
his - Enthalpy of superheater desuperheating spray water in Kcal/Kg.
Pg - Unit output after deducting the power consumption by auxiliaries as listed
below and the same shall be 693MW, and 660MW respectively for 105%,
and 100% TMCR unit load:
(a) Power taken by Excitation system (KW) including transformer
losses, as applicable for various guarantee points. (The
transformer losses at various points shall be based on factory test
to be conducted).
(b) Power required for ventilation of oil and control fluid tanks, if
ventilating fans are separately driven (KW).
(c) Power required for lubrication, if lubricating pumps are separately
driven (KW).
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(d) Power required for control fluid pumps, if control fluid pumps are
separately driven (KW).
(e) Power required for hydrogen, seal oil auxiliaries, if separately
driven (KW).
(f) Power required for stator water cooling system, if cooling pumps
are driven separately (KW).
It may be noted that the heat balance diagrams and guarantees shall be
furnished considering zero spray water quantity for superheater and
reheater spray. During Performance Guarantee Testing, in case water is
required for superheater and/or reheater temperature control, the
contractor shall be entitled to heat rate correction as per correction curves
to be submitted by him with his offer.

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1.02.00 GUARANTEES UNDER CATEGORY - II
NIL
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GUARANTEES UNDER CATEGORY - III
1.03.00 The parameters/capabilities to be demonstrated for various systems/
equipments shall include but not be limited to the following:
1.03.01 Noise
All the plant, equipment and systems covered under this specification shall perform
continuously without exceeding the noise level over the entire range of output and
operating frequency specified in General Technical Requirement, Part-C Section-VI
of 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.
1.03.02 Condenser On Load Tube Cleaning System
Life of sponge rubber balls and number of balls lost during 1000 hours of plant
operation shall be as indicated by Bidder in the offer and accepted by the
Employer.
1.03.03 Deaerator
Dissolved O2 content in Deaerator effluent at deaerator outlet without chemical
dosing at all loads, not to exceed 0.005 CC/litre determined as per ASTM-D-888
Reference method-A or Indigo Carmine method.

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1.03.04 Turbine hall EOT Crane :
Over load test, travel & hoist speed checks etc., shall be demonstrated as per IS:
3177 (latest edition).
1.03.05 Equipment Cooling Water System
Design heat load of plate type heat exchangers and Inlet & Outlet temperatures of
the Plate type heat exchangers on the primary and secondary side to be
demonstrated at site. Pressure drop across the Plate type heat exchanger on the
primary & secondary water circuit to be demonstrated at site.
1.03.06 Condensate Polishing Unit
i) Effluent quality at outlet of each vessel at its rated design flow and design
service length between two regenerations.
ii) Pressure drop across the polisher service vessel (as defined elsewhere) in
clean and dirty condition of resin at rated design flow.
1.03.07 Hydrogen Generation Plant
i) Capacity & discharge pressure of hydrogen gas compressors at its rated duty
point with its job (own) motor shall be demonstrated and proved at shop.
ii) Parallel operation of two streams shall be demonstrated at site. Purity level
and moisture content of Hydrogen shall be demonstrated at site.
iii) Hydrogen generation plant capacity (stream wise) shall be demonstrated at
site.
1.03.08 EOT, HOT Cranes & Monorail Hoist : Over load tests, travel and hoist speed
checks as per relevant Indian standard IS (latest edition).
1.03.09 Passenger Lifts for TG Building & Service Building : Over load tests, travel and
hoist speed checks.

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2.00.00 PERFORMANCE GUARANTEE / ACCEPTANCE TEST
2.01.01 It is the responsibility of the Contractor to perform the Performance
Guarantee/Acceptance test as specified in this Sub-Section. The performance tests
will be performed using only the normal number of Employer supplied operating
staff. Contractor, vendor or other subcontractor personnel shall only be used for
instructional purposes or data collection. At all times during the Performance Tests
the emissions and effluents from the Plant shall not exceed the Guaranteed
Emission and Effluent Limits.
2.01.02 The Contractor shall make their system ready for the performance guarantee tests.
2.01.03 All instruments required for performance testing shall be of the type and accuracy
required by the code and prior to the test, the contractor shall get these instruments
calibrated in an independent test Institute approved by the Employer. All test
instrumentation required for performance tests shall be supplied by the contractor
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 Employer. The protecting tubes,
pressure connections and other test connections required for conducting guarantee
test shall conform to the relevant codes.
Tools and tackles, thermowells (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 contractor free of cost.
2.01.04 The contractor shall submit for Employer's approval the detailed Performance Test
procedure containing the following :
(a) Object of the test.
(b) Various guaranteed parameters & tests as per contract.
(c) Method of conductance of test and test code.
(d) Duration of test, frequency of readings & number of test runs.
(e) Method of calculation.
(f) Correction curves.
(g) Instrument list consisting of range, accuracy, least count, and location of
instruments.
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(h) Scheme showing measurement points.
(i) Sample calculation.
(j) Acceptance criteria.
(k) Any other information required for conducting the test.
The Performance / Acceptance test shall be carried out as per the agreed
procedure. The PG test procedure including demonstration tests shall be submitted
within 90 days of the date of Notification of Award and finalization of the PG test
procedure shall be done within 180 days from the date of Notification of Award. After
the conductance of Performance test, the contractor shall submit the test evaluation
report of Performance test results to Employer promptly but not later than one month
from the date of conductance of Performance test. In case post test calibration takes
longer time then modalities for submission of PG test report by the bidder shall be
mutually agreed upon during the test. However, test data shall be submitted to the
Employer after completing each test run.
2.01.05 Test Interruptions
In the event of a test interruption resulting from an Event of Force Majeure or
Employer-Caused-Delay, Contractor shall be entitled to relief as provided in the
contract, provided that, the interrupted Performance Test must be started again and
test data that were collected during the interrupted test must be ignored.
2.02.00 Turbine Generator Performance/ Acceptance Test
2.02.01 Performance test for the turbine generator set will be conducted in accordance with
the latest edition of ASME PTC-6. Such test shall be binding on the parties to the
contract to determine compliance with the guaranteed heat balance conditions at
693 MW (105% TMCR) MW and 660 MW (100% TMCR) unit outputs corresponding
to the conditions stipulated under Cl. 1.22.01 of Sub-section- A-3 (Turbine Generator
and Auxiliaries), Part-B. Power consumed by the auxiliaries mentioned under clause
1.01.03 of this Sub-section which is to be deducted from electrical power generated,
shall be measured during the performance / Acceptance Test. Wherever the
measurement is not possible, design values of power consumption by an auxiliary
shall be considered.
2.02.02 The essential mandatory requirements for instruments, methods and precautions to
be employed shall be in accordance with the requirements specified in the
respective codes. All the necessary instruments (in duplicate) required for the tests
shall be furnished by the contractor so as to meet the accuracies specified in the
codes. Any advanced class instrument system such as those using electronic
devices or mass flow technique shall be arranged by the contractor, if required. For
determination of primary flow to the turbine, a calibrated low Beta-ratio throat-tap
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nozzle assembly including required machined straight lengths meeting the
requirement of ASME PTC-6 shall be provided. The test procedures, Calibration
Standards, Calibration procedures etc., shall be subject to Employer's approval. All
the instruments including the flow nozzle shall be calibrated by the contractor before
and after the test, in a reputed international institute as approved by the Employer.
However, post test calibration of flow nozzle shall not be mandatory. During the test
if it is found that the parameters are in order as regards to calibrations of instruments
and after post test calibration of instruments, the difference between pre test and
post test calibrations is within code acceptable limits, bidder shall submit the report
of PG test results based on pre test effects (calibration) of instruments. These
calibrations shall be performed in the presence of the Employer. All calibrations shall
be made available prior to the test and calibration certificates in original submitted to
Employer at least 15 days before conductance of the test for Employer's approval.
The instruments shall be sealed after calibration by calibrating lab. The percentage
calibration error/deviation should not be more than accuracy class of the instrument.
Calibration low beta ratio throat tap nozzle assembly including flow straightner,
upstream and down stream machined straight lengths, for main condensate flow
measurements shall be as per ASME PTC6.
Secondary flow devices shall be calibrated flow nozzle / orifice plate as per ASME-
PTC 19.5.
2.02.03 Corrections to the test results for steam turbine shall be applied as per the correction
curves listed in detailed technical specification Part-B. When the system is properly
isolated for a performance test, the unaccounted for leakages should not be more
than 0.1% of the design throttle flow at that load. To achieve the above value of
unaccounted for leakages, the Bidder shall prepare the unit during pretest available
shutdown. However, during the test, if it is found that the unaccounted for leakage is
more than 0.1% of design throttle flow at that load, then heat rate will be increased
by an amount equal to half the difference between actual unaccounted for leakage
expressed as percentage of design throttle flow at that load and 0.1% (allowed by
the code). If the unaccounted leakage during the test shall be more than 0.3 % of
design throttle flow at that load and appreciable leakage is visible in Boiler area,
mutual agreement shall be made regarding consideration of excess leakage in the
calculation of test results.
2.02.04 The performance guarantee test will be carried out after successful completion of
initial operation. Ageing allowance will be given during evaluation of PG test results
and hence guaranteed heat rates shall be increased by the amount calculated as
per the formula given in Cl. No. 3.07, Sub-Section-3 of ASME-PTC-6 Report 1985
(Reaffirmed 1991). Period of ageing shall be considered from the date of first
synchronization to the date of conductance of PG test.
In calculating the above factor any period(s) during which the turbine has not been in
operation at a stretch for more than a week shall not be considered
2.02.05 The tests shall be arranged in a manner that the EMPLOYER's operation is not
disrupted. Duplicate test runs shall be performed at 693 MW and 660 MW unit loads.
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The results of corrected heat rate shall agree within 0.25%. If they differ by more
than 0.25%, third test shall be run at the same point. The corrected result of any one
of the three test runs, which deviates from the corrected averaged result of all the
runs by more than 0.25%, shall be eliminated; otherwise the results of all the three
tests runs shall be accepted.
2.02.06 During Performance/ Acceptance test, following tests shall be carried out for T.G. set
with test grade instruments as per ASME code.
(i) Guarantee Turbine Cycle Heat rate test at 693MW (105% rated load)
corresponding to the heat balance diagram specified in Sub-Section-A-3,
Part-B, Section-VI.
(ii) Guarantee Turbine Cycle Heat rate test at 660MW corresponding to the heat
balance diagram specified in Sub-Section-A-3, Part-B, Section-VI.
(iii) Guarantee Output test of 693 MW (105% rated load) corresponding to the
heat balance diagram specified in Sub-Section-A-3, Part-B, Section-VI.
(iv) CW pumping power in KW for design CW flow and the pressure drop on CW
side being measured between Bidder's terminal points. (Power consumption
shall be computed based on overall efficiency of 83% of CW pump and drive
set).
2.02.07 Performance test for the condensers will be conducted in accordance with the latest
edition of ASME PTC-12.2 with the exception at (a) mentioned below :
(a) Condenser pressure will be measured at 300 mm above the top row of tubes
under VWO conditions, 3% make-up and design C.W. flow & design
temperature. The condenser pressure shall be measured with a vacuum grid
utilising ASME basket tips. The grid is fitted at 300 mm above top row of
condenser tubes.
(b) Combined pressure drop in condenser tube, waterbox, and inlet and outlet
piping will be measured in between intake and discharge point of the C.W.
system at BIDDER'S terminal points with cleanliness factor of 0.9 and
COLTCS in service.
2.03.00 Test Reports
The Contractor shall prepare test reports for the Availability Test, Efficiency Test,
Capacity Test and the Emissions test, in which the methods followed, instrument
readings, graphs, observations, final results obtained, etc., shall be recorded.
SECTION-VI
PART - A
MANDATORY SPARES
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1.00.00 SPARES
The Bidder shall include in his scope of supply all the necessary Mandatory spares,
start up and commissioning spares and recommended spares and indicate these in
the relevant schedules of the Bid Form and Price Schedules. The general
requirements pertaining to the supply of these spares is given below:-
1.01.00 MANDATORY SPARES
(a) The list of mandatory spares considered essential by the Employer is
indicated in this chapter. The bidder shall indicate the prices for each and
every item (except for items not applicable to the bidders design) in the
'Schedule of mandatory Spares' whether or not he considers it necessary for
the Employer to have such spares. If the bidder fails to comply with the
above or fails to quote the price of any spare item, the cost of such spares
shall be deemed to be included in the contract price. The bidder shall furnish
the population per unit of each item in the Bid Forms and Price Schedules.
Whenever the quantity is mentioned in "sets" the bidder has to give the item
details and prices of each item.
(b) The Employer reserves the right to buy any or all the mandatory spares
parts.
(c) The prices of mandatory spares indicated by the Bidder in the Bid Proposal
sheets shall be used for bid evaluation purposes.
(d) 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.
(e) Wherever quantity is specified both as a percentage and a value, the Bidder
has to supply the higher quantity until and unless specified otherwise.
1.02.00 RECOMMENDED SPARES
(a) In addition to the spare parts mentioned above, the contractor shall also
provide a list of recommended spares for 3 years of normal operation of the
plant and indicate the list and total prices in relevant schedule of the Bid
Form and Price Schedules. This list shall take into consideration the
mandatory spares specified in this Section-VI, part-F and should be
independent of the list of the mandatory spares. The Employer reserves the
right to buy any or all of the recommended spares. The recommended
spares shall be delivered at project site at least two months before the
scheduled date of initial operation of first unit. However, the spares shall not
be dispatched before the dispatch of the main equipment.
CLAUSE NO.
MANDATORY SPARES

STAGE-II (2X660 MW)
SECTION-VI
PART-A
MANDATORY
SPARES

PAGE
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(b) Price of recommended spars will not be used for evaluation of the bids. The
price of these spars will remain valid upto 6 months after placement of
Notification of Award for the main equipment. However, the Contractor shall
be liable to provide necessary justification for the quoted prices for these
spares as desired by the Employer.
1.03.00 START-UP & COMMISSIONING SPARES
Start-up and commissioning spares are those spares which may be required during
the start-up and commissioning of the equipment/system. All spares used till the
plant is handed over to the employer shall come under this category. The Contractor
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
Contractor.
1.04.00 The Bidder shall include in his scope of supply all the necessary Mandatory spares,
start up and commissioning spares and recommended spares and indicate these in
the relevant schedules of the Bid Form and Price Schedules. The general
requirements pertaining to the supply of these spars is given below.
2.00.00 The Contractor shall indicate the service expectancy period for the spares parts
(both mandatory and recommended) under normal operating conditions before
replacement is necessary.
3.00.00 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.
4.00.00 All the spares (both recommended and mandatory) shall be manufactured alongwith
the main equipment components as a continuous operation as per same
specification and quality plan.
5.00.00 The contractor will provide Employer with cross-sectional drawings, catalogues,
assembly drawings and other relevant documents so as to enable the Employer to
identify and finalise order for recommended spares.
6.00.00 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
CLAUSE NO.
MANDATORY SPARES

STAGE-II (2X660 MW)
SECTION-VI
PART-A
MANDATORY
SPARES

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detailed list enclosed. All cases, containers and other packages must be suitably
marked and numbered for the purposes of identification.
7.00.00 All cases, containers or other packages are to be opened for such examination as
may be considered necessary by the Employer.
8.00.00 The contractor will provide the Employer 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
Employer, 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.
9.00.00 The Contractor 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.
10.00.00 In addition to the recommended spares listed by the contractor, if the employer
further identifies certain particular items of spares, the contractor shall submit the
prices and delivery quotation for such spares within 30 days of receipt of such
request with a validity period of 6 months for consideration by the Employer and
placement of order for additional spares if the Employer so desires.
11.00.00 The Contractor shall guarantee the long term availability of spares to the Employer
for the full life of the equipment covered under the contract. The Contractor shall
guarantee that before going out of production of spares parts of the equipment
covered under the Contract, he shall give the Employer atleast 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-contractors. Further, in case of
discontinuance of manufacture of any spares by the Contractor and/or his sub
contractors, Contractor will provide the Employers, two years in advance, with full
manufacturing drawings, material specifications and technical information including
information on alternative equivalent makes required by the Employer for the
purpose of manufacture/procurement of such items.

CLAUSE NO.
MANDATORY SPARES

STAGE-II (2X660 MW)
SECTION-VI
PART-A
MANDATORY
SPARES

PAGE
4 OF 41

LIST OF MANDATORY SPARES
A. GROUP-A: MANDATORY SPARES
S. NO. ITEM DESCRIPTION QUANTITY
1 Complete assembly of HPT module (includes inner bladed
casing and bladed rotor including all internals in assembled
condition and fitted in outer casing) along with Breach nuts (if
applicable).
Or
If design is such that stationery Blading is provided in
diaphragms, then full set of bladed diaphragms /Carriers and
nozzle Sets required for all stationary stages of HP turbine,
along with Bladed HP Rotor with applicable finned gland
seals, Diaphragm packings & outer casing if applicable i.e.,
complete HP turbine assembly
1 No.
2 Complete assembly of IPT module (inner bladed casing and
bladed rotor including all internals in assembled condition)
along with full set of both ends of stationery gland seal
segments (Finned).
Or
If stationery Blading provided in the form of diaphragms, then
full set of bladed diaphragms / carriers and nozzle Set required
for all stages of IP turbine and 1 assembled IP Rotor with
applicable finned gland seals, Diaphragm packings.
1 No.
3 a. LP Turbine bladed rotor (if two rotors are there per unit then 2
nos. have to be supplied)
1 No. or 2 Nos.
as per
applicability
3 b. For LP turbine, 1 full set of stationery blades assembled in
applicable casings.
Or
If stationery Blading provided in the form of diaphragms, then
full set of bladed diaphragms for LP turbine.
1 No.
4 LPT inlet pipe compensator assemblies including pins, fixing
material , protection tube as applicable (For 1 unit )
1 Set
5 LP turbine rotor moving blades of free standing type for each
path with all the fastening material required for the above Sl.
No 3a
2 Sets as per
applicability
6 Drive turbine bladed rotor for TDBFP 1 No.
CLAUSE NO.
MANDATORY SPARES

STAGE-II (2X660 MW)
SECTION-VI
PART-A
MANDATORY
SPARES

PAGE
5 OF 41

7 Aux oil pump complete assembly for Main Turbine along with
coupling
1 Set
8 Main oil pump complete assembly WITH DRIVE MOTOR (If
applicable) for Main Turbine along with coupling
1 Set
9 AC jacking oil pump complete assembly for Main Turbine along
with coupling
1 Set
10 DC jacking oil pump assembly for Main Turbine 1 Set
11 EOP along with motor for Main Turbine lubricating system
along with coupling
1 Set
12 BFP Booster Pump
12 (a) Turbine Driven BFP booster pump complete assembly.
including casing , rotor assembly along with bearings and seal
assembly
1 Set
12(b) Motor Driven BFP booster pump complete assembly. including
casing , rotor assembly along with bearings and seal assembly
1 Set
13 BFP
13(a) Turbine Driven BFP cartridge complete assembly which
includes DE, NDE bearing assembly, seals assembly, shaft,
impellers, inlet ring sections, diffusers along with gaskets , O-
rings , soft parts required for replacement in barrel.
2 Sets
13(b) Motor Driven BFP cartridge complete assembly which includes
DE, NDE bearing assembly, seals assembly, shaft, impellers,
inlet ring sections, diffusers along with gaskets , O-rings , soft
parts reqd. for replacement in barrel.
1 Set
13 (c) Complete Gear box assy. between BFP Drive Turbine &
Booster pump including coupling on turbine side
1 Set
14 CEP complete with bowl assembly excluding canister but
including coupling
1 Set
15 Main Turbine Condenser Vacuum Pump complete assembly
including coupling
1 Set
16 Generator & Auxiliaries
a) Turbo generator rotor complete 1 Set
b) Complete generator stator 1 Set
c) Generator Rotor fan/ compressor blades assembly(Fixed
blades mounted on carrier & moving blades)

1 Set
CLAUSE NO.
MANDATORY SPARES

STAGE-II (2X660 MW)
SECTION-VI
PART-A
MANDATORY
SPARES

PAGE
6 OF 41

17 Gas System
a) Refrigeration type hydrogen drier assembly Complete 1 Set
18 Seal Oil System
a) Complete motor and Pump assembly for AC seal oil pump 1 No. of each
type
b) Motor pump set for DC seal oil pump 1 Set
c) Vacuum pump assembly 1 Set
19 Stator Water Cooling System
a) Stator water pump motor assembly 1 Set
20 Motors
a) Condensate Extraction Pump motor complete assembly
including motor bearings
1 Set
b) Boiler Feed Pump motor (BFP) complete assembly including
motor bearings
1 Set
c) ACW Pumps and DMCW Pumps motor including motor
bearings
1 Set each
d) Condenser Vacuum pump motor including motor bearings. 1 No. of each
type
B. Group-B: Mandatory Spares:
All the governing spares vide point no. (I)15, (I)18, (I)21, (I)24, (I)27, (I)31, (I)32,
(I)39 are meant for EHC type governing system, in case of Extra HP governing
being offered equivalent spares need to be offered.
I. TG Items
1 Complete set of all bearings including thrust bearings
for complete turbine rotor system (Complete set of
bearing assembly including torous / spherical pieces ,
cylindrical / spherical supports matched with spherical /
tourus pieces , intermediate pieces & all other
fixing/assembly materials required to complete one
bearing assembly except cap)
2 Sets
2a High Pressure (HP) rotor seals (Complete set of
interstage seals of all the stages of moving blades of
HP rotor with fixing material)
2 Sets
2b Assembly of HP casing (1 set should comprise of
sealing fins, segments, fitted keys, pins, caulking
material for interstage sealings of all the stationary rows
along with inserts , threaded rings , angle rings )
2 Sets
CLAUSE NO.
MANDATORY SPARES

STAGE-II (2X660 MW)
SECTION-VI
PART-A
MANDATORY
SPARES

PAGE
7 OF 41

3a High Pressure (HP) rotor balance chamber dummy
piston seals (Complete set of seals with fixing material)
-if applicable
2 Sets
3b HP Casing stationery dummy piston area seals : (1 set
should comprise of segments, sealing fins, fitted keys,
pins, caulking material) If applicable
2 Sets
3c HP shaft sealing (Complete set for replacement of front
& rear sealing with fixing material corresponding to both
rotating / stationary components)
2 Sets
4 HP inlet & HP exhaust assembly (Sealing rings, lock
washers, connecting nuts/cap nuts between pipe &
casing at inlet and exhaust)
2 Sets
5 HP outer / inner casing-U seal rings , I seal rings
complete set
1 Set final machined & 1
set unmachined
6a Assembly of IP casing (1 set should consist of seal fins,
segments, fitted keys, caulking material , pins, cap
screws for interstage sealings of all the stationary rows
along with threaded rings , inserts , angle rings )
2 Sets
6b IP rotor seals (1 set should consist of seal fins ,
caulking material for all the interstage sealings of the
rotating stages)
2 Sets
7 a) IP shaft seals (Complete set for replacement of
front & rear sealing which includes seal segments,
seal fins, caulking material, springs, fitted keys,
screws, corresponding to both rotating / stationary
component)
2 Sets
b) IP inner outer/piping sealing rings, angle ring (if
applicable)
2 Sets
8a LP Turbine rotor seals (Complete set of interstage
seals of all the stages of moving blades of LP rotor with
fixing material)
1 Set

8b L P shaft seals (Complete set for replacement of front
& rear with fixing material which includes seal
segments, seal fins, caulking material, fitted keys, pins,
springs, screws corresponding to both rotating &
stationary components)
1 Set
9 LP Casing stationery seals (1 set should comprise of
segments, sealing fins, fitted keys, pins, caulking
material for interstage sealing of stationary rows )
1 Set
10a LP extraction line compensator assemblies (complete 1 Set
CLAUSE NO.
MANDATORY SPARES

STAGE-II (2X660 MW)
SECTION-VI
PART-A
MANDATORY
SPARES

PAGE
8 OF 41

set required for a unit including pins , fixing material ,
protection tube)
10b Compensator assembly at LP front / rear between
gland box & casing if applicable including pins, fixing
material, protection tube
1 Set
10c Cross Around pipe Compensators assemblies including
pins, fixing material, protection tube
1 Set
11 MS and HRH strainers elements (for 1 unit) 1 Set
12 Turning Gear assembly complete (including gear
internal with shafts, bearing, bushes, lock washers, oil
seals, "O" rings, housing).
If hydraulically operated
Turning gear assembly complete (includes all nozzle
segments & moving blades / rotor assembly. and
complete set of sealing strips with caulking material )
1 Set

13 Emergency stop valve (Set of all internals required to
complete one valve assembly including valve cover &
excluding body)
1 Set

14 Emergency stop valve servomotor complete assembly 1 Set
15 Test valve for emergency stop valve servomotor (Set of
all internals required to complete one test valve
assembly excluding body)
1 Set
16 IP stop valve (Set of all internals required to complete
one valve assembly including valve cover & excluding
body)
1 Set

17 IP stop valve servomotor complete assembly 1 Set
18 Test valve for IP stop valve servomotor (Set of all
internals required to complete one test valve assembly
except valve body)
1 Set
19 HP control valve (Set of all internals required to
complete one valve assembly except valve body)
1 Set
20 HP control valve servomotor complete assembly 1 Set
21 a. Main Pilot valve for HP control valve / servomotor (Set
of all internals required to complete one pilot valve
assembly except valve body) plus Liners
1 Set

21 b. Auxiliary Pilot valve for HP control valve / servomotor
(Set of all internals required to complete one pilot valve
1 Set each
CLAUSE NO.
MANDATORY SPARES

STAGE-II (2X660 MW)
SECTION-VI
PART-A
MANDATORY
SPARES

PAGE
9 OF 41


22 IP control valve (Set of all internals required to
1 Set each
23 IP control valve servomotor complete assembly 1 Set
24 a. Main Pilot valve for IP control valve / servomotor (Set of
all internals required to complete one pilot valve
1 Set of each type &
size
24 b. Auxiliary Pilot valve for IP control valve / servomotor
(Set of all internals required to complete one pilot valve
size
25 LP Bypass control valve (Set of all internals required to
1 Set
26 LP Bypass control valve servomotor complete
assembly
1 Set
27 Pilot valve for LP Bypass control valve / servomotor
(Set of internals required to complete one pilot valve
assembly except valve body) plus Liner
1 Set
28 LP Bypass stop valve (Set of internals required to form
one valve assembly except valve body)
1 Set
29 LP Bypass stop valve servomotor complete assembly 1 Set
30 Water Injection valve for LP bypass system complete
assembly
1 Set
31
Hydraulic speed Governor assembly 1 Set
32
Over speed trip testing device complete assembly 1 Set
33
HP Bypass Valve complete assembly
1 Set
34 HP Bypass Valve servomotor complete assembly 1 Set
35 Pilot valve for HP Bypass valve / servomotor
(Complete set of internals required to form one pilot
valve assembly except valve body if applicable)
1 Set

36
Spray water injection valve for HP Bypass system
complete assembly
1 Set
37
Pilot valve for spay water injection valve / servomotor
for HP Bypass system complete assembly if
applicable
1 Set

CLAUSE NO.
MANDATORY SPARES

STAGE-II (2X660 MW)
SECTION-VI
PART-A
MANDATORY
SPARES

PAGE
10 OF 41

38
Turbine thrust bearing trip device complete assembly
if applicable
1 Set
39 Emergency Governor complete assembly 1 No
40 Main trip valve complete assembly 1 Set
41
Control fluid pump including motor (Set comprising of
pump or pumps along with motor required to meet the
100% requirement of one TG unit)
1 Set
42 a.
HP Turbine Overload valve: complete set of internals to
form assembly except housing (if applicable)
1 Set
42 b.
HP Turbine Overload valve servomotor assembly (if
applicable)
1 No.
43
Turbine drain valves with actuator including angle
valves up to 65 mm inlet size (complete replacement
for an unit)
1 Set
44 Tube nest of Vacuum pump cooler 1 Set
45 Deaerator safety relief valves 1 Set for one unit
46
Vacuum breaker valve complete assembly along with
actuator
1 Set
47 HP Control valve spindle-cone complete assembly 1 Set
48 IP control valve spindle-cone complete assembly 1 Set
49 Follow up piston assembly - if applicable 1 Set each, type & size
II. OTHER TG RELATED SUB-SYSTEMS
1 CONDENSER ON- LOAD TUBE CLEANING SYSTEM
1.1 Sponge rubber balls for condenser on-load tube
cleaning system (20% abrasive remaining normal)
50000 Nos.
1.2 Ball circulating pumps assembly (set consisting of
shaft, rotor, bearings, seals, gland packing , shafts
sleeves , for complete replacement in one pump)
1 Set
2 CONDENSATE EXTRACTION PUMP
2.1 Complete bearing assembly including bearing housing,
thrust bearing, carrier, journal bearing, cooling coil
1 Set
2.2 Radial bearing / J ournal bearing 1Set
2.3 Thrust pads of thrust bearing 1 Set
CLAUSE NO.
MANDATORY SPARES

STAGE-II (2X660 MW)
SECTION-VI
PART-A
MANDATORY
SPARES

PAGE
11 OF 41

2.4 Set of impellers & shafts 1 Set
3 BOILER FEED PUMP
3.1 Turbine Driven Boiler Feed Pump
3.1.1 Thrust bearing assembly with carrier & thrust collar 1 Set
3.1.2 J ournal bearing / bearing liners 1 Set
3.1.3 Set of thrust pads of thrust bearing 1 Set
3.1.4 BFP shaft 1 No.
3.1.5 Recirculation control valve complete assembly 1 Set/Unit
3.2 Motor Driven Boiler Feed Pump
3.2.1 Thrust bearing assembly with carrier & thrust collar 1 Set
3.2.2 J ournal bearing / bearing liners 1 Set
3.2.4 BFP shaft 1 No.
3.2.5 Recirculation control valve complete assembly 1 Set/Unit
4 BOILER FEED BOOSTER PUMP
4.1 Turbine Driven Boiler Feed Booster Pump
4.1.1 Thrust bearing with carrier & thrust collar 1 Set
4.1.2 J ournal bearings / bearing liners 1 Set
4.1.4 Boiler Feed Booster pump shaft 1 No.
4.2 Motor Driven Boiler Feed Booster Pump
4.2.1 Thrust bearing with carrier & thrust collar 1 Set
4.2.2 J ournal bearings / bearing liners 1 Set
4.2.4 Boiler Feed Booster pump shaft 1 No.
5 DRIVE TURBINE OF BFP
5.1 Emergency Stop valve assembly 1 No
5.2 Emergency stop valve servomotor assembly 1 No
5.3 HP / Main Control valve Servomotor assembly 1 No
CLAUSE NO.
MANDATORY SPARES

STAGE-II (2X660 MW)
SECTION-VI
PART-A
MANDATORY
SPARES

PAGE
12 OF 41

5.4 LP / Auxiliary Control valve complete assembly 1 Set
5.5 LP / Auxiliary control valve servomotor complete
assembly
1 Set
5.6 One set of J ournal bearings and Thrust bearing with
carrier
1 Set
5.7 Auxiliary oil pump complete assembly including
coupling
1 Set
5.8 Emergency oil pump complete assembly including
coupling
1 Set
6 ACW and ECW system
6.1 DMCW pump complete assembly 1 Set
6.2 ACW pump complete assembly 1 Set
7 MD BFP Hydraulic coupling
7.1 Complete Set of J ournal bearings 1 Set
7.2 Complete set of thrust bearings 1 Set
7.3 Aux. lube oil pump assembly 1 Set
7.4 Gear driven lube oil pump / working oil pump assembly 1 Set
III EHC RELATED INSTRUMENTATION
1. Electro-Hydraulic Converter/Servo unit and position
feed back transmitter for main turbine
1 Set
feed back transmitter for LPBP / HPBP
1 Set each
feed back transmitter for BFP Drive Turbine
1 Set
NOTE:
All the governing spares are meant for EHC type
governing system, in case of HP governing being
offered, its equivalent spares should be offered

IV HYDROGEN GENERATION PLANT PLC SYSTEM
a Power Supply Module 20 % or 4 Nos. of each
CLAUSE NO.
MANDATORY SPARES

STAGE-II (2X660 MW)
SECTION-VI
PART-A
MANDATORY
SPARES

PAGE
13 OF 41

type and model,
whichever is more.
b Electronic IO modules 20 % of each type and
model
c CPU controller card 1 No. of each type
d I. CPU communication modules to IO nodes(If
applicable)
II. CPU communication modules to HMI/OWS IO
nodes (If applicable)
1 No. of each type
1 No. of each type

V CONDENSATE POLISHING UNITS RELATED
SPARES

1.0 MEASURING INSTRUMENTS
1) Electronic Transmitters
(i) Transmitters of all types and model. (for the
measurement of Pressure, differential pressure, flow,
level, etc.) including local indication ( if applicable)
10 % or 1 No. of each
type and model
whichever is more
2) Temperature elements
(i) Temperature Transmitter 10 % or 1 No. of each
type and model
whichever is more
(ii) RTD's
1/2
1 No. of each type
(iii) Thermo well
2
1 No. of each type

1
(With head assembly, terminal block and nipple)
2
(to be divided into various insertion lengths in
proportion to main population)

3) Local Indicators (Non-Electrical type) -As applicable for
the package as per the following items

(i) Temperature gauges 1 No. of each range and
type
(ii) Pressure gauges 1 No. of each range and
type
(iii) Differential Pressure Gauges, 1 No. of each range and
type
CLAUSE NO.
MANDATORY SPARES

STAGE-II (2X660 MW)
SECTION-VI
PART-A
MANDATORY
SPARES

PAGE
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(iv) Level gauges 1 No. of each range and
type
(v) Flow gauges excluding Rota meters 1 No. of each range and
type
(vi) All types of Rota meters 1 No. of each range and
type
4) Process Actuated Switch Devices -As applicable for
this package, as per the following items

(i) Temperature switches 1 No. of each range and
type
(ii) Pressure switches 1 No. of each range and
type
(iii) Differential Pressure switches 1 No. of each range and
type
(iv) Level switches 1 No. of each range and
type
(v) Flow switches 1 No. of each range and
type
5) Solenoid Valves 10 % or 1 No. of each
type and model
whichever is more
6) Limit Switches (for Pneumatic Valves and Manual
valves)
2 Nos. of each type
7) ANALYSERS
i) pH Analyzer
(a) Flow Through type cell and Electrode
(b) Electronic Transmitter unit without sensor
(c) Pre-fabricated cable with connector

1 No of each type
1 No of each type
1 Set
ii) Conductivity Analyzer
(a) Flow Through type cell and Electrode
(b) Electronic Transmitter unit without sensor
(c) Pre-fabricated cable with connector

1 No of each type
1 No of each type
1 Set
iii) Sodium Analyzer
(a) Main PCB assembly
(b) Power supply Cards(if applicable)

1 No of each type
1 No of each type
CLAUSE NO.
MANDATORY SPARES

STAGE-II (2X660 MW)
SECTION-VI
PART-A
MANDATORY
SPARES

PAGE
15 OF 41

(c) Rubber Tubes & Capillary Tubes
(d) Pre-fabricated cable with connector
(e) Solenoid Valves
(f) All Chemical Reagents for 12 month
operation(Supply to be staggered as per the shelf life)
1 Set
1 Set
1 Set
1 Set
2.0 PROCESS CONNECTION PIPING (FOR IMPULSE
PIPING/TUBING, SAMPLING PIPING/TUBING AND
AIR SUPPLY PIPING AS APPLICABLE)

i) 2 way, 3way, 5way valve manifolds 1 No. of each type,
class, size and model
ii) Filter regulator 1 No. of each type,
3.0 CONTROL VALVES, ACTUATORS AND
ACCESSORIES

Control valve Smart Positioner Unit 1 No. of each type

VI DISTRIBUTED DIGITAL CONTROL MONITORING
AND INFORMATION SYSTEM (DDCMIS)

1. (a) OWS with licensed software 1 No.
(b) LVS workstation 1 No.
2 Keyboards/Mouse
(a) Keyboard 4 Nos.
(b) Mouse 8 Nos.
3. HMI Devices
i) Server for unit LAN or Information Workstation (as
applicable)
1 No.
ii) GIU(if applicable) 1 No. of each type and
model
4 (a) Power Supply Modules & Power Packs for control
system (If applicable)
20% or 4 Nos. of each
type, model and rating
which ever is more.
(b) Intelligent UPS for
(i) OWS/LVS WS/Server
1 No. of each type and
rating
CLAUSE NO.
MANDATORY SPARES

STAGE-II (2X660 MW)
SECTION-VI
PART-A
MANDATORY
SPARES

PAGE
16 OF 41

5 Electronic modules of each type and model for DCMIS
control system and its data communication system,
(This shall include all type of cards like I/O cards,
Remote I/O cards, communication/Interface cards,
controller cards, CPU module or Card, logic cards, etc.)
type, model and rating
which ever is more
subject to maximum of
20 Nos. of each type
6 Bus coupler/Interface hardware / other communication
devices
20% of each type and
model or minimum 2
Nos. which ever is more
7 Graphical interface units (if applicable) 1 No. of each type and
model
8 Batteries used for battery backup of RAMs (if
applicable)
10 % of each type and
model or minimum 2
Nos. which ever is more
VII. OTHER TG AND TD BFP RELATED SUB-SYSTEMS
Turbine Supervisory System for both TG & TD-BFP
(a) Power Supply assemblies of all types 20% or 4 Nos. of each
type whichever is more
(b) Electronic Cards/PCB's/interface units etc. of all types
used in TSS.
type whichever is more.
VIII. MEASURING INSTRUMENTS
1 (i) Guided wave RADAR for Hot well application 1 No.
(ii) Guided wave RADAR LP heaters 1 No. for each of the LP
heaters
2 Electronic Transmitters
(i) Transmitters of all type, range and model no. (for the
measurement of Pressure, differential pressure flow,
level, etc.)

10% or minimum 1 No.
which ever is more
(ii) Electronic cards / PCB's for each type and model of
transmitters.
10% of each type
3 Temperature elements
(i) RTD's 10% of each type and
length or minimum 1 No.
which ever is more
CLAUSE NO.
MANDATORY SPARES

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(ii) Thermocouples 10% of each type and
which ever is more
(iii) Thermo well for above applications 10% of each type and
which ever is more
(iv) Temperature Transmitters 10%
IX) POWER SUPPLY SYSTEM
24 V DC power supply system
(i) Rectifier Modules 10% of each size/rating
(ii) Controller Module 10% of each type and
model
X) CONTROL VALVES, ACTUATORS & ACCESSORIES
1 Pneumatic and electro-hydraulic actuator assembly
(other than Electro-hydraulic converter for LPBP, Main
Turbine, BFP Drive Turbine)
type, model and rating,
whichever is more.
XI) GENERATOR & AUXILIARIES
1 Generator bearings for TE and EE 1set (complete with
torous, intermediate pieces and all other
fixing/assembly/ insulating material required to
complete one TG unit except housing)
1 Set (both TE & EE)
2 Exciter bearings 1set including oil guard (complete
with torous, intermediate pieces and all other
fixing/assembly/ insulating material required to
complete one TG unit except housing)
1Set
3 Oil guard rings spare for TE and EE bearings complete
assembly. with fixing material
1 Set
4 Stator winding bars and connections (one set
comprising of two bars of each variant)
1 Set
5 Hydrogen Seal Assembly 1 Set
6 Tube bundle for Hydrogen cooler 1 Set
7 Generator phase and neutral bushings complete for
one machine
1 Set
8 Brush- holder assembly with housing for exciter for
rotor winding E/F sensing
1 Set
CLAUSE NO.
MANDATORY SPARES

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9 Brush Gear assembly complete with brushes for slip
ring
1 Set
10 Static excitation system
a Static rectifier element with heat sink and fuse
assembly
1x100% of one bridge
b Relays 2 Nos. of each type
c Electronic modules of automatic voltage regulator
2 Nos. of each type
d Excitation Transformer 1 No
e Complete DC field breaker 1 No
f Field flashing breaker 1 No
g Over voltage suppressor (Thyristor based) 2 Sets
11 Seal Oil System
i) Differential pressure regulator 2 Nos.
ii) Pressure equalizing valve (if applicable) 2 Nos.
12 Motors
i)
DC Motor >14 KW
2 Nos. of each type
ii) AC AOP motor for main turbine 2 Nos.
iii) AC J OP motor for main turbine 2 Nos.
iv) Cooling water booster pump motor 1 no.
v) ECW pump motor for TG auxiliaries. 1 no.

CLAUSE NO.
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C. Group C: Mandatory Spares
All the governing spares vide point no. 1- xvi, xvii, xix, xx, xxi and xxxi are
meant for EHC type governing system, in case of Extra HP governing being
offered, its equivalent spares should be offered besides those mentioned
under II below
1 MAIN TURBINE
i.) Set of oil guard rings for all turbine bearing pedestals
(Complete set of oil guard rings with fixing material)
1 Set
ii.) HP outer & inner casing fasteners & fixing material 100 % of each type &
size
iii.) HP/IP shaft coupling bolts, nuts, lock washers, pins,
screws, coupling guards
1 Set
iv.) IP outer & inner casing fasteners & fixing material 100 % of each type &
size
v.) Steam cooling apparatus or any other means used to
accommodate high HRH temperature in IP Turbine other
than 1
st
stage blades
1 Set
vi.) Set of oil guard rings for exciter bearings (Complete set
of oil guard rings with fixing material)
1 Set
vii.) IP/LP shaft coupling bolts, nuts, lock washers, pins,
screws, coupling guards
1 Set
viii.) LP outer & inner casing fasteners & fixing materials 100 % of each type &
size
ix.) a)LP turbine atmospheric diaphragm (Complete set for
replacement of one diaphragm assembly) with studs
b)LP diaphragm sheets
1 Set
6 Nos.
x.) LP/Generator shaft coupling bolts, nuts, lock washers,
pins, screws, coupling guards
1 Set
xi.) Complete set of fitted keys and packers (Radial & Axial)
of Turbine Sets which includes pedestal to base plate,
pedestal to casing, casing to casing, casing to supports
axial keys / radial keys / palm packers / lubrite plates
2 Sets
xii.) J acking oil hoses for all TG bearings 2 Sets
xiii.) Low vacuum trip complete assembly 1 No.
xiv.) Spray water Pressure Switch assembly for LP bypass
system)
1 No.
CLAUSE NO.
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xv.) Pilot valve for spay water injection valve for LP bypass
system
size
xvi.) Follow up pistons calibrated for governing system
(Complete replacement in governing system of one
turbine)
1 Set
xvii.) Hydraulic amplifier assembly for governing system 1 Set
xviii.) NRV's on J acking oil line to bearings
1 Set
xix.) Release valve for main trip valve 1 No
xx.) Gear for loading device complete assembly 1 Set
xxi.)
Gear for startup device complete assembly
1 Set
xxii.)
Duplex lube oil filter / Control Fluid regeneration system
filter (Complete set consisting of cartridges / filter
elements / dry filter / fine mech. filter / fuller earth filter,
gaskets, O rings except housing) for lube oil and for all
control Fluid systems
2 Sets
xxiii.)
Damping device(complete set of internals to form one
valve assembly except outer body)
1 Set
xxiv.)
Turbine gland steam supply valve complete assembly
1 Set
xxv.) Turbine gland steam leak-off valve complete assembly 1 Set
xxvi.)
Mounting arrangement for position transmitter on HP
control valve (Complete set comprising of bellows,
bushes, couplers, pins, lock washers, position detector)
1 Set
xxvii.)
Mounting arrangement for position transmitter on IP
control valve (Complete set comprising of bellows,
bushes, couplers, pins, lock washers, position detector)
1 Set
xxviii.)
NRVs on CRH line (Complete set consisting of disc,
shaft, gasket, gland packings, lever arm, stopper, hinge)
1 Set
xxix.)
Automatic turbine testing change over valve (Complete
set of internals required to form one change over valve
assembly except for outer casing)
1 Set
xxx.)
NRVs on extraction lines (Complete set of internals
required to form the valve assembly except for outer
1 Set or each type &
size
CLAUSE NO.
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casing & soft parts like gaskets , gland packings)
xxxi.) Actuators for NRVs on extraction lines
size
xxxii.) Butterfly valves for gland steam seal system
size
xxxiii.) LP exhaust hood spray control valve plus spray nozzles
1 No. valve with 1 Set
of spray nozzles
xxxiv.) Vapour extractor for lube oil with motor 1 No
xxxv.) Control fluid vapour exhauster with motor 1 No
xxxvi.)
Condenser manhole cover gaskets (Set comprising of
complete replacement for one condenser)
1 Set
xxxvii.) Bellow for accumulators in governing and HP-LP bypass
system (Set comprising of complete replacement in one
TG unit)
1 Set
Applicability of this
spare part will be
defined at the stage of
engineering
xxxviii.) Expansion joints on C.W. line (Set consisting of
neoprene bellow, SS mesh, fasteners for complete
replacement in one half of condenser) (50% of one unit)
1 Set
xxxix.)
Sealing strips for oil guard rings of Turbine pedestals
2 Sets, to be supplied
in running metre
xl.) Basket strainer/ Filter for Lube oil / Control Fluid system
in tank if applicable
2 Nos. for each
system
xli.) Duplex filter for J acking oil system consisting of filter
elements / cartridges, O-rings, gaskets except housing
2 Sets
xlii.) J acking oil pump pressure relief valve 2 Nos.
xliii.) J acking oil header pressure regulating valve 2 Nos.
xliv.) Complete set of rubber items which shall include O-
rings, Oil seals, Compact gaskets, bellows, Automatic
gaskets, sealing rings for servomotors of ESV/ HPCV/
IPSV / IPCV / LPBPSV / LPBPCV / CRH NRV /
EXTRACTION NRVs, Lube oil throttles, & all
components of Turbine Governing & Protection system
2 Sets
CLAUSE NO.
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xlv.)
Set of bearings. for pilot / pre-control pilot / auxiliary pilot
valves of Turbine governing & protection equipments if
applicable
1 Set
xlvi.)
High density balancing weights for HP/IP/LP turbines for
all balancing planes
20 Nos. for each type,
size
xlvii.) Gaskets / gland packings for extraction NRV's of turbine 200% of one unit
xlviii.)
Valve seat for HPSV,HPCV, HPBYPASS VALVE,
HPBYPASS SPRAY VALVES
1 No. of each
xlix.) HPSV, IPSV spindle with cone 1 No. of each
II
Governing System Spares ( High pressure governing
system) for Main turbine, LP bypass, HP Bypass

II.1. Accumulator for Governing system
1 of each type, size,
rating & class
II.2 Bladders for accumulators of Governing system
4 of each type, size
rating & class
II.3 Pressuring pump complete assembly
2 of each type, size ,
rating & class
II.4 Regulating valves for governing system
2 of each type, size,
rating & class
II.5
Complete set of soft parts (O-rings, gaskets, sealing
rings ) for Governing system
2 Sets each for main
Turbine , LP Bypass &
HP Bypass
II.6
Regenerative system filter elements / cartridges,
gaskets, O-rings for Governing system
3 Sets of each type
II.7 High Pressure hoses for Governing system 200% for each system
III.1
Guides / bushes / sleeves for HPSV, HPCV, IPSV,
IPCV, HPBYPASS VALVE
1 Set for each valve
III.2
Coupling assembly between valve & servomotor for
HPSV, HPCV, HPBYPASS VALVE, HPBYPASS SPRAY
VALVE
1 Set for each valve
III.3
Soft packing like gaskets, gland packing, O rings for
HPSV, HPCV, HPBYPASS VALVE, HPBYPASS SPRAY
VALVE, IPSV, I PCV, LPBYPASS SV, LPBYPASS CV
2 Sets for each valve
III.4
Servomotor spindle with piston for servomotors of HPSV,
HPCV, HPBYPASS VALVE, LPBYPASS SV,
LPBYPASS CV
1 Set of each
III.5 3-way lube oil temperature control valve 1 No.
CLAUSE NO.
MANDATORY SPARES

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III.6
Regeneration system pump for Turbine, LP Bypass, HP
Bypass control fluids
1 No. for each system
III.7 J acking oil system safety valve 1 No.
III.8
Complete set of soft parts like gaskets, o-rings for
Turbine lube oil cooler
2 Sets
III.9
Complete set of soft parts like gaskets, o-rings etc. for
control fluid cooler
2 Sets
2 VACUUM PUMP FOR MAIN TURBINE CONDENSER
2.1
Complete rotating assembly with Impeller, rotor and
Coupling
1 Set
2.2 Seal plates and mechanical seal 2 Set
2.3 Complete set of Bushes & O-rings 2 Set
2.4 Gland packing (if applicable) 4 Sets
2.4 Radial bearing / Thrust bearing 2 Sets
2.5 Complete set of soft parts like gaskets, o-rings etc. for
cooler
2 Sets
3 CONDENSATE EXTRACTION PUMP
3.1 Bowl assembly, wear rings, neck rings, casing wear ring
for all stages
1 Set
3.2 Coupling between motor and pump 1 Set
3.3 Suction strainer 1 Set
3.4 Set of line rubber / carbon bearings. for column pipe /
riser pipe / bowl assembly
2 Sets
3.5 Set of shaft couplings 1 Set
3.6 Set of sleeves, guide bushes 1 Set
3.7 Set of O- rings, gaskets for bowl assembly, riser pipes,
sleeves, bearings required for making complete
assembly of pump
2 Sets
3.8 Mech. seal complete assembly 2 Sets
3.9 Set of rotary & stationary faces for mech. seal 3 Nos. each
3.10 Set of soft parts i.e. O-rings, gaskets for mech. seal 8 Sets
3.11 CEP recirculation valve trim which includes spindle with
cone, seat ring, guide bush, cage
1 Set
CLAUSE NO.
MANDATORY SPARES

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SECTION-VI
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3.12 CEP recirculation valve soft parts i.e. gland packing,
seals, O-rings, gaskets etc.
3 Sets
4 Shell side safety relief valve for the following :
4.1 All HP heater 1 No.
4.2 All LP heater 1 No.
5 Tube side sentinel valve for the following:
5.1 All HP heater 1 No.
5.2 All LP heater 1 No.
6 Tube plugs for all HP heater 30 Nos.
7 Tube plugs for all LP heater 20 Nos.
8 Tube plugs for Gland steam condenser 10 Nos.
9 Trays for Deaerator (set of spray nozzles and trays
including fixing material)
20% required for an unit
10 Gaskets for all HP and LP heaters Two of each type and
size
11 Gaskets for drain Cooler One of each type and
size
12 Gaskets for Deaerator One of each type and
size
13 BOILER FEED PUMP (BFP) / BFP RECIRCULATION
VALVE
13.1 TURBINE DRIVEN BOILER FEED PUMP (BFP) / BFP
RECIRCULATION VALVE
13.1.1 Complete set of wear ring / neck rings (Rotating and
stationary)
2 Set
13.1.2 Balancing drum and balancing drum bush & nut 2 Nos. each
13.1.3 Mech. Seal (both DE/NDE) complete assembly. 2 Sets for each
13.1.4 Complete set of soft parts i.e., O-rings, gaskets for BFP
except for mechanical seal required for assembly of
cartridge & assembly of cartridge in barrel
4 Sets
13.1.5 Set of oil catcher, oil thrower (DE & NDE) 2 Sets of each
13.1.6 Set of filter elements / cartridges, O-rings, gaskets for
Duplex Lube oil filter for both MDBFP & TDBFP
2 Sets each
13.1.7 Complete coupling assembly. between BFP to Turbine,
Turbine to Gear box, Gear box to Booster pump, Booster
1 No. each
CLAUSE NO.
MANDATORY SPARES

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pump to BFP motor, Hydraulic coupling to BFP
13.1.8a Rotary & Stationary faces of mechanical seal (DE &
NDE)
4 Nos. each
13.1.8b Complete set of soft parts for mechanical seal including
O-rings , gaskets (DE & NDE)
8 Sets
13.1.8c Set of fasteners for mechanical seal 2 Sets
13.1.9 BFP Recirculation Valve spares
a Valve stem with plug assembly. 2 No.
b Seat ring / valve seat 2 No.
c Stack / Cage assembly. 2 No.
d Set of soft parts which includes gaskets, O-rings, tech
ring, gland packing
8 Sets
13.2 MOTOR DRIVEN BOILER FEED PUMP (BFP) / BFP
RECIRCULATION VALVE

13.2.1 Complete set of wear ring / neck rings (Rotating and
stationary)
2 Sets
13.2.2 Balancing drum and balancing drum bush & nut 2 Nos. each
13.2.3 Mech. Seal (both DE/NDE) complete assembly. 2 Sets for each
13.2.4 Complete set of soft parts i.e., O-rings, gaskets for BFP
except for mechanical seal required for assembly of
cartridge & assembly of cartridge in barrel
4 Sets
13.2.5 Set of oil catcher, oil thrower (DE & NDE) 2 Sets of each
13.2.6 Set of filter elements / cartridges, O-rings, gaskets for
Duplex Lube oil filter for both MDBFP & TDBFP
2 Sets each
13.2.7 Complete coupling assembly. between BFP to Turbine,
Turbine to Gear box, Gear box to Booster pump, Booster
pump to BFP motor, Hydraulic coupling to BFP
1 No. each
13.2.8a Rotary & Stationary faces of mechanical seal (DE &
NDE)
4 Nos. each
13.2.8b Complete set of soft parts for mechanical seal including
O-rings , gaskets (DE & NDE)
8 Sets
13.2.8c Set of fasteners for mechanical seal 2 Set
13.2.9 BFP Recirculation Valve spares
a Valve stem with plug assembly. 2 Nos.
b Seat ring / valve seat 2 Nos.
CLAUSE NO.
MANDATORY SPARES

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c Stack / Cage assembly. 2 Nos.
d Set of soft parts which includes gaskets, O-rings, tech
ring , gland packing
8 Sets
14 BOOSTER PUMP FOR BOILER FEED PUMP
14.1 TURBINE DRIVEN BOOSTER PUMP FOR BOILER
FEED PUMP

14.1.1 Wear rings, Neck rings (rotating and stationary) 2 Sets
14.1.2 Mechanical seal (Both DE /NDE) 2 Sets for each DE &
NDE
14.1.3 Rotary & stationary faces of mechanical seal (DE & NDE) 4 Sets for each
14.1.4 Complete set of soft parts which includes O-rings,
gaskets for mechanical seal
8 Sets
14.1.5 Set of fasteners for mechanical seal 2 Sets
14.1.6 Oil catcher, oil thrower (DE & NDE) 2 Sets each
14.2 MOTOR DRIVEN BOOSTER PUMP FOR BOILER FEED
PUMP

14.2.1 Wear rings, Neck rings (rotating and stationary) 2 Set
14.2.2 Mechanical seal (Both DE /NDE) 2 Sets for each DE &
NDE
14.2.3 Rotary & stationary faces of mechanical seal (DE & NDE) 4 Sets for each
14.2.4 Complete set of soft parts which includes O-rings,
gaskets for mechanical seal
8 Sets
14.2.5 Set of fasteners for mechanical seal 2 Sets
14.2.6 Oil catcher, oil thrower (DE & NDE) 2 Sets each
15 DRIVE TURBINE FOR BFP and Gear Box between
Turbine & Booster Pump

15.1 HP CONTROL VALVES SPARES (all internals required
to make a valve excluding cover and body)
1 Set
15.2 One set of emergency over speed governor 1 Set
15.3 J acking oil pump complete assembly. 1 Set
15.4 J acking oil pump relief valve / J acking oil header
regulating valve
1 No. each
15.5 Vapour Extractor Fan with motor for lube oil 1 No
15.6 Set of drive & driven gears for Gear Box 1 Set
CLAUSE NO.
MANDATORY SPARES

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15.7 Set of journal & Thrust bearings. for Gear box 1 Set
15.8 Set of filter elements / cartridges, O-rings, gaskets for
Governing system of TDBFP
2 Sets
15.9 I/H converter for Main control valve & Auxiliary control
valve servomotor of governing system of TDBFP (if
applicable)
1 No. each
16 EOT CRANES
16.1 Mechanical :
(a) Bearings for long travel wheels 1 Set
(b) Bearings for cross travel wheels 1 Set
(c) Bearings for Gear Boxes for each type of Hoist (both
main and aux hoist)
1 Set
(d) Brake Liner for all the brakes (both main and aux hoist) 2 Sets
(e) Hydraulic thruster for all Brakes (both main and aux
hoist)
1 Set
(f) Oil Seals (both main and aux hoist) 2 Sets
(g) Brake springs for all brakes (both main and aux hoist) 1 Set
(h) Wire Rope for Aux. Hook 1 No
(i) Contactors, push buttons & relays 1 Set
16.2 Electrical:
i) Solenoid Coils for Brakes 2 Sets
ii) MCBs/MCCBS/Fuse links for the whole crane 1 Set
iii) Contactors and overload Relays 1 Set of each type,
size & rating
vi) Motors of the EOT 1 Set of each type,
size & rating
v) Timers of each type, size & rating 1 Set

vi) Limit Switches for
a) Main Hoist 1 Set
b) Aux. Hoist 1 Set
c) Cross Traverse 1 Set
d) Long Travel 1 Set
CLAUSE NO.
MANDATORY SPARES

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vii) Carbon brushes & brush holders 1 Set
viii) Master Controller for Aux. Hoist, 1 Set
ix) Resistance Box 1 No of each type.
16.3 TG Hall EOT Crane with VFD drive

Drive for MH, AH, CT & LT 1 No. of each type &
rating
17 ACW & ECW SYSTEM
a) Auxiliary Cooling Water Pumps and DMCW Pumps
(i) Shaft Sleeve ( DE & NDE) 2 Sets for each type of
pump
(ii) Casing & impeller Wearing Ring

2 Sets for each type of
pump
(iii) Bearings for Pumps 2 Sets for each type of
pump
(iv) Motor Bearings 2 Sets for each type of
pump
(v) Thrust Bearings 2 Sets for each type of
pump
(vi) Sleeve nuts and O-rings 2 Sets for each type of
pump
(vii) Gland Packing (DE & NDE) if applicable 4 Sets for each type of
pump
(viii) Fasteners 1 Set for each type of
pump
(ix) Complete Coupling ( Pump & Motor) 1 Set for each type of
pump
(x) Mechanical seal (both DE and NDE) if applicable 2 Sets each of DE &
NDE for each type of
pump
xi Rotary & stationary faces for mech. seal (DE & NDE) 4 Sets each of DE &
NDE for each type of
pump
Xii Set of soft parts for mech. seal (O-rings , gaskets) 8 Sets for each type of
pump

CLAUSE NO.
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b) Plate Type Heat Exchangers
(i) Gaskets 20% of each type and
class
(ii) Fasteners 20% of each type and
class
(iii) Plates 20% of each type and
class or minimum 03
nos. whichever is
higher
18 Low Pressure Piping
a) Valves up to size 250 NB 5% of the total
population of each type,
size and class OR
minimum 3 nos. of each
type size & class
whichever is more
b) Valves above 250 NB 5% of the total
population each type,
size & class or
minimum 2 nos. of each
type , size & class
whichever is more
c) Spare gaskets for valves 3 Sets for each, type,
size & class
d) Gland packing for valves 5 Sets for each, type,
size & class
Note: Wherever valves are specified as mandatory spare,
complete valve along with actuator and all other
accessories which are the part of original supply shall
also be supplied.

19 Power Cycle Piping
1) Spare gaskets / pressure seal gaskets of all the gate
valves of sizes above 15 NB
100% of each type, size
& class for one unit
2) Spare sets of gland packings of all the gate valves for all
sizes
CLAUSE NO.
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3) Spare gaskets for all the globe valves for sizes above 15
NB
4) Spare sets of gland packings for all the Globe valves for
all sizes
5) Spare gaskets/pressure seal gaskets for NRV of all sizes

6) Spare set of Gaskets for safety relief valves for all sizes 100% of each type, size
7) Complete gate valves assembly up to the size of 50 NB 100% of each type, size
8) Complete angle valves upto the inlet size of 65 NB 100% of each type, size
9) Complete Globe valves upto the size of 50 NB 100% of each type, size
10) Complete NRVs Assembly upto the size of 50 NB 100% of each type, size
11) Spring hangers (Variable spring & constant spring
hangers)
10% of total population
of one (1) unit for each
type & stiffness or min.
one (1) No.
12a Trim assembly for heater drip line control valves which
shall include spindle with plug, cage assembly, seat (if
applicable), guide bushes
2 sets for each size,
type & class
12b Trim assembly for angle valves up to inlet size 65 NB
which shall include stem with plug, cage assembly, guide
bushes & seat ring(if replaceable)
2 sets for each type,
size, class for size up to
65NB inlet
13a Safety valve up to 50 NB size 2 nos. of each type,
size & class
13b Safety valve above 50 NB size 1 no of each type, size
& class
14) Steam traps and Y-Strainers
14a Steam trap & Y strainers up to 25 NB 20 nos. of each type ,
size & class
14b Steam trap & Y strainer above 25 NB & up to 50 NB 5 nos. of each type ,
size & class
14c Steam trap & Y strainer above 50 NB 2 nos. of each type
size & class
CLAUSE NO.
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15) Other Valves (PCP)
(1) Each type, size and class for 250 NB & below
but above 50 NB
3 nos. each
(2) Each type, size and Class above 250 NB 2 no. each
Note: Whichever valves are specified as mandatory spare, complete valve along
with actuator and all other accessories which are the part of original supply shall
also be supplied.
20 CONDENSER FOR TDBFP
20.1 Gaskets for condenser 1 Set
20.2 Tube plugs for condenser 20 Nos.
21 CONDENSATE EXTRACTION PUMP FOR TDBFP
21.1 Complete thrust bearings with carrier & thrust collar 2 Set
21.2 Radial bearings including bushes 2 Set
21.3
Wear rings comprising of suction and stage impeller,
neck rings, casing wear rings
2 Set
21.4 Coupling between motor and pump 2 Set
21.5 Suction strainer 2 Nos.
21.6 Set of impeller and shafts for CEP
1 Set of impeller & 2
sets of shaft
21.7 Line shaft couplings 2 Sets
21.8 Line shaft rubber / carbon bearings. 2 Sets
21.9 Shaft sleeves / guide bushes 2 Sets
21.10 Set of O-rings, gaskets for pump assembly. 4 Sets
21.11 Mech. seal complete assembly as per applicability 2 Sets
21.12
Gland packing, O-rings, bush, gaskets, follower,
fastener
4 Sets
21.13 Rotary & stationary faces of mechanical seal 4 Sets each
21.14 Soft packing which includes gaskets, O-rings for mech.
seal

8 Sets
CLAUSE NO.
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22 VACUUM PUMP FOR TDBFP CONDENSER
22.1 Complete pump assembly 1 Set
22.2 Seal plates and mechanical seal as applicable 2 Sets
22.3 Complete set of Bushes & O-rings 2 Sets
22.4
Complete coupling assembly between vacuum pump &
motor
1 Set
22.5 Gland packing (if applicable)
4 Sets each of DE &
NDE
22.6 Radial bearing / Thrust bearing 2 Sets
22.7 Gland packing, bush, fasteners of gland 2 Sets
22.8 Rotary/stationary faces of mech. seal if applicable 2 Sets
22.9
Set of soft parts of mech. seal i.e. O-rings, gaskets,
seals etc.
4 Sets of each type &
size
23 COLTCS FOR TDBFP CONDENSER
23.1 Sponge rubber balls for condenser on-load tube cleaning
system (20% ABRASIVE REMAINING NORMAL)
25000 Nos.
23.2 Ball circulating pumps (set consisting of shaft, rotor,
bearings, seals, gland package shafts sleeves for
complete replacement in one pump)
1 Set
24 Control fluid regenerative system: all filters including
fuller earth cartridges
2 Sets
25 HYDROGEN GENERATION PLANT
a) Hydrogen gas analyzer
(i) Cast withdraw able electronic card temp. controller 1 Set
(ii) Bridge mains unit 1 Set
(iii) Temperature protection for heating elements 2 Nos.
b) Dew point meter
(i) Measuring device 1 No.
CLAUSE NO.
MANDATORY SPARES

STAGE-II (2X660 MW)
SECTION-VI
PART-A
MANDATORY
SPARES

PAGE
33 OF 41

(ii) Special connection cable 30 meters
(iii) Amplifier(if applicable) 1 No.
(iv) Charts(if applicable) 100 Nos.
c) Instrument spares
(i) Zenner barrier 2 Nos.
(ii) Limit switch 5% of each type
d) Oxygen analyser sensor 1 No. of each type
e) Miscellaneous instruments.
(i) Pressure switches 1 No. of each type
and rating.
(ii) Pressure gauges 1 No. of each type
and rating.
(iii) Temperature gauge 1 No. of each type
and rating
(iv) Flow indicators 1 No. of each type
and rating.
(v) Differential pressure switch 1 No. each type and
rating
One set means item required for replacement for one
equipment.

26 Local / field instrumentation for T.G
I. Pressure, Differential Pressure, Flow, Level and
temperature switches
20% of the total
population or
minimum 2 Nos. of
each type / rating /
model
II. Pressure, Differential Pressure, Flow, level and
temperature gauges
20% of the total
population or
minimum 2 Nos. of
CLAUSE NO.
MANDATORY SPARES

STAGE-II (2X660 MW)
SECTION-VI
PART-A
MANDATORY
SPARES

PAGE
34 OF 41

each type / rating /
model
27. DISTRIBUTED DIGITAL CONTROL MONITORING
AND INFORMATION SYSTEM (DDCMIS)

a) Long Term Storage Drive Unit 1 No.
b) HMIPIS Devices
(i) Net work components like switch/repeaters/hubs etc. 2 Nos. of each type
and model.
(ii) Other drives/peripheral devices of each type and model
no. in HMIPIS like terminal Servers, DAT tape drive etc.
(as applicable), which are not covered in above items
but are required to make the system complete.
1 No. of each type
and model
c) Cables and Connectors.
(i) Prefab interconnecting cables with connectors 1 No. of each type
and length.
(ii) System bus cable with connectors 1 No. of each type
and length.
(iii) I/O bus cable with connectors for remote I/O units 1 No. of each type
and length.
d) Cooling fans for Power supply and cabinets. 10 % or 1 No. of each
type and model
whichever is more.
28. OTHER TG RELATED SUB-SYSTEMS
Turbine Supervisory System of Main and BFP
turbines

Sensors of all types, range, model etc. for vibration,
eccentricity, proximity, differential expansion, axial shift
EHC position, stop valve / control valve position etc.
type whichever is
more.
29. POWER SUPPLY SYSTEM
24 V DC power supply system
I. Capacitors and diodes 1 Set.
CLAUSE NO.
MANDATORY SPARES

STAGE-II (2X660 MW)
SECTION-VI
PART-A
MANDATORY
SPARES

PAGE
35 OF 41

II. Fuse free Circuit breakers 5% or 1 No. of each
type and rating,
whichever is more
III. Cooling Fans 10% or 2 Nos. of each
type, whichever is
more.
IV. AC/DC isolators, contactors, timers, relays 10% of each type and
rating
V. Fuses of each type and rating 200%
VI. Fuse free Circuit breakers of each type and rating 5%

VII. Relays of all types including overload relays 10%
30. PROCESS CONNECTION PIPING (FOR IMPULSE
PIPING/TUBING, SAMPLING PIPING/TUBING AND
AIR SUPPLY PIPING)

(i) Valves of all types 10%
(ii) 2 way, 3 way, 5 way valve manifolds 10% of each type,
(iii) Fittings 10%
(iv) Purge meters 5% of each model
(v) Filter regulators 20% of each model
31. INSTRUMENTATION CABLE, INTERNAL WIRING
(i) Pre fabricated cable of each type (other than DDCMIS
application) (if applicable)
10% of installed
quantity.
(ii) Pre fabricated cable connector (other than DDCMIS
application) (if applicable)
10% of each type and
model
32. CONTROL VALVES, ACTUATORS & ACCESSORIES
a Valve trim (including cage, plug, stem, seat rings, guide
bushings etc.)
1 Set for each type of
control valve,
whichever is more.
CLAUSE NO.
MANDATORY SPARES

STAGE-II (2X660 MW)
SECTION-VI
PART-A
MANDATORY
SPARES

PAGE
36 OF 41

b Diaphragms, 'O' rings, seals etc. 100% of all types,
make etc.
c Pressure Gauges of all types, make, rating etc. (if
applicable)
type whichever is
more.
d Solenoid valves (if applicable) 10% or 2 Nos. of each
type whichever is
more.
e High pressure hoses for HPBP, High Pressure LPBP etc 2 complete sets
f Control valve positioners and its accessories 10% or 2 Nos. of each
type, model and
rating, whichever is
more.
33. GENERATOR & AUXILIARIES
a) Gaskets of all types (one set should include all types
and sizes of gaskets for one generator, hydrogen seals
for TG and EE hydrogen coolers)
1 Set
b)
Heat exchangers/coolers complete for turbo generator 2 Sets
c) Hydrogen seals rings TE, EE
1 Set each
d) Teflon Hoses with connectors 25% of the no. (for stator
water cooling system)
3 Nos. of each type.
e) Brush- holder assembly for shaft earthing
4 Nos.
33.1 Static excitation system
(1) Shunt trip and closing coil for field circuit breaker 2 Sets
(2) Initial excitation diode 2 Sets
(3) Thyristor cooling fan 1 Set complete for
one unit
33.2 Gas System
a) Diaphragm valve 1 No. of each type
b)
Gas valves of all type & sizes
1 No. of each type &
size
c) Valves for H
2
& CO
2
manifolds 10 Nos.
d) Safety valve 1 No.
e) H
2
gas regulator from cylinder to manifold 10 Nos.
CLAUSE NO.
MANDATORY SPARES

STAGE-II (2X660 MW)
SECTION-VI
PART-A
MANDATORY
SPARES

PAGE
37 OF 41

f) CO
2
gas regulator from cylinder to manifold 3 Nos.
g) Thermostat for gas drier 1 No.
h) Filter for gas analyser 2 Sets
33.3 Seal Oil System
a) Float valve 1 No. of each type
b) Non-return valve 1 No. of each type
c) Filter elements 1 No.
d) Bellow for differential pressure regulator 1 No. of each type
e) Float for level regulator 1 No. (if applicable)
f) Filter elements 1 Set
g) Ferro-dynamic indicator 1 Set
h) Insulators for stator water header 1 Set
33.4 HYDROGEN GENERATION PLANT
a) Motor for compressor 1 No.
33.5 Motors
a) AC AOP motor for TDBFP
1 No.
b) AC J OP motor for TDBFP
1 No.
c) MDBFP lube oil pump motor
1 No.
d) Control fluid pump motor
1 No
e) Control fluid recirculation pump motor
1 No.
f) Control fluid leakage oil pump motor
1 No
g) Control fluid oil vapour exhauster motor
1 No.
h) AC J OP motor for main turbine
1 No.
i) MOT centrifuge motor
1 No.
j) MOT oil vapour exhauster motor
1 No.
CLAUSE NO.
MANDATORY SPARES

STAGE-II (2X660 MW)
SECTION-VI
PART-A
MANDATORY
SPARES

PAGE
38 OF 41

k) TDBFP centrifuge motor. 1 No
l) TDBFP oil vapour exhauster motor 1 No.
m) TDBFP transfer oil pump motor 1 No.
34 Condenser Polishing Unit

A) Screens and Nozzles for Under Drain System

a) Activated Carbon filter 15% of AC filter
vessel

b) Polisher Service Vessel 100% of one vessel

B) Under Drain System screens, nozzles/
headeral lateral /any other type used for

a) Cation Regeneration Unit 1 Set

b) Anion Regeneration Unit 1 Set

c) Mixed Resin Storage Unit whichever
applicable
1 Set

C) All Resins (Cation, Anion & Inert resins) One full charge
required for one
Service vessel
35. Passenger Elevator
35.1 Over current relay 2 Nos. of each type
35.2 Auxiliary relays 3 Nos. of each type
35.3 Friction block 2 Nos.
35.4 Guide roller of each type 20% of total
population or 3 Nos.
of each type
whichever is high
35.5 Contactors of each type 2 Nos.
CLAUSE NO.
MANDATORY SPARES

STAGE-II (2X660 MW)
SECTION-VI
PART-A
MANDATORY
SPARES

PAGE
39 OF 41

35.6 Control transformer 1 No. of each type
35.7 Time device 2 Nos. of each type
35.8 Rectifiers 2 Nos. of each type
35.9 Resistor 3 Nos. of each type
35.10 Fuses of each rating 20% of the total
population
35.11 Limit switches of each type 3 Nos.
35.12 Push button 3 Nos. of each type
35.13 Contact device (if applicable) 3 Nos. of each type
35.14 Brake motor 2 Nos. of each type
35.15 Transmitters 2 Nos. of each type
35.16 Switches of each type 3 Nos.
35.17 Receiver 2 Nos. of each type
35.18 Bearings of each type & size 2 Nos.
35.19 Roller of each type 3 Nos.
35.20 Worm gear spares

a) O rings 3 Sets

b) Sealing ring of each type 3 Sets
35.21 Spares for brake

a) Fan 2 Nos. of each type

b) Magnetic coil 3 Nos. of each type
CLAUSE NO.
MANDATORY SPARES

STAGE-II (2X660 MW)
SECTION-VI
PART-A
MANDATORY
SPARES

PAGE
40 OF 41

c) Brake disc 2 Sets

d) Brake pad 2 Sets
35.22 Bushing (for door front) 2 Sets
35.23 Pinion 2 Nos. of each type
GENERAL NOTE:
1. Unless stated otherwise a 'set', it will include the total requirement of the item
for a unit module or the station as specified. Also set for the particular
equipment e.g. 'set' of bearings for a pump would include the total number of
bearings in a pump. Also the 'set' would include all components required to
replace the item, for example a set of bearing shall include all hardware
normally required while replacing the bearings. It is further, intended that the
assembly / sub-assembly which have different orientation (like left hand or
right hand, top or bottom), different direction of rotation or mirror image
positioning or any other reasons which result in maintaining two different sets
of the spares to be used for the subject assembly / sub-assembly, these shall
be considered as different types of assembly/sub-assembly.
2. 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.
3. 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 in the bid.
4. 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 generally in line with the approach followed in the
above list.
5. Interchangeability and Packings:
All spares supplied under this contract shall be strictly interchangeable with
parts for which they are intended for replacements. These spares should
include all mounted accessories like components, boards, add or items,
fitting, connectors etc. and be complete in all respects so that the
replacement of the main items by these spares does not require any
additional item. The vendors must conform the pair to pair compatibility of
each electrical spares modules with the modules should be supplied in the
original package. All electronic modules should be pre set and/or
CLAUSE NO.
MANDATORY SPARES

STAGE-II (2X660 MW)
SECTION-VI
PART-A
MANDATORY
SPARES

PAGE
41 OF 41

preprogrammed for ready use at site. Alternatively, suitable instruction sheet
indicating the details of required PCB jumper position, BCD which is setting,
EPROM/PROM listing etc should be packed along with each module. Also a
caution mark sign should be put on all such module which needs pre
setting/pre programming before putting them in to service. The spare shall be
treated and properly packed for long term storage
6. Identification:
Each spare shall be clearly marked and labeled 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.
7. Control & Instrumentation Mandatory Spares for specific sub-systems such
as hydrogen generation plant and Condensate Polishing Unit (if applicable),
the spares shall be governed by the spares indicated against the
corresponding specific clauses only. For all remaining systems / equipments
offered under the present scope of work, the spares shall be offered in
totality as per the complete C&I items supplied in accordance with the
applicable clauses of C&I items.
STAGE-II (2X660 MW)
PART - B PART - B PART - B PART - B PART - B
SECTION - VI
TECHNICAL SPECIFICATION TECHNICAL SPECIFICATION TECHNICAL SPECIFICATION TECHNICAL SPECIFICATION TECHNICAL SPECIFICATION
FOR
STAGE-II (2X660 MW)
SECTION - VI
TECHNICAL SPECIFICATION TECHNICAL SPECIFICATION TECHNICAL SPECIFICATION TECHNICAL SPECIFICATION TECHNICAL SPECIFICATION
FOR
SECTION-VI
TABLE OF CONTENTS
A Project Synopsis
A A-1 Provenness
A Essential Data
A A-2 General
A A-7 (NOT USED)
A D-1 Civil Works
A Spares
MECHANICAL
B A-2 Layout
SECTION-VI
B A-7 (NOT USED)
ELECTRICAL
B B-2 Motors
B B-7 Lighting
(DDCMIS)
SECTION-VI
CIVIL
B D-1 Civil Works
B E-10 (NOT USED)
B E-16 Motors
SECTION-VI
B E-20 Cabling
B E-21 Lighting
E TENDER DRAWING
F NOT USED
SECTION-VI
PART-B
SECTION-VI
PART-B
MECHANICAL SYSTEMS
SECTION-VI
PART-B
A - 1
OPERATING CAPABILITY OF PLANT
CLAUSE NO. TECHNICAL REQUIREMENTS
SECTION-VI
PART-B
A-1
OPERATING
CAPABILITY OF
PLANT
PAGE
1 OF 2
STAGE-II (2X660 MW)
OPERATING CAPABILITY OF PLANT
1.01.00 The operating capability of various systems, equipments and associated auxiliaries in
the scope of the Bidder is specified elsewhere in the Technical Specification.
1.02.00 The plant and it's unit(s) shall be designed to operate with all the specified margins for
continuous operation without any limitations under any of the conditions indicated in
the Technical Specification.
The major operating capabilities for the unit(s) / plant shall be as follows :
(a.) Operate continuously with turbine under VWO condition with rated steam
parameters, specified rated condenser pressure and 3% cycle make up.
(b.) Sliding Pressure Operation from rated pressure down to 40% of rated pressure
with as well as without any throttle reserve. At any operating load, the throttle
reserve shall be sufficient so as to achieve an instantaneous increase in turbine
output by 5% of the corresponding load, by opening turbine control valvs wide
open. The throttle reserve shall be 0% for sliding pressure mode of operation.
(c.) Operate continuously with HP heaters out of service with maximum specified
cooling water temperature, 3% cycle make up and normal auxiliary steam
requirement being tapped from cold reheat line, to generate maximum output
without over stressing turbine components. The power output of the unit under
this operating condition shall not be less than 660 MW.
(d.) In case of sudden reduction in demand (load throw off), the unit should get
safely unloaded and stabilized for continuous operation at house load with HP-
LP bypass open to full capacity.
(e.) HP-LP bypass operation under rated steam conditions with bypass valve open
to full capacity and turbine on house load.
(f.) Continuous TG output of 660 MW under rated steam conditions, specified
worst condenser pressure, 3% cycle make-up and 47.5 Hz grid frequency.
(g.) The equipments and auxiliaries shall be suitable for continuous operation in the
frequency range of 47.5 Hz to 51.5 Hz.
1.03.00 All the systems/equipments/auxiliaries under Bidder's scope shall be designed to cater
to the above operating conditions envisaged for the unit(s)/plant by the Owner. Unless
specified otherwise in the Technical Specification the design should cater to the above
operating conditions with adequate margin as per standard practice prevailing in the
fossil fired power plants.
SECTION-VI
PART-B
A-1
OPERATING
CAPABILITY OF
PLANT
PAGE
2 OF 2
STAGE-II (2X660 MW)
1.04.00 The plant shall be designed to operate as a base load station. However, continuous
operation under two shift and cyclic modes during certain periods is also envisaged.
The design would cover adequate provision for quick startup and loading of the units to
full load at a fast rate. The main plant and its auxiliaries with their controls would be
designed to permit operation of the units on house load without there being any
necessity to shut down the units in the event of sudden loss of total load due to
tripping of transmission lines or any other grid disturbances. The design of the plant
equipments and control system would permit participation of the plant in automatic
load frequency control.
SECTION-VI
PART-B
A - 2
LAYOUT
STAGE - II (2 x 660 MW)
SECTION-VI
PART-B
A-2
LAYOUT
PAGE
1 OF 5
LAYOUT REQUIREMENTS
1.01.00 While developing the layouts the Bidder shall ensure the following major layout
Parameters:
1.01.01 Unit pitching 133.0 M between Fifth & Sixth unit.
1.01.02 Area of unloading bays 850 Sq.M at the start of Fifth unit, and 425
Sq.M. at the end of sixth unit.
1.01.03 AB bay, BC & CD bay widths 36.0 M, 12.0 M & 12.0 M
1.01.04 Arrangement of TG set Longitudinal
FLOOR LEVELS IN TG HALL
1.01.05 Floor levels in AB bay. 0.0 M, 8.5 M, 17.0 M
1.01.06 Floor levels in B-C bay 0.0M, 8.5M, 17.0M, 24.0/25.0M, 28.0M, 32.8M
& 38.0/41.0M.
1.01.07 Level of operating floor 17.0 M
1.01.08 Level of mezzanine floor 8.5 M
1.01.09 Floor levels in control 5.1 M, 8.5 M, 13.5 M, 17.0 M, 25.0 M
equipment room area and 32.8M
1.01.10 HT/LT Switchgear and MCC HT Switchgear at 3.5 M and LT switch gear &
location MCC at 12.0 M in A-B bay
1.01.11 Basement, Pits & Trenches a) Regular basement floor are not acceptable
in Main Plant Building.
b) Local Pits/trenches in Main Plant building
are to be avoided as far as possible.
1.01.12 Lay down Area (Minimum on 750 Sq.M per unit
operating floor) with EOT Crane
approach.
1.01.13 Clear walkways in TG hall a) 1.5 m at all levels of AB bay, unless
noted otherwise.
SECTION-VI
PART-B
A-2
LAYOUT
PAGE
2 OF 5
b) 3.5 m along B-row at operating floor level
for interconnection with Service Building &
in front of control room.
c) 3M along gable end at operating floor level.
d) Interconnection between TG hall & Service
building at operating floor level shall be
minimum 3.5M wide.
1.01.14 Minimum clear working space 1200 mm
around equipment.
1.01.15 Control Room Common for unit 5 & 6. Control room is
located in B-C-Dx bay at operating floor level.
1.01.16 Control Equipment Room Control equipment room shall be located in
B-C-Dx-Ex-Fx bay at operating floor and Dx-Ex-
Fx bay at mezannine floor level.
1.01.17 Location of Deaerator In B-C bay at EL. 38.0 M
1.01.18 Location of Heaters HP Heaters at operating floor level
LP Heaters at Mezzanine floor level
1.01.19 Location of BFP TDBFP at Operating Floor and MDBFP at
Mezzanine floor level in AB bay.
1.01.20 Clear Head room within Main 2.5 M
Plant Building for pipes,
structures & cable trays,ducts etc.
1.01.21 No. of Fire Escape staircases in Min. 4 Nos per unit.- However the number
the main plant with fire doors at shall meet the requirement of Insurance
each landing. Companies.
1.01.22 Minimum width of all staircases, 1200mm
landings.
1.01.23 Adequate space shall be provided for handling/removal of pumps, heaters, heat-
exchanger, fans, during maintenance.
1.01.24 In TG bay at crane rail level, walkway with handrails is envisaged for entire column
sectional depth for full length of the building. In addition, it shall be ensured that on A-
Row and B-row columns, through walkway (without hindrance) of minimum 500 mm
SECTION-VI
PART-B
A-2
LAYOUT
PAGE
3 OF 5
clear width is available from the face of the column to the handrail on crane side.
These walkways along with handrails are in Owner's scope of supply.
1.01.25 Layout of facilities and equipment shall allow removal of Generator Stator, Generator
transformers, Station & Unit transformers without disturbing equipments, piping, cabling,
ducts routed in the area.
1.01.26 Valves in the Bidder's scope shall be located in accessible positions and the Bidder
shall provide operating/maintenance platforms alongwith approach ladders & handrails for
the same.
1.01.27 Steam turbine, generator, stator and other equipments located in the turbine hall shall
be accessible by the EOT cranes for their handling during erection and maintenance.
For all other equipment / components covered under this package, the bidder shall
provide suitable handling arrangement for erection and maintenance. TG Hall EOT
cranes shall be capable of handling Generator Stator in tandem operation and in such
case, the combined capacity of two EOT cranes shall not be less than 105% of the
weight of Generator Stator including the weight of lifting beams and slings etc.
Bidder to note that there is no access of rail link to TG Hall. The Generator Stator
can be brought to the plant site by rail to the railway siding in the plant however,
transportation of Generator Stator from railway siding to TG Hall is to be carried out
by road only.
1.01.28 Provision of Condenser water box handling (in case of non-hinged type condenser) with
crane facilities for maintenance/ withdrawal of tubes shall be kept and structure steel
columns, beams, bracings, foundation bolts etc. for the same shall be provided by the
Contractor.
1.01.29 Monorails Beam with elect. Hoists / chain pulley blocks/HOT cranes along with hoists,
as required shall be finalised during detailed engineering stage and shall be supplied
by the Contractor.
1.01.30 Approach for removal of equipment for maintenance shall be provided.
1.01.31 Critical Piping routes shall be identified at conceptual stage. Further spaces shall be
identified for the routing of A/C, Ventilation duct & Bus ducts inside Main Plant
Building.
1.01.32 All other safety requirements as per the factories act, National Electricity code shall be
observed while developing the layout.
1.01.33 Battery rooms shall be properly ventilated to release the gases produced. No roof
openings leading to electrical/C&I panels shall be allowed. Spaces for locating fans for
Electrical / C&I battery rooms shall be identified in the Main Plant Layout Drawings.
SECTION-VI
PART-B
A-2
LAYOUT
PAGE
4 OF 5
An easily accessible washbasin should be provided in the battery room by Employer.
The enclosure of battery room shall be of brick wall.
1.01.34 Suitable rolling shutters shall be considered in the Equipment Layout to be developed
by the Bidder on 'A'-row & 'C'-row to facilitate the movement of Generator transformers,
Station and Unit transformers to the maintenance bays.
1.01.35 Pipe/Cable trenches/slits, if unavoidable, shall be provided with cushioning of sand and
shall be coverd by PCC. Pipe trenches, if unavoidable, shall be covered with chequered
plates.Suitable draining arrangement shall be provided to avoid flooding of trenches.
1.01.36 Each equipment room shall be provided with alternate exits in case of fire /accidents
as per requirements of factory act and statuary Bodies / Insurance companies.
1.01.37 All cranes shall be provided with approach cage ladders at least at four places each
on 'A'-row and 'B'-row. Wherever 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 by the Contractor.
1.01.38 While developing the layout, all fresh air ventilation louvers shall be considered 2500
mm from floor level and directed down wards at an angle.
1.01.39 While developing the layout, ventilation fans on AB bay roof shall be kept staggered
and shall not be near the centerline of Turbo generator set.
1.01.40 All equipment operating platform including supporting structures (excluding main building
columns & beams) such as the grating platform in the Oil Equipment Room, Seal Oil
Room, Control Fluid Equipment Room, Valve Room, Deaerator, Gland Steam Condenser,
Flash Tanks and for other equipment supplied by the Contractor shall be supplied and
erected by the Contractor.
1.02.00 Lay down area for maintenance and overhauling
(i) The layout of the steam turbine units shall permit sufficient lay down area for
all the parts/ components to enable carrying out maintenance and overhauling
operations without any restrictions and without any hindrance to the operating
personnel of other units.
(ii) Each steam turbo-generator unit shall be provided with its own lay down area
thus enabling simultaneous maintenance and overhauling of each steam turbine
generator units. In case any special arrangement for rotor maintenance is
required, the same shall be provided by the Contractor.
(iii) The Contractor shall furnish general arrangement drawings indicating the
equipment lay down area with details such as blocks indicating orientation of
dismantled items, travel path etc.
SECTION-VI
PART-B
A-2
LAYOUT
PAGE
5 OF 5
(iv) All handling arrangement including any special arrangements like trolley, drive,
pedestals, lifting beam etc. for carrying out maintenance and overhauling for
steam turbine generator units shall be provided by the Contractor.
1.03.00 Local Pits/tranches 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.
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.
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 shart automatically and empty the pit.
The general design and construction features of Vertical sump pumps and Submersible
pumps is furnished in Subsection titled "ECW System" of this Technical Specification.
SECTION-VI
PART-B
A - 3
TURBINE GENERATOR AND AUXILIARIES
CLAUSE NO.

STAGE-II (2X660MW)
SECTION - VI
PART-B

A- 3
TURBINE GENERATOR
AND AUXILIARIES

PAGE
1 OF 84

TURBINE GENERATOR AND AUXILIARIES

1.00.00 STEAM TURBINE AND AUXILIARY SYSTEMS

1.01.00 Steam Turbine

1.01.01 Type

The steam turbine shall be tandem compound, single reheat, regenerative,
condensing, multicylinder design with separate HP, separate IP and separate LP
casing(s) OR combined HP-IP and separate LP casing(s), directly coupled with
generator suitable for indoor installation.

1.01.02 Rating

The steam turbine generator unit shall conform to the following design and duty
conditions:

(i) Output under economic maximum continuous
rating (EMCR) at generator terminals
: 660 MW
(ii) Turbine throttle steam pressure :
247 Kg/cm
2
(abs)
(iii) Turbine throttle main steam temp. :
565
o
C
(iv) HPT Exhaust Pressure :
56 5

Kg/cm
2
(abs)
(v) Reheat steam temp. at turbine inlet :
593
o
C
(vi) Design & operational requirement including
variations in rated steam temp. & pressure
: Generally as per IEC
45 or otherwise
specified elsewhere in
the specification
(vii) Pressure drop in reheat circuit i.e. between
H.P. turbine exhaust & IP turbine inlet
: 10% of H.P.T exhaust
pressure
(viii) Condenser design pressure : 77 mm Hg (abs)
(ix) Turbine speed : 3000 rpm
(x) Frequency variation range around rated
frequency of 50 Hz
: +3% to - 5% (47.5 Hz
to 51.5 Hz)

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(xi) DM water make up to thermal cycle under
EMCR condition
: 3% of throttle steam
flow
(xii) Final feed water temp. at TMCR / EMCR
condition
:
287.5 2.5
o
C
(xiii) Turbine protection against water induction : As per ASME-TDP-I-
latest edition

The conditions corresponding to economic maximum continuous rating (EMCR) at
generator terminals shall be 660MW output under rated steam conditions with 13
T/hr of steam extracted from CRH for auxiliaries steam and total cycle makeup of 3%
of throttle steam flow and design condenser pressure. In case of static excitation
system, the EMCR output at generator terminals shall be 660MW plus excitation
power requirement plus power consumption by auxiliaries described in clause no.
1.01.04 (a) to (g) of Section-VI, Subsection-"Functional Guarantee & Liquidated
Damages, Part-A .

Note:

(a) "Throttle/Main Steam Conditions" means initial/main steam conditions (i.e.
pressure, temperature and flow) at inlet to Main Steam Strainer.

(b) "Reheat Steam Conditions" means reheat steam conditions (i.e. pressure,
temperature and flow) at inlet to Reheat Steam Strainer.

(c) Wherever in the specification "Main Steam / Throttle Steam / Reheat Steam /
Rated Steam conditions" have been mentioned, in connection with turbine /
turbine cycle rating and performance guarantees, the same shall be
interpreted as per above two clauses of this note.

(d) Wherever in the specification words or combination of words have been used
to describe Output of the turbine generator set (such as Power at generator
terminals, Output at generator terminals, Unit load, TG load, TG Output, Unit
Output etc.), it shall mean electrical power output as generator terminals after
deducting the power consumption by auxiliaries described in clause no.
1.01.04 (a) to (g) of Section-VI, Subsection-"Functional Guarantee &
Liquidated Damages, Part-A.

1.01.03 Other Features

(a) Turbine shall be capable of operating continuously with valves wide open
(V.W.O.) to swallow atleast 105% of EMCR steam flow to the turbine at rated
main steam and reheat steam parameters and also the corresponding output
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shall not be less than 105% of rated load with 3% make up and design
condenser pressure.

Bidder can offer overload valve (HP stage bypass) to meet the above
specified VWO requirement, if it is a proven practice of the Turbine
manufacturer. In such case VWO shall mean wide open condition of both, the
turbine main control valves and the overload valves. However, if bidder offers
overload valves, then bidder to ensure sufficient margin in the main turbine
control valves so as to generate at least 102% of rated load at rated main
steam & reheat steam parameters at condenser pressure of 77 mm Hg (abs)
with 3% makeup. Load requirement beyond 102% of rated load can be met
with overload valve.

The employer intends to provide a steam generator for each unit having
Boiler maximum continuous rating (BMCR) of 102% of the turbine VWO
steam flow requirement subject to a minimum of 2120 Tonnes/hr. For sizing
of various auxiliaries in Bidder's scope of supply like BFP, HP-LP Bypass
system etc. the Bidder shall therefore consider BMCR steam flow of 2120
T/hr. or 102% of turbine VWO steam flow, whichever is higher.

(b) The steam turbine generator unit shall be suitable for direct connection to
steam generator having no inter connection with other units either on the
boiler feed water side or main steam side.

(c) The steam turbine shall have minimum seven uncontrolled extractions for
regenerative feed heating based on optimised cycle and shall be suitable for
satisfactory operation under tropical conditions.

(d) The cycle will consist of minimum 3 nos. of HP heaters with extraction for top
HP heater from HP turbine, one no. of deaerator and minimum 3 nos of LP
heaters.

(e) Auxiliary steam supply being arranged by the employer will normally be fed
from CRH steam. During unit start up auxiliary steam system will be fed from
Main Steam line. The auxiliary steam system will consist of a High
Temperature unit auxiliary steam header at 16 ata /310
o
C, and Low
Temperature unit auxiliary steam header at 16 ata /210
o
C as specified
elsewhere in the specification. However, when the auxiliary steam system is
being fed with steam from CRH (Load range of 50%-100%), the temperature
in the high temperature aux. steam header will be floating, and shall vary
approximately in the range 280 deg C to 340 deg C depending on the unit
load and the CRH steam parameters. Bidder to take note of this and design
the systems accordingly, wherever, auxiliary steam is being used for
equipment under his scope of supply. Bidder to further note that when
auxiliary steam is being tapped from auxiliary boiler, auxiliary steam will be
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available only at low temperature of 210 Deg. C. If auxiliary steam parameter
is not sufficient to meet the bidder's auxiliary steam requirement, bidder can
provide his own steam system for his own consumption to meet specification
requirement. Bidder to give proper justification alongwith their standard
practice. This will be subjected to employer's approval.

1.01.04 Operational Capabilities

(i) H.P. heaters out of service: Turbine Generator set shall be capable of
continuous operation with HP heaters out of
service with maximum output not less than
660 MW.

(ii) Overpressure Operations: (a) Bidder shall indicate the turbine over
pressurisation (under V.W.O) possible
and ensure corresponding continuous
output of TG set (if applicable).

(b) Turbine shall be capable of accepting
variation in steam temperature &
pressure as per IEC-45 in case
continuous over pressure operation is
possible.

(iii) Two shift & cyclic load Turbine shall be suitable for two-shift
operation & cyclic load variations.

(iv) Part load & start up (a) Turbine shall be capable of operation on
variable pressure mode during part load
& start up operation

(b) TG set shall be capable of being started
from cold condition to full load operating
conditions in as short time as possible.

(v) House load operation: TG set shall be capable of operating on
house load during sudden total export load
throw off using HP-LP bypass system. Unit
shall not trip on overspeed in the event of
total export load throw-off.

1.02.00 MATERIAL REQUIREMENTS

The proposal shall include the schedule of materials used in turbine construction
indicating chemical composition and designation of materials for following
components:
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Description

(i) Turbine Casing
HP outer casing
HP blade carrier
IP casing
LP casing

(ii) Turbine Shaft and Shaft Coupling
HP shaft
IP shaft
LP shaft

(iii) Moving Blades
HP turbine first stage
HP turbine other stages
IP turbine first stage
IP turbine other stages
LP turbine stages

(iv) Fixed Blades
HP turbine first stage
Other stages
IP turbine first stage
Other stages
LP turbine first stage
Other stages

(v) Casing Joint Bolts
HP cylinder
IP cylinder
LP cylinder

(vi) IP/LP crossover/cross around piping

(vii) Turbine steam admission valves
Valve Body
Valve Spindle
Valve seat

The steam turbine shall be built up using materials which are proven for rated turbine
inlet steam parameters.

The contractor shall be required to furnish necessary information during detail
engineering for connection of HP and IP inlet nozzles, HP turbine exhaust nozzles,
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HP and IP stop cum control valve inlet and outlet MS and HRH strainer, inlet and
outlet HP bypass and LP bypass valve inlet and outlet and CRH non return valve
inlet and outlet nozzles in this scope to the employer's piping.

1.03.00 MAINTENANCE REQUIREMENTS

(i) Wet Steam Washing: (a) Each turbine shall be suitable for Wet
(if applicable) Steam washing. Necessary stubs/
connections on turbine/piping shall be
provided for future connection to wet
steam washing system.

(b) Recommended Washing procedures to
be furnished.

(ii) Forced Cooling of : Necessary equipment shall be provided
turbine for forced cooling of turbine during
emergency condition for quick access.

(iii) Turbine Preservation: (a) Provide Turbine preservation system to
protect against corrosion during idle
periods.

(b) Write-up on the recommended system
to be furnished.

(iv) Boroscopic Inspection

1) Provide Boroscopic Inspection ports in turbine for in situ inspection of
turbine internals as per their standard practice. The inspection ports
shall cover turbine internals as maximum as possible as per Bidder's
Standard practice.

2) The inspection port should be designed for ease of accessibility with
leakage proof features while in operation.

3) One set of applicable tool and plants for the inspection port will be
supplied.

4) Bidder to supply one set of latest portable Videoimagescope system
kit (with recording facility) for inspection of turbine internals as per
following:

a) System should consist of video probe of suitable diameter and
length (with Closed Circuit Display i.e. CCD located at the top
of the probe), light and power source, CCD Camera having
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suitable resolution, Camera control unit function, handy LCD
monitor (size not less than 5 inch), suitable USB video port
with software for simultaneous view of inspection at personnel
computer.

b) Video-probe tip should have tip angulation of 120 to 150
degrees in up, down, left and right direction and the facility of
duel view (forward & side) or proper tip adaptor for side and
forward viewing.

c) System to have integrated temperature warning system for
protection of the probe and system from high temperature
damages.

d) It should have the facility of measuring defects / cracks during
inspection.

e) It should have rigid sleeve which simply fit and lock the sleeve
onto the tip of the insertion tube and allow the insertion tube
to perform as a rigid borescope.

f) System should operate with power supply of AC, 220-230
Volt, Single phase, 50 Hz.

g) The scope includes on site commissioning and demonstration
of the complete operation of the equipment and guaranty of
one year after successful installation and commissioning of
the equipment.
h) Bidder to furnish the write up on offered instruments and
diagnostic philosophy i.e. run / repair / replace criteria.
5) Bidder to indicate cost implication due to withdrawal of supply of one
set of latest portable Videoimagescope system kit mentioned at (4)
above from their scope in relevant schedule of BPS.
1.04.00 TURBINE CASING
1.04.01 The turbine casing design shall have following features:
(a) Separate casings for HP, IP and LP or combined casing for HP-IP and
separate casing(s) for LP turbine
(b) Symmetrical in design to minimise effects of thermal stress and creep.
(c) Turbine casing design: Maximum pressure & temperature to be encountered
during service including as specified under operational capabilities.
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(d) Steam tight horizontal joints with metal to metal contact or as per proven
practice of bidder
(e) Provide proven steam chest support arrangement, capable of accepting
piping forces during operation without transmitting these to the casings.
(f) All extractions shall preferably be from the lower half of casing.
(g) Adequate drainage facility with temp. sensing devices (in pair) in casings,
strainers housings, stop and control valves, extraction lines etc and drain
lines.
(h) Provide pressure relief bursting diaphragm for LP casing(s) to limit the
exhaust hood pressure within a safe margin from design pressure.
(i) Provide a completely self contained exhaust hood spray system for L.P
casing(s) to protect the turbine against excessive temperature due to
windage at no load / low load and HP/LP by pass operations.
(j) Dismantling of casing should be possible with minimum removal of insulation.
(k) Provide guide rods to prevent damage to blades during erection and
maintenance.
(l) Bearing inspection should be possible without necessity of dismantling the
turbine casing.

1.05.00 STEAM TURBINE ROTORS

(a) Provide forged alloy steel rotor.

(b) Ensure uniformity of material composition and strength by examining
adequate number of test specimen.

(c) Ensure static & dynamic balancing of composite rotor and blade assembly.

(d) Maximum permissible shaft vibration measured at bearing housing will be as
per zone A of ISO 7919 and maximum permissible bearing vibration
measured at bearing housing will be as per zone A of ISO 10816-2.

(e) Critical speed of composite rotor and blade assembly shall not be within
- 10% and +15% of rated speed.

1.06.00 NOZZLES AND BLADES

(a) Ensure material is hard, corrosion & erosion resistant alloy steel.

(b) Ensure quick & easy site replacement of blading.
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(c) L.P blades design without lacing wires is preferred.

(d) Ensure LP stage design for effective removal of moisture.

(e) Provide LP stage blade hardening (if required) as per the proven standard
practice.

(f) Ensure that there is no resonance of LP blading in the continuous operating
frequency range of 47.5 Hz. to 51.5 Hz. Furnish Campbell diagrams for all
free standing blade stages offered for LP blading.

(g) Ensure independent tuning of all free standing LPT blades to avoid
resonance frequency in the operating frequency range of 47.5 Hz. to 51.5 Hz.

(h) Ensure stress induced in LPT blading due to back end steam loading under
V.W.O. conditions not to exceed 90% of design stress value.

1.07.00 Bearings

(a) Provide adequate number of J ournal and thrust Bearings with:

(1) Tin base babbit lining properly secured to the bearing shell.

(2) Pressure lubrication.

(3) Independent supporting arrangement out side the turbine casings and
easy access.

(4) Horizontally split with the ability to dismantle and replace lower half
with minimum shaft lift.

(5) Provision for measuring bearing temperature as near the point of heat
generation as possible and for measuring the oil temperature leaving
the bearing.

(b) Provide following instrumentation for each J ournal/Thrust bearings.

(1) Local temperature indicators in each bearing lube oil drains.

(2) Embedded redundant duplex resistance elements for monitoring
temperature of bearing in line with standard practice of the turbine
manufacturer.

(3) Necessary pick-ups and accessories for remote monitoring of bearing
metal temperature & vibration (Horizontal & Vertical).
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1.08.00 SHAFT COUPLINGS

(a) Ensure ready disconnection preferably through bolts.

(b) Provide sufficient allowance for taking up reaming/honning of bore holes
during entire life of the machine.

1.09.00 TURNING GEAR

(a) Provide suitable turning gear device, either High-speed hydraulic type or
motorised turning gear as per standard proven practice of the Bidder.

(b) Ensure automatic engagement / disengagement with shaft speed
decrease/increase at preset value.

(c) Provide manual hand barring facility also for manually cranking the turbine in
case of emergency including A-C power failure. Ensure availability of lube oil
to the bearings during manual barring operation.

(d) Provide instrumentation & control for remote operation (from unit control
room).

(e) Ensure proper interlocks of lubrication system with operation of turning gear.

(f) Ensure all other necessary interlocks and protections.

1.10.00 GLAND SEALING SYSTEM FOR STEAM TURBINE and BFPDT

1.10.01 DESIGN REQUIREMENT

(a) Gland sealing system for the T.G set and BFPDT shall comprise of:

(1) Spring back Labyrinth seal or seals as per standard practice of the
bidder.

(2) Turbine shaft glands sealed with steam.

(b) Fully automatic gland sealing steam supply system including necessary
piping, valves, fittings and control and Instrumentation as required.

(1) Gland Steam condenser to condense and return to cycle all gland
leak off steam alongwith 2x100% capacity exhausters (AC motor
drive) to remove air and noncondensible gases. The exhaust gases
shall be left outside the TG hall roof level.

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(2) Suitable arrangement to bypass gland Steam Condenser which shall
be designed to operate under vacuum condition also along with de-
superheating arrangement (if required) for the bypass. The exhaust is
to be left above the TG hall roof level. The gland steam condenser
should be provided with bypass on steam side.

(3) Seal material shall be proven.

1.10.02 Operation and maintenance requirement:

(a) During normal operation, turbine shall be self-sealing.

(b) During start up and low load operation, sealing steam shall be supplied from
alternate source of steam i.e. aux. steam header, along with a facility to
automatically switchover arrangement from alternative source to the main
source and vice-versa.

(c) Two nos. modulating type control valves shall be provided, one discharging
surplus steam to condenser or any other location as optimized by the bidder
and another one for supplying extra steam to gland sealing header from
steam source to maintain sealing steam header pressure at a preset value.

(d) Control valves to be stay put during power failure & sealing steam header
pressure maintained by manual control of these valves.

(e) During changeover of steam supply source from turbine/auxiliary steam
header, there shall be no rubbing at glands and no undue increase in
vibration and the system shall be capable of withstanding thermal shock.

(f) Permit easy examination & replacement of glands.

1.11.00 STEAM ADMISSION VALVES (EMERGENCY STOP, REHEAT STOP,
INTERCEPTOR STOP VALVES AND CONTROL VALVES)

1.11.01 Design, constructional and operational requirement:

(a) Designed to allow blowing out of Steam leads prior to startup.

(b) Designed to avoid seizure under operating condition.

(c) Withstand high Erosion by stelliting or other superior methods as per
standard proven practice of the bidder for internal components of valves.
Ensure that valves are stable and shall not vibrate at high steam velocities.

(d) Locate the steam admission valve close to the turbine casing for limiting
turbine over speeding to safe limits because of entrapped steam volumes.
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(e) NOT USED.

(f) NOT USED.

(g) Lagged with insulation and provided with lifting eyebolts.

(h) Provide Temporary & Permanent steam strainers for Emergency stop and
Reheat Stop valves. In case there is no provision for temporary strainer, one
set of strainers per unit shall be provided in addition to the permanent
strainer. The strainers shall be arranged to permit easy inspection and
cleaning.

(i) Provide hydraulically operated valves, fail safe type & equipped with test
device to permit complete closing of one valve at a time while the Unit is
carrying load.

(j) Valves to close simultaneously & automatically when the over-speed
governor trips and upon the action of other protective devices.

1.12.00 NON - RETURN VALVES

1.12.01 Design and Constructional requirement:

(a) Bidder shall provide Hydraulic / Pneumatic power operated/ supported Quick
closing type & ordinary NRVs for each Steam extraction line (except for
extractions from LP Turbine) including steam extraction line to BFP drive
turbine. For each CRH line and extractions from LP Turbine (except for
heaters in condenser neck) minimum one hydraulic/ Pneumatic power
operated / supported QCNRV shall be provided. The NRVs shall be of
proven design.

(b) NRV shall be suitable for on load testing individually and shall be provided
with fail safe design.

(c) The valves shall be full-bore type designed for minimum pressure drop.

(d) Provide two sets of Limit Switches for both open & close position with two
changeover contacts.

(e) Requirements indicated in the Tender drawings are minimum. However,
based on TSR analysis to be carried out by the successful Bidder, any
additional requirements shall be met by him.

(f) Valves shall be of proven design w.r.t. type, size and rating offered (Furnish
sufficient experience data for the same).

(g) Ensure valves closure during unit trip.
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1.12.02 The material of the NRV's shall be compatible to the material of piping on which they
are mounted. However, it shall not be inferior to the following:

(i) NRVs on CRH line & : Alloy steel (WC9) or equivalent compatible
extractions to H.P. heaters with the connected piping.

(ii) Other NRVs : Carbon steel (WCB) or equivalent compatible
with the connected piping.

1.13.00 INSULATION (STEAM TURBINE AND BFP)

(a) Bidder shall provide insulation & cladding for all equipment & piping with
surface temp. more than 60
O
C.

(b) Bidder to ensure temp. of Cold face of finished insulation not greater than
60
O
C with ambient temp. of 40
O
C.

(c) The HP cylinder, IP cylinder, steam chest and interconnection piping,
crossover / cross-around piping, such parts of LP cylinder as considered
necessary, and all associated piping and valves shall be efficiently insulated
with inner thermal insulating materials. The insulated portion of the steam
turbines shall be covered with fabricated steel cover, provided with suitable
anti-drumming and sound pressure attenuating material inside. The insulation
and steel covering should be so designed and erected as to provide easy
accessibility to parts requiring frequent inspection.

(d) The thermal insulation for the turbine casing shall preferably be insulated by
preformed ceramic mattress blankets conforming to IS15402 or equivalent.
These mattresses are fixed over the casing and held in position by metallic
washers fastened to the MS rod welded to the casing. To meet the thickness
requirements, multiple layers of mattresses may be applied.
Alternatively, bidder may apply turbine insulation as per their standard
practice i.e. sprayed insulation produced by projecting specially prepared
mineral wool along with a fine liquid spray. This should be covered with
prefabricated 'blanket' type insulation. The bidder may apply complete spray
type or complete blanket type or combination of both of above as per their
standard practice. These blankets shall consist of high temperature felted
mineral insulation fully enclosed in wire inserted asbestos free cloth for
temperature exposure to 445
o
C to 595
o
C. A single layer of blanket shall not
be more than 75 mm thick. Voids around the blankets should be avoided.
However, unavoidable voids shall be filled with loose mineral wool.

(e) Nuts and other exposed portions of the casing and valve flanges shall be
suitably insulated for minimum heat loss.

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(f) Suitable stainless steel lugs shall be tack welded on turbine casing to support
the insulation. In places where welding is not permitted, suitable alternative
arrangement shall be provided by the Contractor. The design of the support
shall be so as to involve minimum number of lugs.

(g) The thermal insulation designed, furnished and installed by the Contractor
shall be such that the following items of performance shall be guaranteed,
and the specific design and application features adopted shall be so as not to
exceed the stipulated limits in temperature differentials. The Employer shall
have the option to have any random check of specimen as per his choice, to
establish conformity to guaranteed particulars:

(1) The difference in temperature between upper and lower metallic parts
of HP and IP casings in the zone of governing stage/ steam
admission shall not be more the 40
O
C during cooling of the casing.

(2) The difference in metallic temperatures of upper and lower halves of
both H.P. and I.P. casings, during normal operating conditions shall
not be more than 15
O
C.

(h) Applicable Standards:

1. IS-15402 Ceramic mattress insulation

2. IS - 9742 Sprayed mineral wool thermal insulation.

3. IS - 5696 Loose mineral wool.

4. IS - 3677 Unbonded rock and slag wool for thermal insulation.

5. IS - 8183 Lightly bonded mineral wool for thermal insulation.

6. IS - 7413, IS - 3144, IS - 9482

(i) The use of asbestos in any form for insulation and elsewhere is not
permitted.

1.14.00 TURBINE GOVERNING SYSTEM

(a) Capable of controlling with stability the turbine speed between zero to
maximum power output when the unit is operating isolated or in parallel with
other units.

(b) Overspeeding of turbine during full load loss shall be limited to turbine
overspeed trip value.
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(c) Provide adjustable steady state speed regulation between +3% to +8% of
rated speed.

(d) Ensure dead band at rated speed and at any power output within rated
output shall not exceed 0.06% of rated speed.

1.15.00 TURBINE PROTECTIVE DEVICES

(a) Emergency Governor

(1) Bidder shall provide overspeed trip of the Unit at 110% of rated speed
in case speed governor fails to limit the turbine overspeed.

(2) The emergency governor resetting shall be as per manufacturer's
standard practice. However, it shall meet the IEC-45 requirements for
overspeed trip.

(3) Bidder shall provide means for testing the operation of emergency
governor when the machine is on load without exceeding the rated
speed of the unit.

(b) Emergency Hand Trip

Bidder shall provide emergency local hand trip device to facilitate manual
tripping of the unit alongwith facility to trip turbine from UCB.

1.16.00 UNLOADING GEAR

(a) Initial Pressure Regulator

(1) It shall ensure turbine unloading to a preset point to run on house
load in case main steam pressure falls below a predetermined value.

(2) It shall be possible to adjust or bypass the initial pressure regulator
from UCB at start up condition to facilitate starting with low steam
pressure and during sliding pressure operation.

(3) Contact to be provided for signalling the device in, "Operation" and
"Reset".

(b) Low Vacuum Unloading Gear

(1) Bidder shall provide a low vacuum unloading gear if applicable, based
on his standard proven practice for the unit size in consideration,
which shall ensure progressive decrease of Steam flow to turbine
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below a preset value of condenser vacuum, thus restoring the
condenser vacuum.

(2) Contact to be provided for signalling the devices in "Operation" and
"Reset".

1.17.00 VACUUM BREAKER

Bidder shall provide D.C operated device for rapid reduction of vacuum in condenser
for turbine rotor to be brought to rest as quickly as possible.

1.18.00 TURBINE LUBRICATION OIL SYSTEM

(a) A self contained LUBRICATION oil system for each TG Unit consists of :

(1) Centrifugal / gear type, Main oil pump (MOP) directly driven by
Turbine as per Bidder's standard practice with capacity to cater lube
oil for bearings & emergency seal oil requirement (if applicable for
bidder design). In addition of above 2x100% AC Aux. oil pumps for
start up, shut down of TG unit and as standby to M.O.P. for automatic
operation shall be provided. Each pump shall also be capable of start
up, shut down of TG unit and stand by to each other for automatic
operation to cater lube oil, jacking oil & turning gear oil requirement.

OR

2x100% AC oil pumps as per Bidder's standard practice with capacity
to cater lube oil for bearings & emergency seal oil requirement (if
applicable for bidder design). Each pump shall also be capable of
start up, shut down of TG unit, normal operation and stand by to each
other for automatic operation to cater lube oil, jacking oil & turning
gear oil requirement.

In case of complete power failure including DC supply, Turbine
Generator set shall be capable of safe coasting down.

(2) One DC motor driven emergency oil pump with sufficient capacity for
meeting lube oil requirement of bearings during emergency with
automatic starting on low lube oil pressure preset value.

(3) 1x100% each AC & DC jacking oil pumps with an interlocking not to
start till lube oil pressure is established.

(4) Each Unit Lube Oil tank to have capacity to allow 5 to 8 oil charges
per hour (at normal operating level), fitted with non-corrodable
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strainers, level transmitter & local indicators and necessary manholes,
2x100% duty vapour extraction fans, platforms, railings, necessary
piping, supports and accessories etc.

(5) 2x100% DM water cooled lube oil coolers with 15% excess tube
surface area, designed as per TEMA having oil pressure greater than
water pressure fitted with Dial type Thermometer and Manual 3-way
valve on oil side for change over of coolers. Oil temperature at outlet
of coolers to be maintained within permissible limits at the inlet to the
bearings.

Alternatively 2 x 100% plate type heat exchangers with 15% area
margin on plates also acceptable as per standard practice of bidder.
Following requirement shall also be complied with:

a) Plate material shall be SS 316 and material for other component
shall be compatible for the application.

b) Pressure part as per ASME Sec-VIII.

c) Thermal calculation considering fouling factor, overall heat
transfer coefficient, corrosion allowance, plate thickness etc as
per their standard practice for employers approval

(b) Purification System

Provide permanently Connected, Continuous Oil Purification having following
major equipment.

(1) Oil centrifuge having capacity to purify 20% of total oil charge in
system per hour and constructed from high grade stainless steel.
Purified oil shall have moisture not more than 500 PPM & max.
particle size conforming to code 15/12 as per ISO 4406 or
requirement of the turbine manufacturer which ever is better. The
above particle size and moisture content shall be demonstrated with
inlet oil quality conforming to 21/18 as per ISO: 4406 and 15000 PPM
moisture respectively in one pass.

(2) Carbon steel antiflood tank for each purifier or as per standard
practice of manufacturer.

(3) Positive displacement feed & discharge pumps (if required), each
having capacity 10% higher than purifying unit. Necessary interlocks
for preventing centrifuge operation in case these feed and discharge
pumps are not operating, shall be provided.

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(4) Electric oil heater to heat oil to temperature not more than 65C with
possibility to cut heater elements in steps.

(5) Entire purification equipment to be mounted upon a substantial metal
base having a raised lip around the outside with a drain connection.

(6) Alternatively, Bidder may offer oil purification system as per their
standard practice meeting other requirements specified above. The
material of construction shall be suitable for the application.

(6) Type test(s) to be conducted:

Particle size impurities test, as detailed out in the technical
specification, is to be carried out on one purification system of main
turbine.

(c) Filters & Strainers

Provide duplex type filters/strainers with stainless steel element, with
differential pressure switches with alarm at common oil supply line. The filter
elements size shall be of five (5) microns or a size suited to TG
manufacturer's requirements. In addition to above, the Bidder may provide
filter/strainers at oil supply line to /oil return lines from bearing and generator
seals as per his standard practice.

(d) Oil Piping & fittings

(1) Provide double oil piping or equivalent shielding arrangement for all
high pressure lines and all pipes close to hot pipes and parts to
protect against fire hazards.

(2) Ensure oil return lines from bearings fitted with illuminated sight
fittings, or any other device to see the flow of oil depending upon the
standard proven practice of the bidder.

(3) Oil supply and return lines to / from each bearing may have provision
for oil flushing filters as per standard practice of manufacturer.

(e) Central Turbine Lubricating Oil Storage & Purification System

(1) Provide identical Dirty & Pure Oil tanks with capacity 1.5 times
capacity of unit oil tank.

(2) Ensure Capability to add new oil to any unit oil tank

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(3) Provide purification system identical to Unit purification system as
specified at clause no 1.18.00(b) of this chapter.

(4) Also refer Tender drawing for Central Lube Oil Purification system.

1.19.00 TURBINE CONTROL FLUID SYSTEM

(a) Provide control fluid system for each unit consisting of :

(1) Fire resistant fluid for control fluid system for all hydraulically operated
valves, servo motor for turbine stop and control valves. The Fire
resistance control fluid shall be field proven and detail of the same
shall be provided.

(2) 2x100% AC driven pumps connected to fluid reservoir alongwith
hydraulic accumulators.

(3) Fluid reservoir of adequate capacity fitted with non-corrodable
strainers, level indicators, level alarm switches & overflow devices
alongwith draining and sampling connection.

(4) Ensure surfaces of reservoir in contact with fluid to be stainless steel,
with 2x100% vapour extraction fans (if required) alongwith access
ladders, platforms railings and manholes with covers on reservoir etc.

(5) 2x100% control fluid coolers designed as specified at clause no
1.18.00 of this chapter above and ensure all surfaces coming in
contact with control fluid to be of stainless steel. 2x100% air cooled
coolers are also acceptable depending upon standard practice of the
manufacturer.

(6) Control fluid purifying unit to purify atleast 2% of the total fluid charge
in the system per hour on a continuous by pass basis alongwith
2x100% capacity A.C. driven purification pumps. (for fluid circulation
through purification system).

(7) Filters at down stream of all pumps having mesh size as per Bidder's
standard practice alongwith differential pressure switches for alarm.

(b) Piping and other equipments/components

All the piping of the system coming in contact with control fluid shall be of
stainless steel and any other component of the system to be preferably of
stainless steel or of material compatible to control fluid depending on the
standard practice of the bidder.

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1.20.00 HP-LP STEAM TURBINE BYPASS SYSTEM

(a) Ensure HP bypass aggregate capacity not less than 65% of the main steam
flow at BMCR condition considering rated main steam parameters at the
upstream of valves & CRH steam parameters corresponding to 60% TMCR
condition on the down stream. The HP bypass system shall have minimum
2x50% capacity valves. In addition the aggregate capacity of HP Bypass
valve shall be adequate to evacuate the required minimum steam flow from
the boiler under various start up conditions (viz. Cold/warm/hot start up) as
per combined boiler turbine start up curve. (to be intimated during detail
engineering)

(b) LP bypass shall be designed to condition the incoming steam from re-heater
corresponding to parameters resulting from operation as specified at clause
no 1.20.00(a) of this chapter above to parameters matching with those of LP
Turbine exhaust steam. For LP bypass valve sizing, no steam will be
extracted for regenerative feed heating except for deaerator pegging at 3.5
ata with only MDBFP in service the capacity shall be commensurate with that
of HP bypass system plus the spray water used in HP bypass. Number of LP
Bypass valves shall be as per bidder's standard practice subjected to a
minimum of 2 numbers.

(c) Seat tightness of the HP and LP bypass valves shall be equivalent to block
valve tightness conforming to MSS SP61.

(d) Provide complete HP & LP bypass system with necessary control &
instrumentation. For HP & LP bypass, the positioning electronics between the
respective process controller and the actuator control shall have all
necessary positioners for continuously controlled actuators, power modules,
various converters, power supply & other fault monitoring & alarming
modules, position transmitters etc.

(e) Provide HP bypass station spray water requirement from Boiler feed pumps
discharge & LP bypass spray water requirement from condensate extraction
pump discharge. Spray system to include spray water control valves, NRVs
and isolating valves.

(f) Ensure HP bypass designed to accept continuous spray water at temp.
corresponding to all HP heaters out of service and deaerator pegged at 1.5
ata. Spray water shall be sprayed at the most turbulent zone inside the valve
having steam velocity in the order of 350 to 400 m/sec. The entire
atomization and evaporation of spray water shall be complete within shortest
possible distance but not exceeding 1.0m from the spray point. The HP
bypass spray controller shall have state controller with observer to achieve
accurate control over outlet steam temperature under different operating
conditions including the transients.
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(g) For LP bypass system the de-superheating may be done outside the valve
body with spray water tapped from condensate pump discharge.

(h) Ensure all valves (both in steam and spray water service) to be electro
hydraulically operated.

(i) Provide separate oil system with 100% redundant pumps, motors,
accumulators and control cubicles etc. for both HP and LP bypass systems.
Accumulators shall be sized to take sufficient number of stroking operations
of all actuators under a condition of loss of oil supply from the pumps.

(j) Alternatively for LP bypass system, the control fluid supply can be taken from
steam turbine control fluid system based on Bidder's standard practice.

(k) Provide HP-LP bypass valves with gland cooling arrangement, preferably
using spray water, as per standard practice of manufacturer. Further grafoil
packing rings or equivalent arrangement shall be provided for valve glands.

(l) Provide warming up arrangement of HP/LP bypass valves and associated
piping.

(m) Ensure Suitability for operations under sliding pressure mode to enable short
start-up time.

(n) Capable of operation in parallel with turbine with all feed water heaters in
service.

(o) Facilitate hot/warm restarting following a trip from full/part loads, controlled
shutdown and cold start-up following a long shut down.

(p) Ensure that boiler operation is not affected in the event of loss of load on the
turbine, by disposing off the steam produced in the boiler automatically by
providing a quick opening device. The full stroking time of valve under quick
action shall be within 2 to 3 seconds.

1.21.00 PERFORMANCE REQUIREMENTS

(a) The steam turbine Generator set apart from being capable of operation on
base load shall also be suitable for two shift operation and cyclic load
variations as the unit is expected to operate in automatic load frequency
control system.

(b) Bidder to provide adequate temperature measurement and other
instrumentation etc. for adequately guiding the operator to regulate loading of
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unit to keep the thermal stresses and fatigue levels within safe limit. Ensure
TG Set capability of operating on variable pressure mode.

The logic loop developed by C&I sub-system supplier including set point i.e.
turbine protection, turbine stress control system etc. shall be reviewed and
vetted by turbine manufacturer.

Any additional input data for the PADO system deemed necessary by the
Employer shall be furnished.

(c) Ensure during sliding pressure mode, throttle pressure slides from rated
pressure down to 40% of rated pressure.

(d) Provide adjustable throttling reserve from sliding pressure to modified sliding
pressure.

(e) Ensure TG set capable of operating continuously with any one string of HP
heaters out of service, with 89 mm Hg condenser pressure, 3% make-up &
Aux. Steam requirement tapped from CRH, generating not less than the
rated output without overstressing turbine components.

(f) Use of drip pump, if envisaged, by the bidder shall be restricted to one LP
Heater only.

(g) Only 13 T/hr. steam is expected to be tapped off from CRH during normal
operation for auxiliary steam consumption. Auxiliary steam tap off from CRH
during other special conditions can be higher.

(h) Ensure normal make-up to cycle in the condenser hot well at 3% which at
times may go upto 5%.

(i) Ensure during HP-LP bypass operation deaerating feed water heaters &
accessories shall heat feed water from 45 deg. C to 140 deg. C.

(j) For Heater drains refer tender drawing.

(k) Ensure all cycle drains to condenser through flash tanks. Start-up drains to
be led to a separate atmospheric flash tank.

(l) The steam generators have been provided with the start up recirculation &
drain system with startup drain re-circulation pump. However in such
situation when steam generators start up drain re-circulation pump is not
available, the steam generator start up drains shall be routed to an boiler
atmospheric flash tank (to be provided by employer). Condensate transfer
pumps shall be provided for pumping the condensate from this atmospheric
flash tank to turbine condenser. TG Bidder may route this condensate to
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turbine condenser either directly or through a flash tank within TG bidder's
scope. TG bidder has to provide a stub connection for connecting SG drains.

In such a case bidder shall ensure the temperature of condensate leaving the
condenser does not increase beyond 55 deg C, so that performance and life
of condensate polishing unit, is not affected adversely.

(m) For Turbine cycle diagram refer tender drawing.

(n) Under all conditions of operation, the steam turbine generator set shall
perform continuously without the noise levels of its components and
auxiliaries (individually or collectively) exceeding the limits as specified under
General Technical Conditions.

(o) Maximum permissible vibration for auxiliaries shall conform to Zone-A of
ISO10816.

1.22.00 Heat balance Diagrams:

1.22.01 Following Heat balances complete in all respects to be computed & furnished for the
conditions stipulated with units indicated in MKS system & IAPWS-IF 97 steam
tables. Pressure (in ata), temperature (in deg C), enthalpy (in kcal/kg) and flow (in
tonnes/hr) to be indicated at all required locations to facilitate manual checking by
the Employer. Other conditions for computing heat-balances are given at Annexure-I
to this sub-section.

(a) 693MW (i.e. 105% of rated load) under rated steam condition at condenser
pressure 77 mm Hg (abs), with zero make up (GUARANTEE HEAT RATE &
OUTPUT).

(b) 660 MW output under rated steam conditions at condenser pressure of 77
mmHg (abs) with zero make-up (GUARANTEED HEAT RATE).

(c) 528 MW output under turbine throttle inlet steam conditions corresponding to
sliding pressure operation and rated steam temperature at condenser
pressure of 77 mm Hg (abs) with 0% & 3% make-up.

(d) 396 MW output under turbine throttle inlet steam conditions corresponding to
sliding pressure at condenser pressure of 77 mm Hg (abs) with 0% & 3%
make-up.

(e) 330 MW output under turbine throttle inlet steam conditions corresponding to
sliding pressure operation at condenser pressure of 77 mm Hg (abs) with
zero make-up.

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(f) 660 MW output under rated steam conditions at condenser pressure of 77
mm Hg (abs) with 3% make-up.

(g) 660 MW output under rated steam conditions at condenser pressure of 89
mm Hg (abs) with 3% make-up.

(h) 198 MW output under turbine throttle inlet steam conditions corresponding to
sliding pressure operation at condenser pressure of 77 mm Hg (abs) with 0%
& 3% make-up.

(i) VWO with over pressurisation corresponding to boiler capability at condenser
pressure of 77 mm Hg (abs) with 3% make-up (If applicable).

(j) VWO output under rated steam conditions at condenser pressure of 89 mm
Hg (abs) with 3% make-up.

(k) VWO output under rated steam conditions at condenser pressure of 77 mm
Hg (abs) with 0% makeup & 3% makeup.

(l) HP heaters out of service (One string and both strings) under rated steam
conditions at condenser pressure of 77 mm Hg (abs) and 89 mm Hg (abs)
with zero percent make up and 3% make-up and maximum continuous
output

(m) All HP heaters out of service under rated steam conditions at condenser
pressure of 77 mm Hg (abs) and 89 mm Hg (abs) with zero percent make up
and 3% make-up and rated output

(n) 660 MW output under sliding pressure conditions at condenser pressure of
77 mm Hg (abs) with zero percent make-up and 3% make-up.

(o) HP-LP bypass operation under rated steam conditions with bypass valves
open to full capacity and turbine on house load operation.

(p) HP-LP bypass operation under rated steam conditions with steam generator
output of 65% of BMCR.

(q) 60% unit load with one pass of condenser(s) in isolated condition.

(r) Steam generator output corresponding to BMCR flow under rated steam
conditions, turbine in parallel operation with HP-LP bypass with by pass open
to full capacity.

(s) 462 MW output under sliding pressure operation at condenser pressure of 77
mm Hg (abs) with 0% and 3% makeup.

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(t) Steam Generator output corresponding to BMCR flow under rated steam
condition, turbine under VWO operation, condenser pressure of 77 mmHg,
0% and 3% make up. Difference of BMCR flow and VWO steam flow through
turbine shall be assumed to be drawn off from Main steam line. Same
quantity of flow to be added to condenser as additional make up.

(u) Turbine operation at 40% rated pressure at condenser pressure of 77mmHg,
0% and 3% make up, under sliding pressure operation.

(v) 65% unit rated output under sliding pressure operation at condenser
pressure of 77 mm Hg (abs) with 0% and 3% make up.

Note:

Refer annexure-I for other conditions for computing heat balance diagrams.

Any additional heat balances deemed necessary by the Employer shall be
furnished. All the heat balances shall show turbine output, mechanical and
electrical losses in turbine and generator and input to shaft driven auxiliaries,
if any.

Steam supply to deaerator shall be from IP-LP cross-over / cross around pipe
or from a point as per optimised cycle of the bidder and the minimum
deaerator pressure shall be 3.5 ata during low-load operation and HP-LP
Bypass operation.

Drive turbines of BFP shall get steam from IP/LP crossover/cross around
pipe or from a point as per optimised cycle of the Bidder during operation of
turbine from full load to 60% EMCR load or below, if possible. At low loads,
Drive turbines of BFP shall get steam from an alternate source from the
same unit.

It may be noted that for purpose of HBD quantity of desuperheating water to
boiler superheater and reheater shall be considered as zero

1.22.02 HEAT RATE

The turbine cycle heat rate shall be calculated as per formula indicated in Chapter
for Functional Guarantees and Liquidated Damages in Part-A of the technical
specification.

1.22.03 Correction Curves

(1) Based on cycle condition & covering entire range of operation for Turbine &
Condenser following correction curves for variation in turbine Heat rate &
output to be furnished:
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(a) Variation in main steam pressure and temperature.

(b) Variation in reheater steam temperature.

(c) Variation in reheater circuit pressure drop.

(d) Variation in SH spray flow. (Applicable in case the spray water is
tapped off from regenerative feed cycle up stream of the final HP feed
water heater).

(e) Variation in RH spray flow.

(f) Variation in feed water pressure at inlet to economiser NRV/startup
heat exchanger i.e. Bidder's Terminal point.

(g) Variation in condenser pressure for main condenser.

(h) Variation in power factor, frequency, generator hydrogen pressure
and voltage.

(i) Change in system water storage.

(2) Following condenser pressure variation curves for main condenser and BFP
drive turbine condenser (if separate condenser is offered by bidder for drive
turbine) for change in CW inlet temperature, Heat load & quantity in
condenser to be furnished:

a) Change in CW inlet temperature

b) Change in net heat load

c) Change in CW- quantity.

(3) Following correction curves for variation in CW pumping power to be
furnished:

a) Change in CW flow

b) Change in CW inlet water temperature

The above list of correction curves is conclusive & curves in addition to above shall
not be applied.

1.22.04 Furnish turbine expansion line diagrams for Guaranteed load points alongwith group
efficiencies.
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1.22.05 Furnish thermal kit data for plant performance by DDCMIS and true copies of
Performance Guarantee test reports for sets rated for 660 MW or above.

1.22.06 Furnish turbine clearance diagram indicating values for radial & axial clearances and
leakage rate at EMCR & under worst operating conditions.

1.23.00 Type test(s) to be conducted:

Following type tests as detailed in QA portion of the technical specification are to be
carried out:

i) Life cycle test, meridional yield rupture test and squirm test on one metallic
expansion joints of each type and size.

ii) Life cycle test on one rubber expansion joint of each type and size in
condenser CW inlet and outlet line.

2.00.00 CONDENSING PLANT

(a) Design manufacturing and testing as per Heat Exchange Institute, USA
(latest) with proven design. Bidder to furnish thermal, hydraulic and
mechanical design calculation for checking equipment capability.

(b) Suitable for condenser cooling water as specified. The Condenser on Load
Tube Cleaning System (COLTCS) metallurgy and system design has to be
suitable for cooling water quality specified. As such all material of condensing
plant have to be suitable for intended service.

(c) Suitable for CW system of closed type with cooling Towers.

(d) Provision of isolating butterfly valves and expansion bellows at inlets and
outlets of condenser cooling water of each half of condensers.

(e) Design for installation of LP heater(s) in condenser neck.

(f) Provision of air evacuation pumps. Condenser to be designed for minimum
air leakage and under normal operating conditions, the air leakage in
condenser not to exceed more than 50% of design value taken for sizing of
vacuum pumps. The same shall be demonstrated at site under actual
operating condition failing which Bidder shall carryout necessary
modifications.

(g) Provision of separate sponge ball type condenser on-load tube cleaning
system for each half of condenser including ball circulation pumps, strainer
and ball monitoring system.

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(h) Max. oxygen content of condensate leaving the condenser shall be 0.015 CC
per litre over the entire load range.

2.01.00 Condenser

(a) Horizontal surface type condenser of proven design with integral air cooling
section and divided waterbox construction.

(b) Provision of large box type screening structure with anti-vortex baffling at
each hotwell connection to suction of condensate pumps.

(c) Shell material carbon steel as per ASTMA-285 Gr.C or equivalent & suitable
for intended service, welded construction and 16mm minimum wall thickness.
Hot well of material same as shell material, shall be longitudinally divided
with proper drainage provision.

(d) Condenser shall be spring supported or rigid supported as per standard
practice of bidder and directly welded to the turbine exhaust.

(e) Provide suitable impingement guards or baffles on top row tubes. Similar
guards for any steam or water connection to condenser. Other alternate
arrangements to the satisfaction of Employer to protect top row of tubes shall
also be considered.

(f) Easily removable/hinged type and refittable type water boxes alongwith
suitable handling arrangement and provision of hinged manholes (of 460mm
size) in shell, each water box and each hot well suction.

(g) Water box interiors to be resin coated with suitable corrosion resistant primer
of 0.25 mm minimum thickness.

(h) Tubes shall be welded type stainless steel as per ASTMA-249-TP304 and
meeting the ASME specification for general requirements for carbon ferritic
alloy and austenitic alloy steel tubes SA-450 and continuous without any
circumferential joint suitable for intended duty with average wall thickness 22
BWG (minimum). Top rows of tubes shall be extra thick. Provision for taking
care of thermal expansion of tube bundle and proper drainage of tubes
during shut down shall be ensured.

(i) Water box, tube plates and support plates material carbon steel as per
ASTMA-285 Gr.C. and suitable for intended duty. Water side of tube plates
coated with epoxy resin of 0.25 mm minimum thickness.

(j) Corrosion allowance of minimum 3.2 mm for water boxes, tube plates and
1.6 mm for shell, hotwell and condenser neck.

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(k) Stand pipes with necessary connections for instruments, with water level
gauges and isolation valves.

(l) Ensure efficient steam distribution in the condenser when one half of the
condenser is isolated and ensure atleast 60% of rated output under this
condition.

(m) Suitable provisions to be made for expansion between shell and tubes.

(n) Suitable provision (like sliding and fixed base plate of condenser support feet
etc.) for expansion of condenser shell to be made.

2.02.00 Design requirement:

(a) The Condenser shall be designed for heat load corresponding to unit
operation for VWO, 3% m.u. and design condenser pressure and conditions
given at relevant Annexure of this sub-section. Condensate temperature at all
loads shall be near to the saturation temperature corresponding to condenser
pressure.

(b) Design for full vacuum and min. internal pressure 1.08 Kg/cm2(g). Minimum
shell side design temperature 120 deg. C.

(c) The Condenser hotwell shall be sized for three (3) minute storage capacity
(between normal & low-low level) of total design flow with the turbine
operating at VWO condition, 3% make-up, design condenser pressure. The
low-low level of hotwell shall be atleast 200 mm above the bottom of hotwell.

(d) Sizing of steam dumping device to accept the steam from HP-LP bypass with
necessary spray water including abnormal conditions like HP heaters out of
service etc.

(e) Design of air removal section to cool the air and vapour mixture to atleast
4.17 deg. C below saturation temperature corresponding to 25.4 mm Hg
(abs). Connections to air evacuation pumps shall be made at this section.

(f) Design for exhaust steam from steam turbine, BFP drive turbine (if
applicable), HP-LP bypass system, heater drains and vents, boiler separator
drains during start up, low load and abnormal conditions and other
miscellaneous drains.

(g) Designed to carry flooded weight (upto 1 meter above top row of condenser
tubes) for hydraulic and hydrostatic testing of condenser without installation
of temporary supports or bracing.

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(h) C.W. butterfly valves with actuators to be designed as per AWWA-C-504-80
or Employer approved equivalent standards. Valve's material shall be
suitable for duty intended.

(i) C.W. expansion joints made from high quality natural / synthetic rubber with
carbon steel reinforcement rings and with flanges of 125 LB as per ANSI-
B16.25. The material used shall be suitable for service intended. The
expansion joints shall be designed to the deflections and fluid pressure
through out plant life and shall be suitable to withstand full vacuum without
collapse and the proposed arrangement for this shall be indicated in the offer.
Further the design shall limit the reaction forces/moments on condenser CW
nozzles and on C.W. piping.

(j) Design, Material and construction of CW piping and butterfly valves shall be
as per relevant standards and as specified elsewhere in the specification.

2.03.00 Erection and construction requirement

(a) If the condenser shells call for site assembly, care shall be taken in the
assembly of shells, and the correctness of alignment shall be checked in a
manner acceptable to the Employer prior to stitch welding. With stitch
welding over, and on clearance of final alignment by the Employer, final
welding shall be done by 'seam method' so as to ensure a minimum
deformation of the welded parts. Only approved welders shall perform such
welding operation. All the weld seams shall be properly ground and subjected
to non-destructive examination. At least 10% of butt welded seams shall be
subjected to radiographic examination.

(b) If the superstructure portion or the upper portions of the condenser are not
welded to the condenser shell in the Contractor 'works, then they shall be
properly aligned with the Condenser shells at site. Any special fixtures
required for such alignment shall be furnished along with the equipment and
made use of by the Contractor. All welding shall be done as prescribed under
in this volume above and the weld seams shall be properly ground and
subjected to dye-penetrant test.

(c) The Contractor shall be governed by the following conditions during
condenser tubes insertion and expansion.

(1) The condenser shall be installed in its position prior to tube insertion.
Tube insertion and expansion shall not be carried out in the open.

(2) The tubes shall be free from any dents, mechanical damages or any
other defects caused during the storage.

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(3) Both ends of the tube where tube expansion has to be carried out
shall be thoroughly cleaned to a length of 100 mm to remove oil
grease etc. The cleaning shall be done with a fine emery paper.

(4) The surfaces of the holes in the tube plates and the tube support
plates shall be thoroughly cleaned and shall be free from paint,
corrosion spots, oxide scales etc. The method adopted by the
Contractor for such cleaning of the holes shall meet the approval of
the Employer. Final cleaning shall be performed by a chemical
cleaning agent like Carbon Tetra Chloride.

(5) The cleaned surfaces of the tubes and the reamed tube plate holes
shall be free from any longitudinal scratches.

(6) Tubes shall be inserted such that their ends shall project out 2 to 3
mm beyond the tube plate outer surface. The tube shall then be
expanded using an electronic automatic torque control tube
expanding unit or pneumatic tube expander so as to get thinning of
the tube walls as per bidder's standard design practice and the
elongation of the tube ends shall be 0.40 to 0.60 mm. Tube expansion
shall be so controlled that neither over expansion nor under
expansion of the tubes takes place. Tube expansion shall be checked
with a dial bore gauge indicator. Tube expansion shall be carried out
to a length of 70% to 80% of the tube plate thickness. In no case, the
expansion shall go beyond the tube plate thickness. The tube
insertion shall be such that the excess length of all tubes shall be at
the same tube plate and they shall be cut off by a cutting tool followed
by expansion. Both ends of tubes after expansion shall be flanged
properly. Finally, proper chamfering shall be carried out. Expansion of
condenser tubes shall start from the peripheral holes of the tube plate
and shall proceed towards the centre of the tube plate in such a
sequence as to avoid any deformation of the tube plate.

(d) In case the condenser is supported on springs and the condenser neck is
directly welded to the L.P. cylinder exhaust hood, then the final lifting and
installation of the condenser on permanent support shall be carried out only
after final installation of the L.P. casing. It shall be ensured that all spring
supports are evenly loaded and the gap between the condenser and the
spring supports is within +/- 1.0mm . Suitable adjusting bolts shall be used to
further lift the condenser till the clearance between condenser neck and L.P.
exhaust hood is suitable for welding and such clearances shall not exceed
3.0mm. The welding of the above connection shall be performed as called for
as prescribed in this volume above. Suitable machined permanent spacers
shall be provided and the condenser load shall gradually be transferred on to
these spacers from temporary bolts.

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2.04.00 Hydrostatic and Hydraulic Tests

(a) The hydrostatic testing of condenser steam space shall be carried out after
connecting all the pipes with the condenser along with the condenser
vacuum system by filling the steam space with water 300 mm above final
joint of condenser exhaust neck to turbine. The level of hydraulic test shall be
selected such that all the field welding joints are covered in the test. Any
leakage detected shall be rectified immediately.

(b) The water space shall be tested hydraulically alongwith the circulating water
lines, after assembly of the waterbox doors.

(c) After the hydraulic testing, the waterboxes tube plates and covers shall be
given suitable coatings of anti-corrosive paints. The paints and painting shall
meet the approval of the Employer.

2.05.00 Operational requirement:

(a) Steam dumping device for dumping of desuperheated steam from LP bypass
alongwith all accessories and instrumentation.

(b) No damaging due to vibration during normal, abnormal and transient
conditions and during turbine trip from full load to HP-LP bypass operation,
feed heaters out of operation, VWO condition, 100% load and start-up
condition etc. Bidder to ensure satisfactory operation under above operating
conditions.

(c) Natural frequency well above the frequencies induced by other associated
equipments under all operating conditions including abnormal.

(d) Provision for maximum deaeration and removal of non-condensable gases
from steam and make-up water. Air removal section to be suitably baffled to
prevent water carryover.

(e) Provision of air release valve and drain valve in waterbox and condenser
shell and also for complete drainage of water from hot well.

(f) Provision in water box of adequate size nozzle and valve for priming of
condenser.

(g) Provision of catch trough below tube sheet in hotwell for detection of water
leakage into steam side.

(h) Provision of motorised butterfly valve in each exhaust duct of BFP turbine for
isolation of BFPT, when not in use (if applicable).

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2.06.00 CONDENSER AIR EVACUATION PUMPS

(a) Provision of 2x100% air evacuation pumps per unit alongwith all accessories
and instrumentation.

(b) Single/two stage liquid ring type with both stages (if two stage pumps
provided) mounted on a common shaft.

(c) Suitable for indoor installation and for continuous duty.

(d) Each pump and its accessories shall be mounted on common steel base
plate. Pump shall be connected to motor by flexible coupling.

(e) Heat Exchangers shall be shell and tube type.

(1) Material of tube-stainless steel type 316 and material of shell and
tube plates as M. S. type ASTM-A285 Gr. C properly coated.

(2) For U-tube type : Removable tube bundle provision

Alternatively-plate type heat exchangers with SS 316 plates and 20% area
margin on plates also acceptable.

(f) Sizing as per latest HEI.

(g) Capacity of each pump in free dry air at standard condition with condenser
operating at design pressure of 1 inch (25.4 mm) of Hg (abs) and sub cooled
to 4.17 deg.C below temperature corresponding to absolute suction pressure
shall not be less than 30 scfm (51 m3 per hour) under standard conditions
i.e. 760mm Hg (abs) and 21.1 deg. C.

(h) Capacity of each pump during hogging operation shall not be less than 800
scfm (1360 m3 per hour under standard conditions i.e. 760mm Hg (abs) and
21.1 deg. C) at 10" (254 mm) Hg (abs).

(i) Provision of air ejector (if required) for abnormal operation and selection of
suitable compression ratio for air ejector.

(j) Selection of materials for vacuum pumps and seal water recirculation pumps
as below: -

(1) Casing - Nickel cast iron

(2) Shaft - Carbon Steel (EN8)

(3) Impeller - Nodular iron/stainless steel

(4) Shaft sleeves-Nodular iron/stainless steel

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(k) Operational flexibility of all pumps during hogging and must be able to
evacuate the condenser in specified time as per HEI.
(l) The stand-by pump shall cut in automatically in case running pump fails or
when condenser pressure falls back to a preset value.

(m) No cavitation under all operating conditions without air ejector.

(n) Noise levels should not exceed limitations as specified in Section of General
Technical Requirements and vibration levels shall be "Good" as per VDI-
2056.

2.07.00 Type Test(s) to be Conducted

Following type tests as detailed in QA portion of the Technical specification are to be
carried out on one vacuum pump.

(i) Cavitation test

(ii) Wet air test

3.00.00 CONDENSER ON LOAD TUBE CLEANING SYSTEM

(a) Sponge rubber ball type tube cleaning system designed for continuous &
trouble free operation with provision of abrasive coated balls cleaning in case
of hard deposits inside tubes.

(b) Suitably sized non clog type ball recirculation pump to inject the cleaning
balls into respective CW inlet pipe.

(c) Suitable ball injection nozzles.

(d) Suitable ball collecting strainer to be provided at CW discharge pipe to collect
the cleaning ball and the same will be drawn off to the suction of ball
recirculation pump.

(e) Sufficient capacity ball collecting vessel to hold the full charge of balls

(f) Necessary piping, fittings and accessories for complete installation of the
system.

(g) Automatic / manual ball sorter to sort out under size balls.

(h) The system should be complete with necessary instruments, protection and
interlocks.

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(i) Provision of manual and automatic back washing system with automatic
collection of balls prior to back washing.

(j) Provision of ball monitoring system, which should at least consist of separate
ball circulation monitor and ball oversize monitor.

(k) The ball collecting strainer should have redundant differential pressure
transmitter, switch and gauge with remote seal type connection.

(l) The no. of balls in circulation should be at least 10% of nos. of condenser
tubes.

(m) Bidder should indicate the number of ball losses in 1000 hrs. of normal
operation.

(n) Enough provision for homogeneous ball injection and even distribution of
balls through out the condenser tubes.

(o) Provision to avoid any dead zone inside the water box.

(p) Bidder should ensure that there should not be crowding of balls at the inlet of
ball collecting strainer at discharge pipe.

(q) Provision to prevent losses of ball during normal and abnormal condition
including tripping of CW pump.

(r) Tender Drawing for COLTCS may also be read in conjunction with the
specification.

(s) The ball recirculating pumps, collector, monitor etc. shall be skid mounted.

4.00.00 CONDENSATE EXTRACTION PUMP

(a) Configuration:

3 X 50 % Condensate extraction pumps per unit.

(b) Drive

Constant speed squirrel cage induction motor with speed of 1500 rpm
(synchronous)

(c) Constructional Requirements

Vertical, Multistage, Cannister type, Centrifugal, diffuser type with double
suction first stage impeller.
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(d) Shaft sealing

Either mechanical seals or packed type with external water sealing designed
to prevent air ingress to condenser even when the pump under shut down
and exposed to condenser.

(e) End Connections

Discharge and suction connection of weld neck type, raised steel flange as
per ANSI B. 16.5 and to be located above floor mounting flange.

(f) Thrust Bearing

Thrust bearing for the combined thrust load of pump and motor with a rigid
coupling between pump and motor or individual thrust bearings for pump and
motor with a flexible coupling between motor and pump.

(g) Impeller/Casing design

Closed and nonover-loading type impeller with wear rings on pump bowls.

(h) Pump Sizing

(i) Design Capacity

Combined flow of 2 x 50 % CEP to be based on 15% margin over
highest condensate flow envisaged during unit operation (excluding
HP/LP bypass operation).

Design Head

Corresponding to above considering 10% margin over deaerator
pressure.

(ii) Best efficiency point

Combined flow of 2x50% CEPs shall be based on TG unit EMCR and
corresponding head.

(iii) Maximum Capacity

One pump shall be capable of handling the flow and head
corresponding to 65% unit load.

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(iv) Other Capabilities:

(a) 2 pumps shall be capable of handling the flow corresponding
to Unit EMCR, all HP heaters out, 3% m.u. and worst
condenser pressure at 47.5 HZ.

(b) 2 pumps shall be capable of handling the flow corresponding
to HP - LP by pass operation with turbine under tripped
condition as well as turbine on house load.

(i) MOTOR RATING

Motor rating at 50 deg. C ambient temperature shall not be less than the
maximum load demand of its driven equipment in its entire operation at
frequency variations from 47.5 Hz to 51.5 Hz and motor shall not be over
loaded during any mode of operation of driven equipment.

(j) NPSH Margin

NPSH (R) at 3% head drop shall not be more than half the NPSH(A) at
design flow with low-low hotwell level and NPSH(R) at 3% head break shall
be well below NPSH(A) under all conditions.

(k) Motor bottom level

Bottom of motor to be above zero meter by suitably considering the pit level
and motor stool dimensions.

(l) Minimum recirculation flow

Individual recirculation line for each CEP shall be provided. Minimum
recirculation flow requirements of the pump shall be not less than 25% of
design flow or on set recirculation (discharge/suction) whichever is higher.

(m) Performance curve

Characteristic curve of pumps should be continuously rising type with
decrease in flow and shut off head shall be between 115% to 130% of TDH
at design point.

(n) Critical Speed

First critical speed in water shall not be within 20% of design speed.

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(o) First stage impeller life

Life due to wear due to Cavitation of first stage Impeller not less than 40,000
running hours.

(p) Peripheral speed at the eye of the impeller

Not to exceed 20m/sec.

(q) Suction specific speed

Suction specific speed of first stage impeller not to exceed 11,000 U.S. units
based on 3% head break of that impeller at design point.

(r) Interchangeability

Complete interchangeability in all respects of the pumps and their
components.

(s) Design Pressure

(1) Bowls and discharge components design pressure shall correspond
to shut off head at 51.5 Hz and operating specific gravity and
maximum suction condition.

(2) Suction components shall be designed for 8 ata and full vacuum.

(t) The pump internals to be capable of being lifted out of casing after removal of
motor and disconnecting discharge flange but not disturbing the discharge
piping.

(u) Material

The material adopted shall not be inferior to those mentioned below:

(a) Suction bell/Pump casing - cast iron
(b) Impeller/Wearings/Shaft/ Shaft sleeves - 12% Cr. stainless steel.
(c) Cannister - Fabricated mild steel.

(v) Applicable Code

HIS (Latest edition)

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(w) STRAINERS AT CONDENSER EXTRACTION PUMP SUCTION

(1) Strainer body simplex and cylindrical type

(2) The clear area of strainer to be Five times the inlet cross sectional
area of the connecting piping.

(3) Strainer to be constructed of 16 gauge perforated stainless steel (304
grade) and lined with stainless steel (316 grade) screen.

(4) At design flow and clean condition, Pressure drop not to exceed 0.1
Kg/cm2.

(5) At design flow and 50% clogged condition, Pressure drop not to
exceed 0.15 kg/cm2.

(6) Strainer design to permit ease of inspection and cleanliness.

4.01.00 Type test(s) to be Conducted

Following type tests as detailed in QA portion of the Technical Specification to be
carried out:

i) NPSH (R) test on one CEP.

ii) Pressure drop test on one CEP suction strainer

4.02.00 DRIP PUMP (IF OFFERED)

If the bidder optimizes the Cycle with drip pump at any one location for forward
cascading of LP heater drain, then 2x100% Drip pumps shall be provided for each
unit.

(a) Configuration:

2 X 100 % drip pumps per unit.

(b) Drive

Constant speed squirrel cage induction motor with speed of 1500 rpm
(synchronous).

(c) Constructional Requirements

Vertical, Multistage, Cannister type, Centrifugal, diffuser type.

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(d) Shaft sealing

Either mechanical seals or packed type with external water sealing designed
to prevent air ingress to heater even when the pump under shut down and
exposed to heater.

(e) End Connections

Discharge and suction connection of weld neck type, raised steel flange as
per ANSI B. 16.5 and to be located above floor mounting flange.

(f) Thrust Bearing

Thrust bearing for the combined thrust load of pump and motor with a rigid
coupling between pump and motor or individual thrust bearings for pump and
motor with a flexible coupling between motor and pump.

(g) Impeller/Casing design

Closed and nonover-loading type impeller with wear rings on pump bowls.

(h) Pump Sizing

(i) Design Capacity

1x100% drip pump flow to be based on 15% margin over highest drip
flow envisaged during unit operation.
Design Head

Corresponding to above considering 10% margin over deaerator
pressure.

(ii) Other Capabilities

1 pump shall be capable of handling the flow corresponding to Unit
EMCR, all HP heaters out, 3% m.u. and worst condenser pressure at
47.5 Hz.

(i) MOTOR RATING

Motor rating at 50 deg. C ambient temperature shall not be less than the
maximum load demand of its driven equipment in its entire operation at
frequency variations from 47.5 Hz to 51.5 Hz and motor shall not be over
loaded during any mode of operation of driven equipment.

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(j) NPSH Margin

NPSH (R) at 3% head drop shall not be more than half the NPSH(A) at
design flow with low low heater level and NPSH(R) at 3% head break shall
be well below NPSH(A) under all conditions.

(k) Motor bottom level

Bottom of motor to be above zero meter by suitably considering the pit level
and motor stool dimensions.

(l) Performance curve

Characteristic curve of pumps should be continuously rising type with
decrease in flow and shut off head shall be between 115% to 130% of TDH
at design point.

(m) Critical Speed

First critical speed in water shall not be within 20% of design speed.

(n) First stage impeller life

Life due to wear due to Cavitation of first stage Impeller not less than 40,000
running hours.

(o) Peripheral speed at the eye of the impeller

Not to exceed 20m/sec.

(p) Suction specific speed

Suction specific speed of first stage impeller not to exceed 11,000 U.S. units
based on 3% head break of that impeller at design point.

(q) Interchangeability

Complete interchangeability in all respects of the pumps and their
components.

(r) Design Pressure

(1) Bowls and discharge components design pressure shall correspond
to shut off head at 51.5 Hz and operating specific gravity and
maximum suction condition.

(2) Suction components shall be designed for 8 ata and full vacuum.

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(s) The pump internals to be capable of being lifted out of casing after removal of
motor and disconnecting discharge flange but not disturbing the discharge
piping.
(t) Material

The material adopted shall not be inferior to those mentioned below:

(a) Suction bell/Pump casing - cast iron

(b) Impeller/Wearings/Shaft/ Shaft - 12% Cr. stainless steel.
Sleeves

(c) Cannister - Fabricated mild steel.

(u) Applicable Code

HIS (Latest edition)

(v) STRAINERS AT DRIP PUMP SUCTION

(1) Strainer body simplex and cylindrical type

(2) The clear area of strainer to be Five times the inlet cross sectional
area of the connecting piping.

(3) Strainer to be constructed of 16 gauge perforated stainless steel (304
grade) and lined with stainless steel (316 grade) screen.

(4) At design flow and clean condition, Pressure drop not to exceed 0.1
Kg/cm2.

(5) At design flow and 50% clogged condition, Pressure drop not to
exceed 0.15 kg/cm2.

(6) Strainer design to permit ease of inspection and cleanliness.

4.02.01 Type test(s) to be Conducted

Following type test as detailed in QA portion for CEP of the Technical Specification
to be carried at:

NPSH (R) test on one Drip Pump.

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5.00.00 FEED WATER HEATING PLANT

(a) The plant shall be designed as per ASME Boiler and pressure vessel code,
section VIII, Division-I (Latest) Heat Exchange Institute Standards (USA). In
addition the requirements of ASME-TDP-1- latest code for turbine damage
prevention shall also be taken care of. Plant shall be designed for all
operating conditions including transients like sudden load throw-off, HP-LP
bypass coming in operation, preceding one or two heaters going out of
service etc.

(b) The plant shall be suitable for operation in conjunction with the turbine. It
shall be designed for raising the temperature of feed water from that in the
condenser to a final feed water temperature 287.5 2.5
O
C at the outlet of
top heater at rated output with zero percent make-up and design back
pressure. TTDs and DCAs of heaters shall correspond to the 100% TMCR
heat rate guarantee conditions..

(c) Each heater shall be designed for removal from service individually without
shutdown of unit, using hydraulically operated or motorised bypass and
isolating valves except HP heaters which can be isolated as a string and not
individually. Bypass arrangement of HP Heater string shall be in line with the
arrangement shown in the tender drawing. In addition, 2 X 50% capacity
spring loaded relief valves shall be provided in the bypass arrangement of
HP Heaters with each spring loaded valve capable of passing feed flow equal
to 50% BMCR capacity.

(d) Design with Minimum pressure drop on tube side. Velocity of water through
the tubes shall be restricted to 3.05 m/sec under all operating conditions.

(e) Design for handling drains from preceding heaters for all operating conditions
and emergency drains to condenser bypassing the drain cooling zone.

(f) Easy for floor mounting and shell removal dismantling except for LP heaters
in condenser neck.

(g) Provision for complete drainage both shell side and tube (water box) side.

(h) Provision of start-up and operating vents with orifices and relief valves and
provision for removing non-condensable gases collecting on shell side
individually to condenser. Vent orifice shall be sized to pass one half percent
of TMCR extraction steam flow to respective heater under TMCR conditions.

(i) Tube material stainless steel as per ASTM. A 213 Gr. TP 304 for seamless
tubes without circumferential joints or ASTMA 688 Gr. TP 304 for welded
tubes. Maximum content of carbon shall be limited to 0.05%.

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(j) Tube sheet material carbon steel as per ASTM. A516 Grade 70 or SA 350
LF-2 and shall be welded to shell and water box. Tube support plates of
common quality steel of 16mm (min) thickness.

(k) Prevention of super heated steam contact with tube plate and joint at entry to
heaters.

(l) Water box channels to have access openings of minimum 450 mm dia. or of
elliptical shape with minimum size 450 mm x 350 mm. These shall be self
sealing type and bolted design is not acceptable.

(m) Preservation by nitrogen blanketing during shut down.

(n) Minimum tube size and minimum wall thickness after bending shall be as per
applicable codes.

(o) Minimum fouling resistance tube side 0.00004098 hr-m2-deg.C/Kcal and an
additional 0.000061475 hr-m2-deg.C/Kcal on outer tube as per HEI.

(p) Corrosion allowance of 3.2 mm for each heater shell and water box.

(q) Stand pipes with necessary connections for instruments with water level
gauges and isolation valves.

(r) Proper drainage of bled steam lines to be ensured. Each bled steam line to
have ordinary and power assisted NRVs and motorised isolation valves
except for heater mounted in condenser neck.

(s) Adequate baffling to prevent vibration, ensure uniform steam distribution and
free drainage of condensate.

(t) Provision of pass partition plates to facilitate easy removal and access to
tube sheet.

(u) Design to minimise space requirements for tube nest/shell withdrawal as the
case may be.

(v) Provide sentinel relief valve on tube side. Relief valve on shell side sized to
pass flow from two ruptured tubes (four open ends) or 10% of water flow
corresponding to VWO condition with 3% make up and design condenser
pressure at 10% accumulation whichever is higher and set to open at heater
shell design pressure.

5.01.00 Low Pressure Heaters and Drain Cooler

(a) Horizontal and U-tube type with integral drain cooler.
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(b) Shell of rolled steel as per ASTM A-516 Gr. 70 with SS-304 bands at cut
points on shell to prevent damage against flame impingement during torch
cutting.

(c) Water box channel of carbon steel as per ASTM A-516 Gr. 70 and welded to
tube sheet.

(d) Rolled expansion of tubes to tube sheets. Tube shall be cold bent for
fabrication.

(e) Roller support for shell removal of all heaters except for LP heater in
condenser neck and for LP heater in condenser neck roller support for heater
channel during the tube bundle removal.

(f) Straight or U-tube for drain cooler of LP heater installed in condenser neck (if
separate drain cooler offered).

(g) Provision of shell attachments for supports of LPH in condenser neck and
antiflash baffles to protect the turbine from water ingress.

(h) Each of LP heaters and drain cooler shall be capable of handling 110% of
design condensate flow from 2x50% condensate extraction pumps without
undue vibration and deleterious effects.

(i) Provision for differential expansion between shell and tube.

(j) Details of tube sheets, tube to tube sheet joint, tube support plates to be
given. Drain cooler Material of construction shall be identical to other LP
Heaters.

(k) Design pressure:

Tube side - CEP shut off head at 51.5 Hz and full vacuum

Shell side - Not less than Max. Extraction Steam pressure and full
vacuum with minimum design pressure of 3 kg/cm2 (g).

5.02.00 DEAERATOR

(a) Horizontal, spray-cum-tray with integral direct contact vent condenser
mounted on horizontal storage tank.

(b) Alternatively, Spray type STORK or Equivalent with minimum two (2) spray
control valves of disc type or equivalent, in order to ensure fine atomisation of
incoming condensate and rapid heating up by the steam.

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(c) Design and construction as per Indian Boiler Regulations (if applicable),
ASME code for unfired pressure vessels, Section-VIII or any other equivalent
code.

(d) Reinforced wide mesh strainer and antivortex baffles at discharge
connections from deaerator.

(e) Fixed and Saddles support on storage tank.

(f) All pressure parts like shell, heads and nozzles shall be of carbon steel as
per ASTM A-516 Gr. 70. Shell plate min. thickness 15.8mm of welded
construction.

(g) Hardened 400 series stainless steel impingement plates for flashed drain
inlet from HP heaters, BFP recirculation, boiler startup drains etc.

(h) All water spray valves, splash plates, trays, vent condenser and other
elements in contact with undeaerated water or non-condensable gases shall
be of stainless steel SS-304.

(i) Deaerator safety valves of adequate relieving capacity shall be made of 13%
Cr. stainless steel disc and spindle.

(j) Design for efficient steam distribution and deaeration of condensate under all
operating conditions including VWO, 3% m.u., HP-LP bypass, one string/both
strings of HPH out of service.

(k) Floating pressure type. Pegging pressure 3.5 ata during HP-LP bypass
operation, major load rejection, turbine trip and low loads when extraction
steam pressure is less than 3.5 ata. During cold start-up the deaerator
pressure shall be maintained at 1.5 ata with steam from auxiliary steam
header. During hot and warm startup, if boiler startup drain circulation pumps
are in service, deaerator pressure shall be maintained at 3.5 ata. In case
startup drain circulation pumps are not in service and startup drains are
routed through condenser, deaerator pressure shall be maintained 1.5 ata.
Steam supply shall be from auxiliary steam header. Deaerator pressure shall
vary with load when it gets steam from turbine extraction. Design pressure &
temp. shall not be less than extraction /CRH pressure or worst operating
condition with sufficient margins above the same.

(l) Sources for heating:

(1) Extraction steam from turbine IP-LP cross over/ cross-around pipe
(normal operation) or as optimized by the bidder.

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(2) Steam from CRH till extraction steam (normal source) pressure is
available.

(3) Steam from Auxiliary steam header till CRH steam pressure is
available.

(m) Minimum feed water storage tank capacity shall be based on 6 (six) minutes
of BMCR flow (approx.) between normal operating level and low-low level
with a filling factor of 0.66. This capacity shall be exclusive of the volume of
internal piping, baffles and volume of the dished end. It shall be designed for
maximum incoming steam flow when none of the LP heaters are working
under HP/LP bypass condition.

Bidder to take into account the transient operating conditions such as sudden
load throw off, cold condensate entering into the deaerator, low-low water
level in feed water storage tank etc. w.r.t. NPSH requirement of booster
pump while calculating the capacity of feed water storage tank.

(n) Design to withstand full vacuum and pressure decay .

(o) Max. oxygen content shall be 0.005 cc/litre at deaerator outlet measured as
per ASTM-D-888 reference method-A or Indigo carmine method at all
operating conditions.

(p) Free carbon dioxide as measured by APH method shall be non-traceable at
all loads.

(q) Shell thickness corrosion allowance 3.2 mm.

(r) Provision of sparger pipe and nozzle for feed water heating.

(s) Size of vent orifice for one half percent of TMCR extraction steam flow to
deaerator.

5.02.01 Sizing for handling all incoming condensate, HP heater drains etc.

5.02.02 Provision of access platforms and ladders alongwith hand rails on deaerator and
storage tank. Provision of manholes of 450 mm dia (min) on deaerator and storage
tank for access to and removal of internals including trays.

5.03.00 HIGH PRESSURE HEATERS

5.03.01 Design Requirement

(a) 2X50% capacity HP heaters horizontal and U-tube type desuperheating,
condensing and drain cooling sections.
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(b) Shell of carbon steel as per ASTM-516 Gr. 70 and water box channel as per
ASTM A-266 class-II and shall be welded to tube sheet.

(c) Roller supports for shell removal.

(d) Tubes to be welded to tube sheets and then roller expanded.

5.03.02 Design Pressure

(a) Tube side: Discharge pressure of HPHs shall be 105% of discharge
pressure corresponding to emergency point of BFP operation.
However, pressure relief valve across the HPHs shall be
provided, as per the tender drawing, so that HPHs are not
subjected to shut off condition. The HPHs shall be designed
for full vacuum also.

(b) Shell side: Not less than max. extraction steam pressure and full vacuum.
For heaters taking extraction from CRH line, the maximum
expected HPT exhaust pressure shall be taken into account.

5.03.03 Each of HP heaters shall be capable of handling 110% of the design flow from one
BFP without undue vibration and other deleterious effects.

6.00.00 BOILER FEED PUMP

6.01.00 (a) Configuration

2 x 50 % Turbine driven feed pumps (normally working) and 2 X 30 % Motor
driven feed pump (stand by) per unit.

(b) Drives

Constant speed squirrel cage induction motor with hydraulic coupling
between motor and main pump and booster pump at other end of motor for
MDBFP and variable speed turbine drive with suitable coupling between
turbine and main pump and booster pump at other end of turbine with a gear
box for each TDBFP.

(c) Construction Requirements

(1) Main Pump

Horizontal, centrifugal type, multistage, outer casing barrel type with
end rotor removal.

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(2) Booster pump

Single stage, two bearing design and double suction impeller type.
Overhung impeller not acceptable.

(d) Suction and discharge connections

(i) Main pump

Location of suction and discharge connections of TDBFPs on the
bottom of barrel (if located on operating floor). Butt welding type
discharge connections and either butt welding or flanged connection
type suction connection.

(2) Booster pump

Side suction and discharge connections of flanged, weld neck raised
face as per ANSI B16.5.

(e) Shaft Sealing

Mechanical seals for booster pump and main pump.

(f) Pump sizing

(i) TDBFP

(1) Design capacity and design head

Combined flow of 2x50% Turbine driven Boiler feed pumps to be
based on 10% margin over feed flow corresponding to turbine V.W.O.
condition, 3% makeup, design condenser pressure and
corresponding head.

In case continuous over pressure operation of unit is envisaged then
the capability of pump for such an operation shall be verified.

(2) Best efficiency point

Combined flow of 2x50% TDBFPs shall be based on TG unit EMCR
and corresponding head.

(3) Runout point One TDBFP shall be capable of handling
flow and head corresponding to 65% of unit
rated load.

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(4) Emergency point Two Turbine driven feed pumps to be
capable of generating the discharge
pressure not less than 3% over steam
generator highest safety valve set pressure
corresponding to 105% of boiler maximum
continuous rating. MDBFP set should be
designed to meet this condition at 50 Hz
grid frequency. Bidder to note that the
highest saftey valve set pressure in steam
generator is tentatively 305 Kg/cm
2
(g). The
pressure drop between bidder's terminal
point and highest set safety valve shall be
furnished to the successful bidder during
contract execution stage.
(5) Other Capabilities
Combined flow of 2X50% TDBFP shall meet the following:
(a) BMCR flow and head corresponding to rated steam pressure.
(b) V.W.O. output, 3% makeup, worst condenser pressure.
(ii) MDBFP
(1) 2x30% MDBFP shall meet all the above conditions (i.e. (i) (1)
to (5) above) except that the Combined flow of 2x30% Motor
driven Boiler feed pumps shall be 60% of the total flow arrived
for 2x50% TDBFPs. The head developed by MDBFP shall be
calculated in the same way as done for TDBFPs for all the
above conditions so that TDBFPs and MDBFPs can be
operated in parallel.
(2) The conditions corresponding to (i) (5) shall be meet by
MDBFP at 47.5Hz.
(iii) One TDBFP and one MDBFP operating in parallel shall be able to
generate flow -and head corresponding to minimum 95% of unit load.
(iv) Bidder may consider the following for boiler feed pump sizing.
(a) Design discharge flow of each TDBFP - not less than half of
110% of VWO feed water flow. Design discharge flow of each
MDBFP - not less than 60% of the discharge flow of each
TDBFP.
(b) Design discharge pressure for both TDBFP and MDBFP at
boiler feed water piping terminal point in boiler area - 310
Kg/cm
2
(g). (This is tentative and subject to change with 15
Kg/cm
2
)
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(c) Rated discharge flow through interstage bleed off from turbine
driven feed pump for reheater attemperation - not less than 140
T/hr. Rated discharge flow through interstage bleed off from
MDBFP - not less than 60% of the discharge flow through
interstage bleed off from TDBFP.
The above data are tentative. Based on finalisation of boiler
data, which would be furnished during detail engineering stage,
the contractor shall furnish detailed calculations as per design
criteria as specified as per clause no. 6.01.00 (f) (i) to (iii)
above for employer approval. However, Bidder may indicate
cost implication due to variation in Design discharge pressure
at terminal point in relevant schedule of BPS.
Note : Discharge flow of main pump not to include any seal flow,
warm-up flow and balance drum leakage flow.

(g) Motor Rating

The maximum continous motor rating corresponding to maximum cooling
water temperature at cooler inlet not less than the maximum load demand of
driven equipment at its entire range of operation at frequency variations from
47.5 Hz to 51.5 Hz and motor should not be overloaded during any mode of
operation of driven equipment.

(h) NPSH Margin

The ratio between NPSH (A) and NPSH (R) at 3% head drop for booster
pump and main pump shall be not less than 2.5 at design point
corresponding to Low-Low level of deaerator.

(i) Interstage bleed

Interstage bleed tap off for boiler reheater desuperheating preferably from the
lowest available intermediate stage pressure of main pump. (To be finalised
during detail engineering stage).

(j) Trip speed of TDBFP

10% above the design speed of the feed pump.

(k) Performance curve

The characteristic curves of booster pump and main pump should be
continuously rising type with decrease in flow and shut off head shall be in
the range of 115% to 130% of TDH at design point.
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(l) Minimum recirculation

(1) The minimum flow of the booster pump and main pump shall not be
less than 25% of design flow.

(2) ON-OFF type minimum recirculation valve with valve body designed
for 40% of design flow.

(m) Inter-changeability

Identical design of boiler feed pumps, booster pumps, drive turbines, motors,
hydraulic coupling and major equipments in order to provide complete
interchangeability.

(n) Motor drive start up time

Motor shall be able to accelerate the pumps from standby conditions to rated
pumping conditions in less than 15 seconds after receipt of starting signal
while operating either singly or in parallel with other operating pump and
MDBFP and associated auxiliaries to be designed for auto startup on failure
of running equipments/auxiliaries.

(o) MDBFP lube oil system

Common lubricating oil system for BFP, booster pump, motor and hydraulic
coupling complete with shaft driven lube oil pump, AC motor driven auxiliary
oil pump, one full capacity each of working oil cooler / lube oil cooler / oil
filters / strainers, valves, fittings, instruments etc.

(p) Shaft design

Stiff shaft design and minimum internal clearances more than maximum
static shaft deflection.

(q) Critical speed

The first critical speed in water above the speed corresponding to turbine
overspeed trip condition and internal clearances being 150% of new
clearance or 130% of design speed whichever is higher.

(r) First Stage Impeller life

Life due to wear due to cavitation of first stage impeller not less than 40000
running hours.

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(s) Dry running

Capable of accepting complete loss of water due to incidents such as
inadvertent complete closure of suction valve and brought down to rest in
controlled manner from design condition with simultaneous closure of suction
valve.
(t) Clearances between periphery of impeller and casing of boiler feed
pump:

Not less than 4% and 6% of impeller outer diameter for diffuser and volute
type pumps respectively.

(u) Efficiency

Not more than 83% (hot).

(v) First stage suction specific speed

Not in excess of 8000 (US units) and 9500 US units based on 3% head break
down of that impeller of main pump and booster pump respectively at their
respective design point .

(w) TDH per stage

Not to exceed 670 m at design point.

(x) Casing design pressure

TDH at minimum flow and operating at trip speed for TDBFP and TDH at
minimum flow and maximum pump speed at 51.5 Hz for MDBFP under
lowest operating density plus maximum suction pressure at booster pump.

(y) Brinnel Hardness

Casing wear rings Brinnel Hardness 50 points different from that of impeller
wearing surfaces.

(z) Axial thrust

Balancing drum designed to balance 95% of total pump axial thrust.
Balancing disc not acceptable.

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(aa) Thermal shock withstand capabilities

The pump should be design to with stand thermal shock encountered during
the entire operating regime (normal & abnormal) of the unit. Bidder to
substantiate with appropriate document.

(bb) Thrust bearing of booster pump and main pump

Two times the worst thrust under turbine on trip speed for TDBFP and
maximum speed of MDBFP, pump at shut off head and internal clearances
200% of new clearance. Thrust bearing should be suitable for reverse
rotation.

(cc) Base Plate

Fabricated steel base plates shall be as per standard practice of bidder. The
bed plate shall extend under all parts of the equipment from which oil or
water may drip and shall have a raised lip with tapped drain connection with
suitable grout holes.

(dd) Materials :
(a) Main Pump
(i) Barrel:
(ii) Inner casing impellers, stage pieces:
(iii) Wear rings, balancing drum bush:
(iv) Balancing drum:
(v) Pump shaft:

(vi) Shaft sleeves:

(b) Booster pump

(i) Shaft:

(ii) Wearings/Shaft sleeves:

(iii) Casing:

The materials adopted shall be field proven for the rated
parameters. The proposal shall include the schedule of
material indicating chemical composition and designation of
material of above BFP components.

(ee) Applicable Code : HIS (latest edition)

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6.02.00 Operational and maintenance requirement:

(a) Availability/Reliability

The pumps to be designed for the highest practicable degree of availability
and reliability under all conditions of operation such as operation on turning
gear during startup, maximum and minimum temperature of feed water
encountered during operation, abnormal pressure decay in deaerator,
sudden generator load throw off, frequency variations (47.5 Hz to 51.5 Hz),
HP-LP by pass operation etc.

(b) Warm up arrangement

Suitable warm up arrangement (if required) to start the pump rapidly shall be
provided. However, pump should preferably be capable of starting from any
conditions without having any warm up in emergency.

(c) Parallel Operation

Response and Performance characteristics of BFP (MD and TD) shall be
such that while operating in parallel the difference in flow handled by them
and the flow proportionate to their rating corresponding to the load shall not
be more than 5% of flow through any one pump.

(d) Emergency Lubrication of MDBFP

Pressure lubrication (if necessary) of MDBFP at the time of coasting down of
the motor driven boiler feed pump set in the event of AC power failure shall
be arranged by Bidder.

(e) Maximum Flow handling

If Bidder foresees any possibility of the feed pump operating at flow beyond
its maximum flow handling capability due to low system resistance, then
Bidder shall make necessary arrangements to protect the pump from such
high flow condition without any necessity of reducing the plant load.

(f) Cartridge Concept

The inner pump element comprising shaft, impellers, stage casings capable
of being removed and replaced as a unit without disturbing feed piping in not
more than 12 hours and shall be demonstrated by Bidder. Suction, discharge
and interstage bleed connections need not be broken to dismantle the
pumps.

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(g) Handling arrangement

MDBFPs and TDBFPs to be accessible to turbine hall EOT cranes for their
erection and maintenance.

6.03.00 Mechanical Seals

(a) Type : Fully cartridgised design.

(b) Seal face Materials : Not inferior to rotating silicon Carbide and
stationary Carbon seal face combination.

(c) Life : Not less than 20,000 running hours between
overhauls and having dry running withstand
capability as specified.
(d) Supporting system

Each seal to be provided with 2x100% magnetic filters, 2x100% tubular
coolers, Piping, Valves, Control and instrumentation etc. Each cooler to be
designed with margin of 20% over worst condition of heat generated in seals.
Further in case of AC power failure, seal should be able to withstand without
cooling water.

6.04.00 GEAR BOXES

(1) Type

Double helical gear by hobbing process, dynamically balance. The high
speed pinion of heat treated forged steel with integral shaft and low speed
gear of forged steel keyed to the input shaft. The gear casing shall be
horizontally split and accurately machined to provide oil tight joints. The
gears shall be enclosed in an oil and dust proof gear casing made of grained
cast iron or fabricated steel. Oil used to be same as for the pump, motor and
turbine and supplied from pump lubrication system. Gear to be designed for
continuous service.

(2) Instrumentation

Two oil level gauges, drain fill vent thermometer dipstick with approved
mounting valves, fitting etc. on gear casing.

(3) Service Factor

MDBFP (combined gearing/Hydraulic coupling) ........ 1.4

Between turbine drive and booster pump ......... 2.0
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(4) Bearings

Gear box with separate thrust bearings to meet worst duty conditions.
Bearings shall be of split sleeve type bronze backed with a high grade
centrifugally cast Tin-base babbit lining. Gear journal bearing shall have
babbitted thrust faces next to the gear to act as locating surfaces for the gear
train.

(5) Applicable Code : AGMA 420 and 421 (Latest)

6.05.00 HYDRAULIC COUPLING

(1) Type

Combined fluid Coupling/Gear box type, Electric actuator and linkages
alongwith necessary amplifier units.

(2) Rating

Adequately rated to meet the requirement of pump characteristics while
operating in the range of capacities specified.

(3) Material and other accessories

Complete with stainless steel impellers and casing, self supported double
duty roller bearings, pillow blocks and Kingsbury or Mitchell thrust bearing or
proven thrust bearing as per bidder's standard practice for input/output with
removable Covers, oil sump, duplex filters to remove all particles upto 25
microns, oil temperature and pressure gauges, Control pump for oil
regulation if provided, regulating Valves, stainless steel scoop tube, 1x100%
lube oil cooler, 1x100% Working oil cooler, one portable type oil purifier per
station of adequate capacity to be included to form the centralized lubrication
system for MDBFP set. The specification and capacity of portable type oil
purifier shall be as specified in drive turbine section.

6.06.00 OTHER COUPLINGS

Either flexible Metal diaphragm type coupling designed to limit the rotor end play with
spacer or flexible gear coupling as per standard practice of the manufacturer shall be
provided.

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6.07.00 OIL COOLERS

(1) Type

Tube bundle of removable type and tubes to be roller expanded and flared at
the ends.

(2) Material

Tubes of type 304 stainless steel and shell of mild steel construction.
Suitable Corrosion allowance shall be added to all carbon steel and iron parts
including shell, flanges etc.

(3) Rating

Adequately rated with suitable fouling allowance in accordance with TEMA
with necessary arrangements for changing over the cooler without
interrupting the oil flow.

(4) Cooling Arrangement

Cooling medium shall be demineralized water taken from closed loop cooling
system. Cooling medium shall flow in tube side.

(5) Instruments

Connections alongwith temperature and pressure indicators on inlet and
outlet branches of the water side and also on the shell side of each Coolers.
Adequate draining and venting of all parts of cooler.

6.08.00 DRIVE TURBINE:

6.08.01 Type

Dual admission type or Single admission type with an external control valve, single
cylinder, condensing type.

6.08.02 Casing

(a) To withstand the maximum pressure and temperature likely to be subjected
during normal operation and 25% over rated pressure for short term duration.

(b) Symmetrical to maintain thermal balance.

(c) Uniform shape and thickness and free from sharp corners.

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(d) Provision to be made to take care of the effects of temperature changes on
the alignment of the rotating parts relative to the casing and glands and free
movement of casing due to expansion, both longitudinal and transverse.

(e) To permit inspection of the main bearings without dismantling the casing.

(f) Horizontally split at the centre line for raising and lowering the upper halves
and rotor to clear off remainder of machine.

(g) Horizontal casing joint to be made tight with metal to metal contact. Gasket or
grooves not acceptable.

(h) Horizontal joint bolts to be heat tightened and necessary bolt heating
equipment and accessories (if required) to be made available by Bidder.
(i) Control valve chest to be an integral part of the drive turbine.
6.08.03 Drive Turbine Rotor
(a) Forged steel, heat treated, accurately machined and proportioned in order to
keep critical speed away from operating speed.
(b) Statically and dynamically balanced rotor.
(c) Turbine blading designed to have a high efficiency of energy conversion,
consistent with low loading, stressing and vibration consideration to ensure
high degree of availability.
(d) All nozzles and blading in steam path to be of corrosion and erosion resisting
alloy steel suitable for temperature encountered.
(e) Rotor blading shall be securely fixed and readily renewable type.
(f) Blading to be designed to minimise the blade end leakages.
(g) Turbine blading to operate smoothly over the operating speed range and
natural and harmonic frequency of vibration of last few rows of blades shall
be such that they are well outside the operating range so as to avoid
resonant vibrations.
6.08.04 Drive turbine stop control valve
(a) Valves to be arranged to close through a trip device actuated either by over
speed governor or by action of other protective devices.
(b) Stop Valves to be provided with removable stainless steel steam strainer for
normal operation and one additional strainer element shall be provided for
initial operation.
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(c) Valves to be provided with removable internals to allow for steam blowing.
(d) Valves to be designed to resist erosion due to steam flow and to be stable
and not to vibrate over entire operating range.
(e) Control valves to be designed to provide the required steam flow control
when operating in conjunction with turbine governing system as specified
elsewhere.
(f) Control valves and their seats to have stellite inlays with their stem hardened.
Alternatively, bidder may offer nitriding for seats and stems, if it is suitable for
maximum encountered temperature.
(g) Stop valves to have provision for on load testing.
(h) Inlet to control/stop valve to be flanged.

6.08.05 Bearings

(a) The bearing to be designed to avoid oil whip. Bearings to be spherically
seated, horizontally divided type, with provision of adjustment and alignment
of rotor, forced feed lubricated type, lined with babbit or suitable antifriction
alloy. Thrust bearing of the Kingsbury or equivalent with pad type.

(b) Bearings to be arranged so that these are outside drive turbine for readily
accessibility. Lower half of bearing to be capable of being removed and
replaced by minimum lifting of Shaft.

6.08.06 Turning gear

(a) Drive turbine to be provided with an adequately sized AC motor driven or
hydraulically operated turning gear for rotation of complete TDBFP train i.e.
booster pump, gear box, drive turbine and main pump while unit being
started or taken out of service.

(b) Turning gear shall be so arranged that drive gear is engaged manually by
means of external lever while turbine is at rest. When steam is admitted to
the turbine drive and its speed reaches beyond turning speed, its gear shall
automatically disengage and latch in a disengaged position.

(c) Necessary interlock shall be provided to prevent the starting of turning gear
motor and shall trip on loss of lube pressure and should have provision of
starting from the control room.

(d) Hand barring gear shall be provided for manually rotating the drive turbine in
an emergency. The lube oil shall be made available to the bearing during
such operation.
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6.08.07 Drive turbine Lubricating oil system

(a) Each drive turbine shall be provided with a complete lubricating oil system
which shall provide lube oil for drive turbine, main pump, booster pump and
couplings and shall also cater the control oil of governing system and turning
gear oil requirements. The lube oil system shall consist of

- One AC motor driven main oil pump

- One AC motor driven auxiliary oil pump

- Two full capacity oil coolers as specified in clause no. 6.07.00- of this
chapter

- Oil reservoir with five minutes retention time.

- An oil conditioning centrifuge of type as specified at clause no
1.18.00(b) of this chapter above except moisture at outlet of purifying
system not more than 0.05% by volume.

- One DC motor driven emergency oil pump for bearings oil
requirements only.

- Duplex type full capacity oil filters of cartridge type with automatic
bypass facility.

- 2x100% AC motor driven oil vapour extractors.

- One full capacity AC motor driven jacking oil pump (if required).

- Other accessories to render the system complete.

(b) It is preferable to have quality of lube oil/working oil for MDBFP and TDBFP
identical to that of main turbine lube oil quality.

(c) Suitably sized hydraulic accumulators shall be provided in governing oil
system to maintain system pressure, when there is a change over from one
running pump to stand by oil pump. Also provision shall be made for initial air
purging of the governor system.

(d) Type test(s) to be conducted

Particle size impurities test, as detailed out in the technical specification, is to
be carried out on one oil centrifuge of BFP drive turbine.

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6.08.08 Turbine exhaust pipe

Separately piped to the main condenser of main TG unit in the downward direction.

Alternatively bidder can also offer separate condenser for the drive turbine. In such
case all requirements, as applicable for the Main Condenser, Condenser air
evacuation system and Condenser on load tube cleaning system shall also be
applicable for the Condenser for BFP drive turbine, except the following:

a) Condenser shall be designed for the maximum heat load envisaged under
various modes of operation.

b) Provision of LP heater in condenser neck is not applicable.

c) Connections for HP-LP Bypass discharge, heater drains & vents, boiler
separator drains, makeup are not applicable.

d) 2 x 100% Condensate extraction pumps shall be provided for removal of
condensate from condenser of BFP drive turbine to main condenser.

Capacity of Condenser Air Evacuation Pumps for Condenser of BFP drive turbine
shall be as per latest HEI.

6.08.09 Codes

Design of drive turbines generally in accordance with API 612 and 614 except as
modified here in and proven practice of the manufacturer and also generally followed
in thermal power plants and testing in accordance with ASME PTC-6.

6.08.10 Blades tuning

Turbine blades, in particular last stage blades to be independently tuned to keep the
blade resonant frequencies away from operating speed.

6.08.11 Turbine to be designed for protection against water induction. All drains consisting of
motorised drain valves with isolating valves and drain piping for connection to drain
flash tank for warming up drains before and after valve seats, casing drains. Gland
steam system drain, IP extraction CRH and auxiliary steam lines alongwith
necessary controls.

6.08.12 Last stage blading of turbine to be designed for protection against erosion/corrosion
by moisture.

6.08.13 Turbine to be designed for electro hydraulic control system to control speed from 0%
to 100%. It shall be of the type which provides continuous corrective action until
equilibrium conditions are obtained in response to changes in external signals or
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speed change resulting from other causes, such as changes in energy of the steam
available to a turbine during sudden load pick ups or rejection on the main turbine
generator unit. The system shall ensure controlled accelerating of the drive turbine
and shall prevent over speed without tripping of the equipment under any operating
condition or in the event of maximum load rejection.

6.08.14 Operational Requirement

(a) Drive turbine of BFP shall get normal motive steam from IP-LP
crossover/cross around pipe or from a point as per optimized cycle of bidder
during operation of turbine from full load to 60% EMCR load or below, if
possible.

(b) During low unit load conditions, turbine bypass operation, shutdown
operation when extraction pressure of the normal motive steam source is
insufficient to operate the drive turbine, steam from alternate source, from the
same unit, shall be admitted through a separate set of stop and control
valves. Both sets of control valve to be controlled by electro hydraulic
governing system. Bidder can offer single admission turbine with an external
control valve (to be operated from the governing system).

(c) An additional alternate source of steam from other unit shall be provided by
the bidder for Drive turbine of BFP for cold/ hot start of boiler (in case
MDBFP is inoperative). For this additional alternate source during startup,
bidder may opt for the auxiliary steam supply at parameters 16 ata/310 C at
high temperature header, if the auxiliary steam parameter suits the drive
turbine requirement. Bidder may however note that it is not envisaged to start
the unit with TDBFP when auxiliary steam is available only from auxiliary
boiler at 210 C.

(d) All other auxiliaries to be designed for auto start-up on tripping of running
auxiliaries.

6.09.00 STRAINERS AT BOOSTER PUMP AND BOILER FEED PUMP

(a) Strainer body simplex and cylindrical pipe

(b) The clear area of strainer to be five times the inlet cross sectional area of
connecting piping.

(c) Strainer to be constructed 16 gauge perforated stainless steel (304 grade)
and lined with stainless steel (316 grade) screen.

(d) At design flow and clean condition, Pressure drop not to exceed 0.1 Kg/cm2.

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(e) At design flow and 50% clogged condition, Pressure drop not to exceed 0.15
kg/cm2.

(f) Strainer design to permit ease of inspection and cleanliness.

6.10.00 Type Test(s) to be conducted

Following type tests as detailed in QA portion of the technical specification to be
carried out;

(i) NPSH (R) Test on one BFP and one BP

(ii) Pressure pulsation test on one BFP

(iii) Dry running withstand capability test on one BFP and preferably with
corresponding BP.

(iv) Axial thrust measurement on one BFP

(v) Visual cavitation test on one BFP

(vi) Complete strip down test of BFP which undergone above tests

(vii) Pressure drop test on one strainer for each type and size

7.00.00 TURBINE HALL EOT CRANE:

(i) RATING
(a) Capacity Two (2) number of Electrically operated
overhead travelling cranes shall be provided.
Each crane shall be capable of lifting at least
105% of the weight of single heaviest
component/ equipment, including lifting beam
and slings etc. (as applicable) to be handled in
TG hall for erection as well as maintenance of
the equipment provided in AB bay.
In addition, it shall also be possible to handle
Generator Stator with tandem operation of two
Turbine hall EOT cranes for which necessary
arrangements shall be provided. In such case,
the combined capacity of two EOT cranes shall
not be less than the 105% of weight of
Generator Stator, including the weight of lifting
beam with swiveling arrangement and slings.
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(b) Auxiliary Hoist Not less than 20 Tonne
Capacity

(c) Crane span To suit the span of turbine hall
(i.e. centre to
centre of rail tracks)

(d) Total height of crane Top most level of crane w.r.t. the top of
runway rail level not to exceed 4.5m

(e) Main/Aux. hook To suit handling requirements of equipment
levels (Above operat-
ing floor level &
below ground floor
level)

(f) Top of Rail To be confirmed by the vendor
Elevation

(g) Approximate max.
full load speeds

- Main Hoist 1.6 m/min

- Auxiliary Hoist 7.5 m/min.

- Trolley travel 15.0 m/min.

- Crane travel 30.0 m/min.

(h) Creep speed of 10% of max. speed
main hook and
auxiliary hook

(i) Creep speed for 10% of the maximum speed
cross travel and
long travel

(ii) Type

Electrically operated indoor travelling type.

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(iii) Applicable codes

(a) Design and duty of crane structure, main hoist, auxiliary hoist, cross
travel, long travel in accordance with class M5 of IS: 3177 (latest
edition).

(b) All other structure of cranes in accordance with IS-807.

(c) Main hook Ramshorn type conforming to BS:3017 (latest edition) or
equivalent Indian standard and auxiliary hook shank type conforming
to IS 15560 (latest edition)

(iv) Bridge structure

(a) Vertical deflection caused by safe working load and weight of trolley
in central position not to exceed 1/900 of the span.

(b) Trolley stops of spring type to be mounted independently on bridge
rails to prevent trolley from running off.

(v) Buffer

(a) Suitable buffer to be fitted to each end of carriage assembly and crab.

(b) Buffers to be designed to bring the loaded crane to rest from a speed
of 50% of the rated speed.

(vi) End trucks, wheels and axles

To be designed in accordance to IS: 3177 (latest edition)

(vii) Bridge and trolley drive Mechanism

(a) One drive at each end of bridge.

(b) One drive for trolley drive.

(viii) Operator's cabin and platform

(a) Open type for indoor service to be located at B-row column. Cabin
shall be designed as per IS3177 so as to have unrestrictive view of
load from operator's cabin.

(b) The area of cabin to be 2500/1850 mm with a head room of 2000
mm.

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(c) A foot operated electric warning horn of double bell type suitable for
240 V AC. of noise level 95 dBA at 3.5 m.

(d) One brass gong suspended outside the Cabin and operated from
inside.

(e) A distinct type alarm with conspicuous warning lights on either side of
the crane bridge to indicate overloading of crane.

(f) Adequate carbon dioxide gas cylinders of 4.5 Kg.

(g) One non oscillating ventilating fan.

(h) Suitable inspection cages to accommodate two persons to facilitate
inspection of down shop lead.

(i) Access walkways of not less than 800 mm (clear) with hand railing of
height of 1100 mm along the both side of bridge girder and cross over
walkways.

(ix) Drums

To be in accordance with IS-3177 (latest edition).

(x) Lifting tackles

(a) Main hook of Ramshorn type conforming to BS: 3017 (latest edition)

(b) Auxiliary hook of shank type conforming to IS 15560 (latest edition).

(c) Wire rope of extra flexible plough steel and of 6/36 or 6/37
construction conforming to IS: 2266 (latest edition).

(xi) Bearings and lubrication

(a) The type of bearings for various parts as per IS:3177 (latest).

(b) Bearing life not less than 10,000 working hours.

(c) Centralised grease lubrication with hand operated grease pump for all
bearings as per bidder's standard proven practice.

(xii) Guarding

(a) Suitable guard to push forward or off the rail track any object placed
across.
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(b) Suitable guards to live electrical wirings downshop lead.

(c) Other guarding as per relevant standard.

(xiii) Safety

(a) Suitable anti-collision device of two cranes, alongwith stoppers at
both the gable ends.

(b) To meet the requirements of Factories Act.

(xiv) Runway/trolley Rails and rail joints

Rails to be as per relevant Indian Standard and joints to be butt welded by
thermit welding or fusion welding.

(xv) Brakes

2 X 100 % Brake shall be provided for each motion. Each brake for hoisting
motion, cross travel, long travel etc., shall be designed as per following:

Brakes to be as per IS 3177. The Capacity of hoisting motion brakes to be
150% of torque transmitted to the brake drum with full load and that of cross
travel and long travel to be 125% of motor rated torque before deaerating.

(xvi) Common lifting beam for generator stator

a) Suitable common lifting beam for lifting generator stator by means of
two cranes operating in conjunction with suitable swiveling
arrangement.

b) A suitable indicating device to indicate the difference in the lifts of the
two cranes, which shall be limited to 500 mm shall be provided on the
lifting beam. The level difference indication shall be visible from
ground level.

c) A limit switch shall be provided to give alarm at both the cabins to
enable the crane operators to control the level difference within
500mm.
The bidder shall furnish the GA drawing of the beam designed and
proposed to be furnished by him showing all the dimensions,
constructional details, details of crane hooks to the beam etc
alongwith the bid. The design calculation for the lifting beam shall be
submitted for approval before taking up the fabrication.
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7.01.00 Motors

Three phase Squirrel Cage Induction motors to be operated from VFD system shall
be suitable for speed range and torque without exceeding temperature rise limits as
specified elsewhere in this specification. These motors shall be provided with VPI
insulation and insulated bearing on one side and shall be suitable for Inverter duty.

Motors shall conform to latest revision of IS 325, IS 3177 and motor subsection of
this specification.

7.02.00 Controls

i) Speed control of EOT crane shall be through Variable Voltage Variable
Frequency System (VVVF) with minimum 6 (six) pulse design.

ii) Necessary input & output devices to be provided to reduce harmonics, as per
IEE519, at supply side of the drive at the switchgear.

iii) All necessary protections e.g. Input Phase Loss, Earth Fault, Over Voltage,
Output Short Circuit, Load Loss, Input Transient Protection, Overload etc to
be provided.

iv) VVVF system shall be capable of generating suitable starting torque (upto
400% typical) with / without encoder, however starting current shall not
exceed 150% of the rated torque.

v) VVVF system shall be capable of withstanding upto 50 deg C ambient temp
without derating

vi) Provision for controlling the motion from operator cabin as well as remote
control shall be available.

vii) Squirrel cage Induction motor with VPI insulation shall be provided With
VVVF system.

viii) Master controller - Desk type having following features.

(i) Five speed control points in each direction of hoist motion.

(ii) Four speed control points in each direction of bridge and trolley
motion.

(iii) Release of operator's hand from the controls shall stop motion and
set brakes automatically.

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ix) Protective Panel

Provided with isolating switch, power contactor control and indication to
switch ON/OFF power to starter panels, control and lighting transformer.

x) Starter Panel

Separate VVVF system panels to be provided for CT, LT and hoist motion
(main and auxiliary drives).

a) Contactors : AC 4 duty for reversing application AC 3 duty for non
reversing application

b) Switches: AC 23 for motor application, AC 22 for other application.

c) Fuses: HRC

d) Overload relay : Temperature compensated, bimetallic with single
phasing preventor.

xi) Panel shall be fabricated out of 1.6 mm thick rolled sheet steel. IP 52 degree
of protection. Paint shade shall be RAL 9002 for front & rear and RAL 5012
for side covers. Space heaters to be provided.

7.03.00 Radio remote Control of EOT Crane:

i) The equipment should have facility to control EOT crane by radio frequency
based wireless remote unit. The equipment should be supplied with
transmitter unit, receiver unit, encoder unit, decoder unit, interface panel,
coupling system, battery unit and any other control gear if required.

ii) The equipment should be based upon the microprocessor based digital
technology with almost nil hard wiring.

iii) The remote unit should communicate up to the distance of approximately 100
meters.

iv) The system has to integrate with the control system of crane, which operates
at 110 V AC, Single phase.

v) The remote unit should have transmitter which can be mounted on shoulder
by suitable belt. Main controls can be of single joystick movement or double
joystick movement type stepped control with spring return. The Micro control
should be toggle switch type or push control type.

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vi) Frequency allotment for radio remote unit from Govt. of India, Deptt. of
Telecommunication or any other agency shall be the responsibility of
supplier.

vii) The transmitter and receiver unit should have its own frequency and address
code with each system having its own security code so that one particular set
becomes unique and there is no interference from any other remote unit
device. A microprocessor should check all security codes. The processor
should have its own watchdog circuit. The receiver FM band should be
sufficiently narrow to allow only passing of desired frequency and valid
command. Any error should shut down the system immediately.

viii) The remote unit should have safety key to prevent any unauthorized
operation. All the crane operations should stop at once the communication
break down occurs.

ix) On local unit (receiver side), the system should be provided with one selector
switch so that EOT crane can be operated either from Operator cabin or
radio remote unit.

x) In case tandem operation is envisaged, a suitable selector switch shall be
provided in the cabin for selection of Tandem/normal operation.

xi) The receiver unit along with I/O interface unit should be able to bear the
vibrations and shocks encountered in normal usage of EOT crane.

xii) The system should have very fast response time.

7.04.00 Power Supply

(a) Incoming numbers: Employer shall provide two (2) numbers 415 volts, 3
phase, 4 wire supply at operating floor near A-row column at centre of bay
length. Bidder shall provide a changeover switch in enclosure to receive
above power supply.

(b) Down shop Lead (DSL):

(i) Shall conform to IS : 282 and shall be sized to

- Cater to all cranes working simultaneously with 40% cyclic
duration factor for load.

- Limit voltage drop at motor terminals within 2% at extreme
positions.

(ii) DSL shall be sized with a margin of 10% over load requirement.
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(iii) Protective cover over DSL to be provided.

(iv) Two (2) numbers isolating switches in enclosure shall be provided at
extreme ends of operating floor for disconnecting supply to DSL while
maintaining the crane.

(v) DSL shall be located on 'A' -row side.

(c) Transformers

Dry type, with insulation class B or better. Following transformers shall be
provided.

(i) Control Transformers : 2x100%, 415V / 110V

(ii) Lighting Transformers : One 415V/240V

(iii) Hand lamp : One 415V/24V

7.05.00 Illumination

HPSV lamps under the bridge. Florescent lamp over the bridge and inside thecabin.

7.06.00 CABLES

(a) EPR insulated, copper conductor trailing cables, as per IS:9968, on the
bridge.

(b) Extruded PVC insulated, copper/Aluminium conductor, 1100 Volt grade
power cables. This shall include cable lengths between changeover switch &
DSL and isolating switch & DSL.

(c) Extruded PVC insulated, copper conductor 1100 volt grade control cables.

7.07.00 Mechanical overload protection - to be provided for hoist mode.

7.08.00 MAXIMUM SPAN/DEPTH RATIO FOR GIRDER:

(a) Plate girders : 18

(b) Lattice girders : 12

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7.09.00 Material

(i) Structural steel plates : Mild steel, grade 'B' of IS 2062 in 100% killed,
rolled section normalised and ultrasonically tested quality or
high strength steel of IS 8500 as appropriate

(ii) Nuts & Bolts : As per IS:1363, IS:1364 and IS:1367. High
Tension
Friction grip bolts as per IS : 3757. High Tension
Friction grip nuts as per IS : 6623.
(iii) Electrodes : Radiography quality, covered electrodes with
heavy covering as per IS : 814 and relevant
requirements of ASME Sec. IX and IIC. Bare
Electrodes as per IS:7280 and flux wire
combination as per IS : 3613.
(iv) Chequered plates : IS: 3502 (Minimum 6 mm thick O/P)
(v) Hand rail pipes : 32 mm NB Medium class of IS : 1161 having top
and bottom rail at height of 1050 mm and 600 mm
and vertical post spacing not exceeding 1500 mm
with provision of kick plate(100 mm high and 6
mm thick).
(vi) Crane Rails : As per IS : 3443 Grade 50 C 12.

7.10.00 Minimum thickness of Structure Members:

(a) Load Carrying members : 8 mm

(b) Tubes with both ends sealed : 4.9 mm (6 SWG)

(c) Tubes with unsealed ends : 8 mm

(d) Chequered plate : 6 mm O/P

8.00.00 PRECOMMISSIONING ACTIVITIES

The pre-commissioning activities including some of the important checks & tests for
certain major equipment/ systems are mentioned under respective equipments,
although it is the Contractor's responsibility to draw up a detailed sequential &
systematic list of checks / tests and various activities / procedures connected with
pre-commissioning of the complete facilities with all systems, sub-systems and
equipment supplied and installed by him and get the same approved by the
Employer.

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9.00.00 COMMISSIONING OF FACILITIES

Upon completion of pre-commissioning activities/test the Contractor shall initiate
commissioning of facilities. During commissioning the Contractor shall carryout
system checking and reliability trials on various parts of the facilities.

Contractor shall carry out these checks/tests at site to prove to the Employer that
each equipment of the supply complies with requirements stipulated and is installed
in accordance with requirements specified. Before the plant is put into initial
operation the Contractor shall be required to conduct test to demonstrate to the
Employer that each item of the plant is capable of correctly performing the functions
for which it was specified and its performance, parameters etc. are as per the
specified/approved values. These tests may be conducted concurrently with those
required under commissioning sequence.

10.00.00 NOISE LEVEL

In case the noise level pertaining to equipments covered under the scope exceeds
the specified values, as given in relevant clause of General Technical requirement
portion of Technical Specification, suitable acoustic enclosures alongwith all
accessories in order to complete the system shall be provided to achieve the
specified values. The acoustic enclosures & accessories shall be designed as per
internationally accepted standards and shall be subject to Employer's approval.

11.00.00 INSULATION

(a) Bidder shall provide insulation for all equipments, valves, piping etc. with
surface temperature more than 60
o
C. The insulation and sheet covering
should be so designed and erected as to provide easy accessibility to parts
requiring frequent inspection.

(b) The density of the mineral fiber felt shall be carefully controlled at about 200
kg/m and the thermal conductivity of mineral wool shall be 0.052kcal/m. hr.
o
C at mean temperature.

(c) The mineral wool shall be capable of passing standard combustibility test,
both immediately after application and also after being subjected to its
maximum operating temperature for not less than 100 hours. The mineral
wool shall be free from objectionable odour at the ambient conditions in
which it is used. The mineral wool shall not contain substances, which will
support pests or encourage growth of fungi. The mineral wool shall not suffer
permanent deterioration as a result of contact with moisture due to
condensation. The mineral wool shall not suffer quality deterioration under
the specified conditions of use. In this connection, both hot and cold face
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temperatures are relevant. The mineral wool shall be capable of being
applied to the surface concerned without causing corrosion of the surface
being insulated or the cladding on it under normal site conditions.

(d) The temperature difference between the cold face of finished insulation and
ambient shall not be more than 20
o
C. The ambient temperature shall be
considered as 40
o
C.

12.00.00 AVAILABILITY REQUIREMENTS OF TG AND AUXILIARIES

The steam turbine generator unit and auxiliaries shall be designed for maximum
reliability and availability, operability and maintainability particularly in respect of the
following:

12.01.00 All equipment and systems shall be of proven design, using proven materials with
well established physical and chemical properties and as appropriate to the service
as intended.

12.02.00 The steam turbine generator unit and its auxiliaries shall be suitably designed and
provided with required instrumentation for rapid starting, loading and unloading
without causing undue vibration, distortion, differential expansion or producing
excessive thermal stresses. Complete technical data including criteria for thermal
stresses, cyclic loading, thermal fatigue, together with values of thermal stresses at
critical locations shall be furnished to establish the suitability of design for cyclic and
two shift operation.

12.03.00 The steam turbine generator unit alongwith auxiliaries is normally expected to
operate in sliding pressure mode from rated pressure down to 40% of rated pressure
in conjunction with steam generator, HP-LP bypass system and plant
instrumentation and control system.

12.04.00 All stand-by auxiliaries shall be designed for auto start up, on failure of running
auxiliaries with minimum time delay and without runback on unit load.

12.05.00 Adequate maintenance facilities shall be provided as required for assembly,
disassembly, alignment work particularly in respect of HP barrel, casing, inner and
outer casings, diaphragm glands, steam valves, journal bearings, thrust bearings,
turbine rotors, generator rotor, particularly end rings, shaft seals, generator bearings,
hydrogen coolers, condenser waterbox, vacuum pumps, condensate extraction
pumps and boiler feed pump catridges, BFP drive turbines, regenerative feed
heaters, turbine oil coolers and pumps, etc. The offer shall give details like
components requiring replacement or repairs during the life cycle of the plant,
meantime between failures and list of tasks to be carried out during major overhauls.

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13.00.00 TYPE TESTS

13.01.01 The contractor shall carry out the type tests as listed in the " TYPE TEST(S) TO BE
CONDUCTED" on the equipment mentioned therein. The Bidder shall indicate the
charges for each of these type tests separately in the relevant schedule of BPS and
the same shall be considered for the evaluation of the Bids. The type test charges
shall be paid only for the test(s) actually conducted successfully under this contract
and upon certification by the Employer's Engineer.

13.01.02 The type tests shall be carried out in presence of the Employer's representative, for
which minimum 15 days notice shall be given by the Contractor. The Contractor shall
obtain the Employer's approval for the type test procedure before conducting the
type test. The type test procedure shall clearly specify the test set-up, instruments to
be used, procedure, acceptance norms, recording of different parameters, interval of
recording, precautions to be taken etc. for the type test(s) to be carried out.

13.01.03 Irrespective of the requirement of conducting the type tests under this contract, the
Contractor shall submit the reports of the type tests listed in the " TYPE TEST(S) TO
BE CONDUCTED" and carried out within last five years from the date of bid
opening. These reports should be for the tests conducted on the equipment same
(model / type / size / rating) to those proposed to be supplied under this contract and
the test(s) should have been either conducted at an independent laboratory or
should have been witnessed by a client. The Employer reserves the right to waive
conducting of any or all of the specified type tests under this contract, in which case
the type test charges shall not be payable for the type tests waived by the Employer.

14.00.00 PAINTING

a) All un-insulated equipments, pipes, valves etc covered in this sub-section shall
be painted with paint not inferior to Epoxy resin based paints with minimum DFT
of 150 micron.
The paint shall be applied in three stages i.e primer, intermediate and finish
coats in following manner.

Primer coat -Epoxy based Zinc phosphate

Intermediate- Epoxy based TiO2 pigmented coat

Finish Coat- Epoxy based Finish coat.

b) Equipment, pipes etc with high temperature shall be painted with Heat Resistant
Aluminium Paint (to be selected based on the service condition of component as
per IS-13183). Two coats of paint shall be applied with total DFT 40 microns.

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c) Surface Preparation before painting shall be carried out according to requirement
indicated in Sub Section A-9 (Power Cycle Piping) of Part-B and international
standard.

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ANNEXURE-I

Other conditions for computing heat balance diagrams:

1. Throttle steam pressure Kg/cm2(abs) 247

2. Throttle steam temperature deg. C 565

3. Reheat steam temperature deg. C 593

4. Worst pressure in the condenser mm Hg (abs) 89

5. Design condenser pressure mm Hg (abs) 77

6. Make up water % throttle flow 3.0
(as applicable)

7. Quantity of steam tapped off from t/hr. 13 (normal)
cold reheat line for meeting normal (tentative)
auxiliary steam requirement

8. Final feed water temperature deg. C To be optimised
optimised at 100% TMCR by the Bidder in
the range
287.5 2.5
O
C

9. Pressure drop in the reheat % of HP turbine 10.0 (maximum)
circuit (from HP turbine exhaust exhaust
flange to IP turbine inlet) pressure
(Refer Note -11 below)

10. HPT Exhaust Pressure Kg/cm2 (abs) 56 5

11. Design pressure drop in :

(i) All extraction steam lines % of the 5 (maximum)
except to the deaerating pressure (abs) at
heater the turbine
extraction flange

(ii) Steam extraction line to -- do -- 8 (maximum)
deaerator

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(iii) Steam extraction line to -- do -- 12 (maximum)
boiler feed pump drive turbine

12. Feed Water Pressure at economiser inlet (Bidder's terminal point)

(i) At 105% TMCR (693 MW) Kg/cm(abs) 300
Unit load

(ii) At 100% TMCR (660 MW) Kg/cm(abs) 295
unit load under modified
sliding pressure operation.

Note :

(1) The above mentioned values of final feed water temperature and pressure
drop in reheater circuit and extraction lines shall be at the heat rate
guarantee point of 660 MW output at 77 mm Hg back pressure and 0%
make-up.

(2) During H.P./L.P. bypass operation, the source of steam supply of deaerator
shall be from cold reheat line and the deaerator shall be pegged at 3.5
Kg/Cm2 (abs). For heat balance diagrams and for sizing of the HP-LP
bypass system, no steam shall be tapped off for any of the feed water
heaters other than the deaerator.

(3) The heat balances with zero percent make up shall be computed without any
auxiliary steam tapped off from CRH line. Other heat balances with 3% cycle
make-up shall be computed with 13 T/hr. of steam tapped off from CRH line
for meeting auxiliary steam requirements of the unit.

(4) The auxiliary steam drawn off from CRH line shall be treated as loss from the
cycle which in turn shall be made up in the condenser hot well.

(5) The temperature of make up water shall be taken same as that of the hot well
condensate under any load condition.

(6) In the sliding pressure mode of operation the throttle pressure will slide down
from rated pressure to a value corresponding to 40% of rated pressure. For
computing heat balance for sliding pressure mode of operation at 80%, 70%,
60%, 50% & 30% of Unit rated load, rated temperature of 565 deg.C and 593
deg.C shall be used for main steam and hot reheat steam respectively.

(7) Tentative figures wherever indicated are for the purpose of preparing heat
balance diagrams.

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(8) The 3% make-up to the cycle will be 3% of the main steam flow at HP turbine
inlet. For the purpose of computation of heat and mass balance with 3%
cycle make-up the difference of the mass flow between the make-up and the
mass of steam drawn from CRH for auxiliary steam shall be assumed to be
lost from the cycle as feed water down stream of the top HP heater.

(9) It may be noted that the heat balance diagrams and guarantees shall be
furnished considering zero spray water quantity for superheater and reheater
spray. During Performance Guarantee Testing, in case water is required for
superheater and/or reheater temperature control, the contractor shall be
entitled to heat rate correction as per correction curves to be submitted by
him with his offer.

(10) Feed water pressure at economiser inlet (Bidder's terminal point) to be
considered for computation of the guaranteed heat rate and computation of
heat balance diagrams for guarantee conditions, shall be as tabulated under
Sl.No. 12 (i) & (ii) above. Bidder shall be entitled of heat rate correction for
variation in feed water pressure at economiser inlet (from the values
tabulated above) as per correction curves to be submitted alongwith his offer.

For computation of heat balance diagrams for all other sliding pressure
conditions, values of feed water pressure at economiser inlet (Bidder's
terminal point) is to be read from the curve attached at Annexure-III.

(11) Pressure drop across reheat circuit specified above at point no- 9 of 'Other
conditions for computing heat balance diagrams' is inclusive of pressure
drop across CRH NRV. For arriving at pressure drop across reheat circuit,
pressure drop across CRH NRV has been considered 0.4% of HPT exhaust
pressure. If the pressure drop across CRH NRV envisaged by the bidder is
more than 0.4% of HPT exhaust pressure, then bidder shall increase the
pressure drop to be considered in reheat circuit accordingly for HBD.

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ANNEXURE-II

1. Condenser Design Parameters:

(i) Number of Passes : Single pass/Double pass

(ii) Design cold water temp. : 33 Deg. C

(iii) Min. size (O.D) of the tube : 22.225 mm

(iv) Minimum thickness of the tube : 22 BWG

(v) Tube velocity : 1.6 to 2.2 m/sec.

(vi) Design condenser pressure : 77 mm Hg (abs)

(vii) Max. tube length between tube : 15 meters (Indicative)
plates

(viii) Temperature rise in circulation : 10 to 11 deg.C
water across the condenser

(ix) Tube material : Stainless Steel as per
ASTMA-249-TP304

(x) Cleanliness factor : 0.9

(xi) Maximum CW side pressure drop : 5 mwc
in condenser and associated
systems under design CW flow
and CW inlet temp. (between
bidder's terminal point) with tube
cleaning system in operation.

(xii) maximum and minimum : 36 deg.C (max.) and 15
circulating water temperature deg.C (min.)

(xiii) Condenser arrangement : Perpendicular to T.G. axis.

2. Water box design pressure : 0.1 kg/cm (abs) and
5 kg/cm(g)

3. Water box test pressure : 1.3 times the design pressure

4. Water box design temperature : 60 deg. C

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5. Shell side design pressure : Full vacuum and
1.08 Kg/Cm2 (g)

6. Shell side design temperature : 120 deg.C

7. Design parameters for expansion joints:

(a) Design pressure : 0.1 kg/cm (abs)
and 5 kg/cm(g)

(b) Design temperature : 60 deg.C

(c) Test pressure : 1.5 times the design pressure

8. Design parameters of isolating butterfly
valves with actuator

(a) Design pressure : 0.1 kg/cm (abs) and
5 kg/cm(g)

(b) Design temperature : 60 deg.C

(c) Test pressure : 1.5 times the design pressure

9. Condenser air evacuation system
design parameters :

(a) Source of vacuum pump : Condenser cooling water as
heat exchanger cooling water per analysis given else where
in the specification

(b) Source of sealing water : Condensate

(c) Source of make-up water : Condensate

(d) Design pressure (cooling water : 0.1 kg/cm (abs) &
side for vacuum pump heat as per ACW System
exchanger Design Pressure

(e) Pressure of make-up water : CEP discharge pressure

(f) Maximum temperature of : 36 deg.C
condenser cooling water

(g) Duty code : HEI (Latest)

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(h) Design condenser pressure : 25.4mm (1 inch) of Hg (abs)

10. Design pressure for CW piping, valves, : 0.1 kg/cm (abs)
fittings, COLTCS equipment on the and 5 kg/cm(g)
CW line etc

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ANNEXURE-III

SECTION-VI
PART-B
A - 4
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SECTION-VI
PART-B
STAGE-II (2X660 MW)
1.00.00 BRIEF DESCRIPTION OF SYSTEM
1.01.00 The Equipment Cooling Water System shall be separately provided for Unit Auxiliaries
and Station Auxiliaries.
1.02.00 For unit Auxiliaries, the Equipment cooling water system shall be installed on a unit
basis. The cooling system for steam turbine generator auxiliaries shall be of closed
circuit type with demineralised (DM) water in the primary circuit. Water tapped off
from CW System would be used in the secondary circuit for cooling the primary circuit
DM water. Hence all materials of construction used in primary and secondary side of
the auxiliary cooling system should be suitable for the water quality. The scheme shall
be as per relevant tender drawing listed elsewhere in the specification. It is proposed
to provide two independent primary cooling circuit; one for TG Auxiliaries and another
for cooling of Steam Generator Auxiliaries. However the Secondary circuit pumps shall
be common for both the systems.
1.03.00 Quality of water
(a) Primary circuit - Demineralised (DM) water
(b) Secondary circuit - Condenser cooling water
Sodium Hydroxide dosing equipment shall be provided to maintain pH around 9.5 in the
D.M. water side.
1.04.00 The station auxiliaries such as Instrument and Service Air compressors, compressors of
ash handling plant, compressors of mill reject system and Condensing water circuit of
Air Conditioning systems of Main plant & Service Building etc shall be cooled by a
separate ECW system using separate set of pumps and cooling tower. Circulating
water from the CW pump house shall be pumped through all the station auxiliaries
and the hot water shall be cooled in a cooling tower and led to the Circulating water
channel.
2.00.00 SYSTEM DESIGN (UNIT AUXILIARIES)
2.01.00 The system design for ECW system for Unit Auxiliaries of TG System shall be as
follows:
For each unit, in the primary circuit a set of Demineralised cooling water (DMCW)
pumps of 3 X 50% capacity shall discharge cooling water through 3 X 50% capacity
plate type heat exchangers (PHE). The outlet header from plate heat exchangers shall
be suitably branched off to supply cooling water to the following auxiliary coolers. No
booster pumping system shall be provided in the primary system by the bidder. Outlet
from these auxiliary coolers shall be connected back into a common return header and
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led back to the suction of DMCW pumps to complete the closed loop primary cooling
circuit. Following coolers Bidder's Auxiliaries shall be cooled by ECW System (Unit
Auxiliaries) of TG System.
(a) Generator hydrogen coolers.
(b) Turbine lube oil coolers.
(c) Turbine control oil coolers.
(d) Generator seal oil coolers.
(e) Stator water coolers.
(f) Generator slip ring coolers.
(g) Sampling coolers /SWAS coolers (as applicable) in the scope of the
Bidder (if any)
(h) Water cooled electric motors.
(i) BFP turbine oil coolers.
(j) Hydraulic couplings of BFP.
(k) Condensate Extraction (CEP) bearing oil coolers.
(l) Any other unit auxiliary coolers under bidder's scope not covered above.
2.02.00 For the primary cooling circuit, for each unit, an overhead tank of minimum (normal)
capacity of 10 Cu.M shall be provided by the bidder. Outlet of this tank shall be
connected to the closed circuit return header to serve the following:
(a) Expansion of closed cycle water due to temper-ature fluctuations and to control
other tran-sients.
(b) For adequate Net Positive Suction Head (NPSH) for DMCW pumps.
(c) For normal make-up to closed loop cycle.
(d) Emergency water supply to critical coolers in case of power failure.
(e) The normal capacity of the tank shall be at 60% of the tank height.
2.03.00 The pH of DM water in the closed loop shall be continuously monitored and controlled
at around 9.5. The control shall be achieved by dosing sodium hydroxide in DM
water overhead tank. The dosing shall be done manually by operating dosing valve.
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2.04.00 The secondary circulating system shall operate in parallel to the condenser and shall
receive water through a tapping on the CW inlet line to the main condenser. This
water will be further pressurised by a set of 3 X 50% capacity auxiliary cooling water
booster pumps and fed through the plate type heat exchangers back to the CW
discharge line of the main condenser.
2.05.00 The heat exchangers shall be designed with a (Terminal Temperature Difference) TTD of
3 deg.C (max.). The outlet temperature of cooling water on the secondary circuit shall
in no case exceed the design outlet temperature of circulating water in the condenser.
2.06.00 Frame of each plate type heat exchanger shall have about 25% extra capacity i.e. the
frame shall be able to accommodate about 25% extra plates.
2.07.00 Self Cleaning Filters
To prevent fouling on the secondary circulating water side of the PHE, self cleaning
type filters, (2 X 100%) shall be provided by the bidder on the circulating water inlet
header to the PHE. The filter shall be provided with an automatic backwash
arrangement to facilitate cleaning of the choked filter while the pumps are in operation.
Backwashing shall be actuated and controlled either according to differential pressure
and /or by timer.
2.08.00 Make up to the closed loop primary circuit shall be taken from the DM water transfer
pumps located near DM water storage tank and emergency make up shall be from the
discharge of condensate transfer pumps. The make up would be given to overhead
storage tank.
2.09.00 Required orifices shall be provided in the primary and secondary circuit of Equipment
Cooling Water system for balancing of pressure.
3.00.00 CONSTRUCTION FEATURES
3.01.00 Pumps and Heat (PHE) Exchangers
3.01.01 The general design and construction features of various pumps of the Equipment
cooling Water System shall be as per the Annexure titled "General Specification For
Horizontal Pumps" enclosed with this sub-section.
3.01.02 Specific features of various pumps and plate type heat exchangers of ECW system
shall be as follows :-
A) Pumps (ECW System - Unit auxiliaries)
i) Type : Horizontal Centrifugal type
ii) Casing : Axially split type.
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iii) Impeller type : Closed
iv) Speed : 1500 rpm (max.)
v) Drive transmission : Direct
vi) Seal : Mechanical seal for primary water pumps
and Self water/gland for secondary side
vii) Lubrication : Oil/Grease/Selfliquid.
viii) Coupling : Spacer type.
ix) Drain plug, vent, : Required.
priming connection,
x) Coupling guard, : Required
lifting lugs
xi) Operating range : 40% to 120% of rated flow
xii) Pump characteristic : Non overloading type & stable
xiii) No damage should occur to any component due to flow reversal.
xiv) Parallel operation : Required.
xv) Material of Primary Side D.M. Secondary side Cooling
Construction cooling water pumps water pumps
a) Casing ASTM-A-351 CF8M 2.5% Ni CI to IS 210
GR FG-260
b) Impeller ASTM-A-351 CF8M Bronze to IS 318 Gr. I/II
or SS - 316
c) Imp Wearing SS-316 High leaded bronze to
Rings IS-318 Gr.V / SS -316 in
case of SS Impeller.
d) Casing wearing rings --------As per manufacturer's Standard -----
xv) Material of Construction: Primary Side D.M. Secondary side Cooling
cooling water pumps water pumps
a) Shaft SS-316 SS-316
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b) Shaft Sleeve SS-410 SS-410
c) Gland ----------- 2.5% Ni CI to IS 210
GR FG-260
d) Lantern Ring SS-316 Bronze
e) Glandpacking ------------ As per Manufacturer's
Std.
f) Mechanical Seal Manufacturer's Std ------------
g) Base plate ------------------ MS fabricated - IS:2062 -----------------
h) Stuffing Box -------------------- 2.5% Ni CI to IS 210
GR FG-260
i) All fasteners Stainless steel Stainless steel
B) Plate type Heat Exchangers - Design Parameters
(i) Type : Plate type, single pass
(ii) Design pressure : Maximum expected pressure to which PHE
may be subjected plus 5% additional margin.
Maximum expected pressure shall be based
on the shut-off head of pumps (either the
secondary or primary side whichever is
maximum) plus the suction pressure of the
pumps.
Material of Construction
(i) Heat transfer plate : SS-AISI-316
(ii) Compression / Fixed plates : IS:2062
(iii) Movable pressure plate : IS-2062
(iv) Guide rail : IS-2062 with stainless steel cladding
(v) Support Beam/Column : IS 2062
(vi) Plate gasket : Nitrile Rubber
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(vii) Nozzle : Carbon steel
(viii) Flanges : Carbon steel
(ix) Nozzle flange Gasket : 3 mm wire inserted Red Rubber.
(x) Nozzle flange Bolts/ Nuts : SA 193 B7/SA 194 2 H.
(xi) Name plate : AISI-316
(xii) Tightening Rods : IS-1367 or equivalent
Other Features:
(i) Double sealing arrangement should be provided at outer edge and around ports
to avoid intermixing of fluids. The interspace should be vented to atmosphere.
(ii) Plate thickness should be adequate to withstand all operating conditions but
not less than 0.6 mm.
(iii) Frame of exchanger should be designed so that 25% additional plates can be
added in future.
(iv) Flanges shall be per ANSI B 16.5 for equivalent.
(v) Thickness of pressure and frame plates as per ASME sec. VIII Div. I.
(vi) Minimum corrosion allowance for heat exchanger parts of carbon steel material
shall be 1.6 mm.
(vii) After pressing all the plates shall be tested by light box/vacuum/air chamber
test as per manufacturers standard practice.
(viii) The corrosion allowance for the heat exchanger plate such as pressure parts
(support plates), nozzles, sliding channels and frame shall be 1.6mm
(minimum).
3.02.00 Piping, Valves /Tanks:
Construction features of Piping, Valves and tanks shall be as per the sub-section titled
"Low Pressure Piping" of this Technical specification
3.03.00 Self Cleaning Filters:
(a) Body of filter shall conform to IS:210Gr. FG260 or ASTM-A-515 Gr. 75/IS: 2062
and internally painted with epoxy.
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(b) Strainer element shall be constructed of perforated stainless steel plant linked
with stainless steel (SS316) screen for fresh water and SS316L grade SS
screen for sea water.
(c) The mesh size shall be selected on the basis of average clearance between
the plates of the plate heat exchanger.
3.04.00 Construction features of ECW overhead tank
Sl . Description Tech. Particulars
No.
I. Quantity per Unit : One (1)
II. Capacity : 10 Cu.M (Minimum.)
III. Type : Horizontal Dished ends
IV. Design Pressure : Atmospheric
V. Design Standard : ASME Boiler and Pressure Vessel code
Section-VIII/IS:2825 (Class 3)
VI. Material of Construction : Plates to IS:2062/ ASTM A36.Minimum
shell thickness shall be 6mm.
VII. Location : Power House floor at suitable elevation.The
tank shall be placed at a height above the
cooler located at highest position
VIII. ACCESSORIES
(a) Vent, overflow and : Required (Overflow drain to be taken upto
drain '0' M plant drain)
(b) CO
2
absorber for vent : Required
(c) Seal for overflow : Required
(d) Manhole & approach : Required
ladder/platform/
3.05.00 Construction features of Alkali dosing tank.
Quantityper Unit : One (1)
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SECTION-VI
PART-B
STAGE-II (2X660 MW)
Useful Capacity of Each Tank : Suitable for the system (Minimum 500 lt)
Size (Dia. x Height) : Adequate
Type : Vertical cylinder, dished bottom
Design Pressure : Atmospheric
Design Standard : ASME Boiler & Pressure vessles Code
Section-VIII. Div.I/ IS:2825 (Class-3)
Material of Construction : MS Plates to IS:2062/ ASTM A36. with
rubber lining of 4.5 mm thick & Minimum
shell thickness shall be 6mm. OR SS
plates of minimum thickness of 6 mm .
Dissolving Basket : AISI-316,
Agitator : Propeller type agitator (shaft, propeller etc.
of stainless steel 316SS construction)
along with drive motor of suitable rating
and protection class. (With Slow speed
reduction gear unit)
Accessories
(a) Vent, overflow and Drain : Required
(b) Sample Connection : Required
4.00.00 SIZING / DESIGN CRITERIA
4.01.00 Pumps
a) Flow : Secondary Water pumps:
Design flow for TG plus SG secondary
water requirement,
Primary Water pumps.
Design flow of all TG Auxiliary coolers
b) Head : As per system requirement +10% margin
on friction head.
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c) Motor rating : Continuos motor rating (at 50 degree C
ambient) for all pumps shall be at least
ten percent (10%) above the maximum
power requirement at any condition of the
entire characteristic curve of the pump.
d) No. of Primary side pumps : 3 x 50% pumps/unit
e) No. of Secondary water : 3 x 50% pumps/unit
pumps
f) Re-circulation control Valves, : Required
Piping & Pressure break
down orifice.
g) Additional design requirements : a) To be referred in the annexure
sub-section titled "GENERAL
SPECIFICATION FOR HORIZONTAL
PUMPS" enclosed with this section.
4.02.00 Plate Type Heat Exchangers
a) Design Secondary water : Not less than 36 deg. C
inlet temperature
b) Secondary water outlet : Not more than the design hot water
temperature temperature at condenser outlet.
c) Primary water outlet : 39 deg C (maximum)
temperature
d) Overall fouling factor (minimum) (f) : 0.8x10
-4
Hr M
2
deg C/Kcal
e) No. of heat exchangers/ unit : 3 x 50% capacity
f) Overall Heat transfer coefficient[U(o)]: As per per manufacturer's deisgn
g) Dirty Heat transfer Coefficient [U(d)]: [1 / (1/U(o) +f) ]
h) Heat Transfer Area (Sqm) : Total Heat Load (in Kcal/hr)
U(d) x LMTD
i) Heat transfer area of PHE shall be selected such that each Sq.M of heat
transfer plate shall transfer not more than 6500 Kcal/hr.
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STAGE-II (2X660 MW)
4.03.00 Piping & Valves :
Design features of Piping and Valves of Equipment Cooling Water system shall be as
per the sub-section titled Low Pressure Piping.
5.00.00 INSTRUMENTATION
5.01.00 All instruments, such as thermowell, temperature element, flow element, pressure/DP
and temperature gauge/transmitters/sensors/switches, DP switch, pH analyser, Rotameter
etc. alongwith associated devices should meet the requirement as specified in relevant
sub-section of this Technical Specification and shall be sufficient to meet all interlock/
protection & operation requirement.
5.02.00 Minimum instrumentation required for the Equipment Cooling water system shall be as
per tender P & I Diagram wherever included in the specification.
6.00.00 CONTROL / OPERATION PHILOSOPHY
6.01.00 Complete Operation and Control shall be provided as described in relevant Subsections
of Control & Instrumentation System.
6.02.00 The pump suction valves, re-circulation valves and discharge valves shall be motor
actuated type to enable remote operation.
6.03.00 Pump suction valves shall be provided with required limit switches for interlock &
control.
6.04.00 The pumps shall be designed to operate under discharge valve open and as well as in
close condition.
6.05.00 Wherever more than one sump/tank is provided, Suction header shall be interconnected
such a way that any of the sump/tank may be selected from the panel for operation.
6.06.00 Any of the pump shall be selectable as standby duty. Standby pump shall come into
operation whenever tripping of working of working pump or inadequate pressure in the
discharge header.
6.07.00 Suction and Discharge valves of pumps to interlock with start/stop of respective pumps.
6.08.00 Local emergency stop provision of each pump shall be kept.
6.09.00 All the working pumps shall be interlocked with the suction level or suction pressure
condition as the case may be. Pumps operation shall be interlocked with the high
discharge condition so that the pump may not operate at shut-off pressure.
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6.10.00 Automatic inlet valves at supply line to each of the tank/sump shall be provided so
that the valves shall open and close at low-level and very high-level respectively.
6.11.00 A control valve shall be provided to maintain a constant pressure differential between
the main supply and return headers of DM water (primary circuit of ECW system of
unit auxliaries). The valve will bypass flow to maintain a constant return header
pressure to compensate for fluctuations in coolant flow to the process heat exchangers
due to modulating control valves on the process coolers or if any cooler goes out of
service in DM circuit.
6.12.00 Alarm to indicate high differential pressure across self cleaning filter strainers, heat
exchangers as the case may be.
6.13.00 Manually operating globe / regulating valves shall be provided in the water side of each
of the cooler outlet for control of flow as specified in respective equipment specification.
6.14.00 Detailed Interlock & protection logic shall be as finalised during detailed engineering.
7.00.00 PAINTING
7.01.00 All the equipments such as pumps, tanks and plate type exchangers of this system
shall be protected against external corrosion by providing suitable painting as mentioned
below. For painting of valves and piping, relevant section shall be referred to.
7.02.00 The surfaces of stainless steel, Gunmetal, brass, bronze and non-metallic components
shall not be applied with any painting.
7.03.00 The steel surface to be applied with painting shall be thoroughly cleaned before
applying painting by brushing, shotblasting etc as per the agreed procedure.
7.04.00 For all the steel surfaces exposed to (outdoor installation) atmosphere, a coat of
chlorinated rubber based zinc phosphate primer of minimum thickness DFT of 50
microns followed up with undercoat of chlorinated rubber paint of minimum DFT of 50
microns shall be applied. Then, intermediate coat consisting of one coat of chlorinated
rubber based paint pigmented with Titanium di-oxide with minimum DFT of 50 microns
and topcoat consisting of two coats of chlorinated rubber paint of approved shade and
colour with glossy finish and DFT of 100 microns shall be provided. Total DFT of paint
system shall not be less than 200 microns.
7.05.00 For all the steel surfaces inside the (indoor installation) building, a coat of red oxide
primer of minimum thickness of 50 microns followed up with undercoat of synthetic
enamel paint of minimum thickness of 50 microns shall be applied. The top coat shall
consist of two coats each of minimum thickness of 50 microns of synthetic enamel
paint and thus total thickness shall be minimum 200 microns.
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7.06.00 Internal surfaces of ECW over tank shall be painted with One coat of unmodified epoxy
resin alongwith polymide hardener and minimum two (2) coats unmodified epoxy resin
alongwith Aromatic adduct hardener and total thickness of primer and paint should not
be less than 400 microns.
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Annexure-I to ECW system Specification
GENERAL SPECIFICATION FOR HORIZONTAL PUMPS
(1) SCOPE
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) CODES AND STANDARDS
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.
(3) LIST OF APPLICABLE STANDARDS
IS : 1520 : Horizontal Centrifugal Pumps for clear cold fresh water
IS : 5120 : Technical requirements of rotodynamic special purpose pumps
API : 610 : Centrifugal pumps for general refinery service.
IS : 5639 : Pumps Handling Chemicals & corrosion liquids
IS : 5659 : Pumps for process water
HIS : Hydraulic Institute Standards, USA
ASTM-1-165-65:Standards Methods for Liquid Penetration Inspection.
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.
(4) DESIGN REQUIREMENTS
(a) 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. The
operating range of the pump shall be 40% to 120% of the duty point unless
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otherwise mentioned elsewhere. The maximum efficiency of pump shall preferably
be within 10% of the rated design flow as indicated in data sheets.
(b) The total head capacity curve shall be continuously rising from the operating point
towards shut off without any zone of instability with the highest head at shut-
off condition. Shut-off head shall be more than the rated design head and the
percentage variation may vary depending on the specific speed of the pumps (i.e)
10-15% for pumps of specific speed upto1000 US units, about 15 to 20% for
specific speed in the range of 1000 to 2000 US units, about 20% to 40% for
specific speed of 2000 to 4000 US units and above 50% for specific speed of
4000 to 7000 US Units
(c) 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.
(d) Pumps shall run smoothly without undue noise and vibration. Peak to peak
vibration limits shall be restricted to the following values during operation:
Speed Antifriction Bearing Sl eeve Beari ng
1500 rpm and below 75.0 micron 75.0 micron
3000 rpm 50.0 micron 65.0 micron
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 surface.
(e) 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.
(f) Pumps shall be so designed that pump impellers and other accessories of the
pumps are not damaged due to flow reversal.
(g) The Contractor under this specification shall assume full responsibility in the
operation of pump and motor as a unit.
(5) DESIGN CONSTRUCTION
(a) 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.
CLAUSE NO.
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EQUIPMENT COOLING
WATER SYSTEM
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SECTION-VI
PART-B
STAGE-II (2X660 MW)
(b) Pump Casing
Pump casing shall have axially or radially split type construction as specified. The
casing shall be designed to withstand the maximum shut-off pressure developed
by the pump at the pumping temperature.
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.
(c) Impeller
Impeller shall be closed, semi-closed or open type as specified elsewhere and
designed in conformance with the detailed analysis of the liquid being handled.
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.
(d) Impeller/Casing Wearing Rings
Replaceable type wearing rings shall be provided at suitable locations of pumps as
per manufacturer's standard practice. Suitable method of locking the wearing ring
shall be used.
(e) Shaft
The critical speed shall be well away from the operating speed and in no case
less than 130% of the rated speed.
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.
(f) Shaft Sleeves
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.
CLAUSE NO.
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EQUIPMENT COOLING
WATER SYSTEM
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SECTION-VI
PART-B
STAGE-II (2X660 MW)
Shaft sleeves shall be fastened to the shaft to prevent any leakage or loosening.
Shaft and shaft sleeve assembly should ensure concentric rotation.
(g) Bearings
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.
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 20,000 hrs. of continuous operation
at maximum axial and radial loads and rated speed.
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.
Bearings shall be easily accessible without disturbing the pump assembly. A drain
plug shall be provided at the bottom of each bearings housing.
(h) Stuffing Boxes
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.
(i) Mechanical Seals
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.
(j) 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
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WATER SYSTEM
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SECTION-VI
PART-B
STAGE-II (2X660 MW)
provision for seal water supply along with complete piping fittings and valves as
required shall form integral part of pump supply.
(k) Pump Shaft Motor Shaft Coupling
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.
(l) Base Plate
A common base plate mounting both for the pump and motor shall be furnished.
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 minimise 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.
(m) Assembly and Dismantling
Assembly and dismantling of each pump with drive motor shall be possible
without disturbing the grouting base plate or alignment.
(n) Drive Motor (Prime Mover)
Continuous Motor rating (at 50
0
C ambient) shall be at least 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 in no case less than the
maximum power requirement at any condition of the entire characteristic curve of
the pump. 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).
CLAUSE NO.
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EQUIPMENT COOLING
WATER SYSTEM
PAGE
18 OF 21
SECTION-VI
PART-B
STAGE-II (2X660 MW)
Annexure-2 to ECW system Specification
SUBMERSIBLE PUMPS
1.00.00 SCOPE
1.01.00 This specification covers general requirements in respect of design, material, manufac-
ture, construction, testing & inspection at Vendor's / sub-vendor's delivery to side, of
submersible pumps.
2.00.00 CODES AND STANDARD
The design manufacture and performance of submersible pumps shall be comply with all
currently applicable statues, regulation, and safely codes in the locality where the
Equipment will be installed. The Equipment shall also conform to the latest applicable
Indian standards listed below other Nation Standards are acceptable, if they are estab-
lished to be equal or superior to the listed standards. Nothing in these specifications
shall be construed to relieve the contractor of this responsibility.
2.01.00 List of Applicable Indian Standards
IS:8034 - Submersible pumps for clear cold fresh water
IS:5120 - Technical requirement of Rotodynamic Special
Purpose pumps.
In case of any contradiction with aforesaid standards and the stipulations as per tech-
nical specification as specified hereinafter the stipulation of the technical specification
shall prevail.
3.00.00 DESIGN AND PERFORMANCE REQUIREMENTS
a) The pump shall be of single stage mono - block type with non-clog design.
b) Components of Identical pumps shall be interchangeable.
c) Pumps shall have a continuously rising head characteristics.
4.00.00 MOTOR RATING
Continuous motor rating (at 50 deg. C ambient) for pumps shall be atleast ten percent
(10%) above the maximum load demand of the driven equipment in the complete oper-
ating range to take care of the system frequency variations.
5.00.00 FEATURES OF CONSTRUCTION
a) Pumps shall be of Submersible, wet pit type.
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EQUIPMENT COOLING
WATER SYSTEM
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SECTION-VI
PART-B
STAGE-II (2X660 MW)
b) Pumps shall be able to pass through solids upto 40 mm and capable
of handling waste water which may contain, sludge, plastic solids etc.
c) Coupling device shall ensure leak proof joint between the pump and discharge
elbow. This shall also enable pump to be removed from the sumps without the
necessity of dismantling any nuts, bolts etc.
d) Pumps shall be portable type and capable of using in any sump as and when
required. Pump shall be provided with required stool, flexible, hoses chain con-
nection etc. for easy installation, removal and maintenance. Adequate length of
chain required for lowering the pump into the sump and flexible type discharge
pipe shall be provided.
e) Impeller
Impeller type shall be open/semi-closed type/closed as indicated elsehwhere.
Enclosed impellers shall be equipped with seal rings on their hubs. In case of
open impeller, the pump shall be design to take care of the additional thrust
produced.
6.00.00 MOTOR
i) Motor shall be coupled directly to the impeller shaft.
ii) The motor shall be suitable for operation when submersed in water. The hous-
ing shall have required degree of protection.
iii) Necessary arrangement to be made to make cable entry absolutely water tight,
with cores cast in insulation along with cable gland 'O' ring seat.
iv) Built in temperature sensors are to be provided to enable tipping of motor if
temperature rises above the design temperature limit. These sensors are to be
used directly in the circuiting of control panel. The control circuit should trip the
motor if the temperature rises beyond safe limits.
v) Moisture sensors are to be embedded in motor chamber to trip the motor in
case of moisture entry in motor due to failure of pump mechanical seal.
vi) Motor shall be oil filled/oil lubricated or water filled type. Pressure equalizing
diaphragm and sand guards with seal shall be provided to prevent the water and
sand entering the motor.
vii) Power supply to the motor and control connections shall be preferably com-
bined in one cable and shall be flexible copper conductor PVC insulated,
armoured and overall hard grade PVC sheathed, and suitable for under water
service. The cable gland shall be properly sealed to prevent entry of pumped
CLAUSE NO.
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EQUIPMENT COOLING
WATER SYSTEM
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SECTION-VI
PART-B
STAGE-II (2X660 MW)
liquid the motor. Length of the cable shall be of suitable for site conditions.
The cable shall be terminated on the control panel with necessary facility to
terminate with the power receptacle.
viii) For pumps which are specified under portable application, Cable shall be suit-
able for continuous winding/unwinding duty on a cable reeling drum and shall
be installed on a trolley mounted on wheels. Associated control panel is also
to be mounted on the trolley.
ix) Water level controller shall be provided which should be with two level controls,
high to start and low to stop.
7.00.00 Equipment Data Sheet
Type of pump : Submersible type fixed inside pits/ sump
with guides /lifting chains
Type of Working Fluid : Drains with particle size upto 40 mm
Type of impeller : Open
Type of lubrication : Self / Grease / Oil
Speed : Preferrably 1500 rom (maximum)
a) Casing : 2% Nickel Cast Iron, IS:210
Grade FG 260;
b) Impeller : SS-316
c) Shaft : SS- 410
d) Bolts & nuts : SS-316
e) Accessories : Suction Strainer, Pump stand, Adaptors for
discharge flange, Level measuring devices/
Controllers, Lifting hook & chain Handle to
agitate debris etc, Discharge hose
connected with piping upto the drains etc.
f) The discharge, suction /column pipes shall be heavy grade Carbon steel
externaly lined with epoxy or galvanised.
CLAUSE NO.
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EQUIPMENT COOLING
WATER SYSTEM
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SECTION-VI
PART-B
STAGE-II (2X660 MW)
Annexure-3 to ECW system Specification
VERTICAL SUMP PUMPS
1.00.00 Equipment Data Sheet
Type of pump : Vertical (volute type casing) sump pump
with coloumn pipe, discharge flange etc.
Type of Working Fluid : Drains with particle size upto 40 mm
Type of impeller : Open
Type of lubrication : Self / Grease / Oil
Speed : Preferrably 1500 rpm (maximum)
a) Casing : 2% Nickel Cast Iron, IS:210
Grade FG 260;
b) Impeller : SS-316
c) Shafts : SS- 410
d) Coloumn pipe : Carbon steel as per IS:2062
e) Discharge pipe : Carbon steel as per IS:2062
f) Stuffing box : 2% Nickel CI,IS:210 Grade FG 260;
g) Gland : 2% Nickel CI,IS:210 Grade FG 260;
h) Bolts & nuts : SS-316
i) Accessories : Suction Strainer, Level measuring devices/
Controllers etc.
SECTION-VI
PART-B
A - 5
CONDENSATE POLISHING PLANT
CLAUSE NO.

STAGE II (2X660 MW)
SECTION - VI
PART-B
A - 5
CONDENSATE
POLISHING UNIT
PAGE
1 OF 27

1.00.00 GENERAL

1.01.00 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.

1.02.00 The proposed schematic arrangement of the Condensate Polishing Plant has been shown in
the relevant Tender Drawing (P&ID). Arrangement of piping and valves shown in them are for
guidance only. The Contractor shall propose the complete system including regeneration
facilities as per their standard design and as elaborated in this specifications meeting the
basic functional requirements.

1.03.00 The Condensate polishing Plant shall consists of one set of Condensate polishing Units
(CPU) for each TG unit inside TG Building and a common regeneration system. Each CPU
shall consist of Three (3) service vessels of 33.33% capacity for each TG Unit.

1.04.00 The regeneration system shall be external and common to the CPU of all the TG units. 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.

1.05.00 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).

1.06.00 Make-up water to the turbine cycle will be added to the condenser hotwell as required. The
analysis of the cycle makeup water (DM Water) is exhibited in the specification elsewhere.

1.07.00 In the event of a tube failure in the condenser, circulating water will enter the condensate
system and will contaminate it. Typical composition of the circulating water is exhibited
elsewhere in the technical specification and the condensate polishing plant shall be designed
for such tube leakage condition as mentioned.

1.08.00 Proposed general arrangement of the plant identifying the areas available for the equipment
are shown in Tender Drawings (for equipment layout). The condensate polisher service
vessel will be located near corresponding units. All the components of the CPP plant shall be
located indoor and regeneration system equipments shall be kept under shed and
neutralising pit shall be located outdoor.

1.09.00 The waste water generated during regeneration, resin transfer operations, rinsing etc shall be
drained / led to locations as detailed out in subsection titled Terminal Points & Exclusions in
Part-A of Technical Specification.

1.10.00 The equipments covered under this subsection, other than in service vessel areas shall be
located outdoor (in open) and no superstructures are envisaged to be provided for these
equipments/pump houses. However the equipments may have localized shade provisions
and pumps maintenance area shall be provided with roof cover. All the instruments
CLAUSE NO.

STAGE II (2X660 MW)
SECTION - VI
PART-B
A - 5
CONDENSATE
POLISHING UNIT
PAGE
2 OF 27

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.

2.00.00 SALIENT DESIGN DATA

2.01.00 The design flow (through working vessels) for each condensate polishing plant shall be the
corresponding condensate flow of TG unit at VWO (Valve wide open) condition at 3% cycle
make-up.

2.02.00 The following dissolved solids concentration and conditions shall be used as a basis of
design for the condensate polishing system. The ionic concentrations indicated below are as
such.

Influent Effluent
Ammonia ppb 100 --
Total solids, ppb 100 20
Silica, ppb 30 5 (refer Note 1 below)
Iron, ppb 50 5
Sodium, ppb 10 2
Chloride, ppb 10 2
pH 8 8.5 --
Effluent conductivity after removal of ammonia
and amines (micro mhos/cm) at 25 deg. C.
-- 0.1 or less

Note : 1. Silica value shall be 7 ppb in case the temperature of the condensate
is 50 deg C & above.
However the Contractor to check and reduce the ionic concentrations at the effluent based on
their requirement. 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.

2.03.00 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 25 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.

CLAUSE NO.

STAGE II (2X660 MW)
SECTION - VI
PART-B
A - 5
CONDENSATE
POLISHING UNIT
PAGE
3 OF 27

2.04.00 During start up conditions, quality of the influent may deteriorate to
TDS, ppb 2000 maximum
Silica, ppb 150 maximum
Crud, ppb (mostly black oxide of Iron) 1000 maximum
For design purposes, average crud loading shall be considered as 500 ppb. Under such
conditions, total crud content of the effluent shall not exceed 150 ppb. However the
Contractor to check and reduce the crud content at the effluent based on their requirement.
2.05.00 Under condenser tube-leakage condition, the plant shall be designed for 2000 ppb TDS in
addition to the normal influent contaminants stated in as specified at clause no 2.02.00 of this
Sub-section above. The cation and anion load in 2000 ppb TDS shall be based on the
circulating water analysis furnished elsewhere. Under such condition, both sodium content
and silica content of the effluent shall be limited to 20 ppb maximum. Useful service run
between regeneration under the Startup conditions as specified at clause no 2.04.00 of this
Sub-section and under condenser tube leakage condition as specified at clause no 2.05.00 of
this Sub-section above, shall not be less than 50 hours each.

2.06.00 Influent water quality as indicated in the above clauses are 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.

2.07.00 The bed cross section shall be such that the velocity of condensate through it, shall not
exceed 2 meters/min at the design flow rate. Internal diameter of the service vessels
(excluding the rubber lining) of cylindrical type shall be selected meeting the above
mentioned velocity criteria. For vessels of spherical shape, where the bed cross section vary,
the diameter (excluding the rubber lining) of the vessel shall be selected considering velocity
not exceeding 1.75 meters/minute. The effective depth of the mixed resin bed in the
condensate polisher service vessels shall not be less than 1100 mm.

2.08.00 At the design flow rate, the pressure drop across the polisher service vessels with clean resin
bed shall not exceed 2.1Kg/sqcm. 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 will be restricted to 3.5 kg/sq.cm including the pressure
drop across effluent resin traps.

2.09.00 Cation resins shall be regenerated by 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 or as flakes.

In no case, the regeneration levels can not 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.

2.10.00 Rinse water outlet header of each condensate polishing unit shall be provided with a
pressure reducing station with isolating valves, suitably designed to enable the water entry to
the condenser hot well which is operating under vacuum.The pressure reducing station shall
CLAUSE NO.

STAGE II (2X660 MW)
SECTION - VI
PART-B
A - 5
CONDENSATE
POLISHING UNIT
PAGE
4 OF 27

consist of either 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.

2.11.00 While calculating pump head, 10% margin (minimum) shall be considered of the value of
friction losses. Pipe friction loss shall be calculated as per Willam-Hazen formula and C
value to be adopted shall be as described in subsection titled Power Cycle & Low Pressure
Piping System in Part-B of this Technical Specification. Pump recirculation with a regulating
valve shall be provided for all the pumping system.

3.00.00 GUARANTEES
All the design parameters at clause no 2.00.00 of this chapter, i.e. the effluent quality, the
design flow, design service length, Chemical consumption for regeneration and Pressure
drop across the resin bed in clean and dirty condition at rated design flow shall be
guaranteed by the Contractor.
4.00.00 SYSTEM REQUIREMENT

4.01.00 The regeneration process offered by the Contractor/Sub-vendor, shall be of proven design
and shall essentially be the same process by virtue of which the Contractor/Sub-vendor is
qualified and shall give resin-separation compatible with the desired effluent quality.
Documentary evidence shall be submitted by the Contractor/Sub-vendor to the Employer to
establish this requirement during detailed engineering stage if required.

4.02.00 The Contractor shall include inert resin in the system if they feel that it helps in better resin
separation.

4.03.00 In case, after separation of resins, there are undesired contaminant resins, the Contractor
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.

4.04.00 Exchange Resins

a) The bidder shall include with the plant adequate resins for all the condensate polisher
service vessels. In addition separate charge of resin shall also be included for using
the resins during commissioning stage of unit. Therefore, total number of charges
supplied by bidder shall include total resin charges for TG units plus one spare
charge plus commissioning charge.

b) The resins shall be in the form of spherical beads. Base of the ion-exchange resins
shall be a copolymer of styrene and divinyl benzene forming a macroporous or
macrorecticular structure. Other details are as follows:

Cation : Strong acid, with sulfonic acid functional group.

Anion : Strong base, with quanternary ammonium (type I) functional group.

Inert : Non ionic, compatible with the above resin types.
CLAUSE NO.

STAGE II (2X660 MW)
SECTION - VI
PART-B
A - 5
CONDENSATE
POLISHING UNIT
PAGE
5 OF 27

Cation resins shall be supplied in hydrogen form and Anion resins shall be supplied
in hydroxide form.

c) Physical Properties:

(i) 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.

(ii) 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.

d) 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 : 1.0

(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.

(iii) Cation-Anion resin ratio shall be 1.5 parts cation to 1.0 part anion by volume.
In case the bidders process require any non ionic resin the same shall
represent at least 10 percent of the bed volume, but not less than 15 cm of
the bed depth in the resin separation tank of the external regeneration
facility.

(iv) Manufacturer:

It is not the intent to pre-select any specific brand name for this application.
Resins will be accepted by the Employer strictly on their merits. The resins
shall be of reputed manufacturer with adequate past record of successful
service for not less than 3 years in similar application.

CLAUSE NO.

STAGE II (2X660 MW)
SECTION - VI
PART-B
A - 5
CONDENSATE
POLISHING UNIT
PAGE
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(v) Bidder shall submit all necessary data and information in this regard along
with his proposal. Some of these possible resin terms are as follows:

1) Duolite C - 26 TR & A - 161 TR Rohm and Hass 252 C & TRA-900C.

2) Dowex MSC-1, MSA-1 C grades.

3) Inert resin Duolite sec, Rohm & Hass 359 or Dow-buffer beads.

Above listing is by no means exhaustive, and shall not be construed to be a
recommendation for their selection for this plant. Bidder shall fully satisfy himself as
to the suitability of the resin system selected by him before offering it in his proposal.

e) 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.

4.05.00 Condensate Polishing Units

a) Condensate polishing unit of each TG unit shall consist of the following:

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 appurtenances etc. as specified
and as required.

2) External resin traps at the outlet of each of the polisher vessels, designed for
in-place manual back washing.

3) Condensate inlet and outlet headers for each installation with pipe
connections to the condensate polisher vessels.

4) Resin transfer headers and pipe lines connecting the external regeneration
facility to the condensate polisher vessels of each installation.

5) Rinse water outlet headers from condensate polisher vessels of each
installation upto the condenser hotwell.

6) All necessary valves and fittings for the installations with actuators necessary
for their remote operation. These shall include suitable fool-proof
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 polisher service vessels.

7) A common drain header for the condensate polisher service vessels of each
unit upto the hotwell.

CLAUSE NO.

STAGE II (2X660 MW)
SECTION - VI
PART-B
A - 5
CONDENSATE
POLISHING UNIT
PAGE
7 OF 27

8) All necessary drains, vents and sampling points, with valves as specified and
as required.

9) Gland sealing water piping for the valves in the rinse water line.

10) Emergency bypass between the condensate influent and effluent headers
with its automatic valve, isolation valves on both sides and controls.

11) Two (2) nos. 100 percent capacity (one working and one standby) oil free
type, air blowers to supply necessary air for mixing the resins in the service
vessels for each TG unit CPP.

12) Complete instrumentation, controls etc for automatic operation.

b) Operating pressure for service vessels shall be normal operating pressure of
condensate extraction pump. Service vessel design pressure shall be equal to shut
off pressure of condensate extractions pump plus 5% margin.

c) Design temperature of the service vessel shall take care of all operating regimes
including HP-LP bypass operation.

d) Emergency bypass system :

1) Each condensate polisher service unit shall be provided with an automatic
bypass system for the condensate polisher on the condensate inlet and
outlet headers of the unit with a set of control valve with its isolation valves
on the upstream and down stream sides of the control valve.

2) In the event of excessive pressure differential 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 all vessels/ two vessels/one vessel/no vessel
is in operation.

3) Contractor to provide either 2x50% capacity valves or 1x100% control valve
to achieve proper control under all operating conditions as per Employers
approval of Engineering Documents.

4) 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 Contractor as part of this package.
All tubing, wiring, air sets, and other fittings, required to complete the system,
shall also be installed by him.

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.
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6) The control system shall be so designed that the control valve is able to
bypass 33% of rated flow when any of the service vessel is out of service,
67% of flow when two vessels are taken out of service and 100% of flow
when all the service vessels are out of service.

4.06.00 External Regeneration Facility (Regeneration Plant)

a) One (1) common facility for regeneration of the ion-exchange resins from the
condensate polishers of all the turbo-generator units shall be provided utilizing three
tank concept, and consisting of :

1) Resin Separation & Cation Regeneration Vessel

2) Anion Resin Regeneration Vessel

3) Two (2) nos. Mixed Resin storage vessels

4) Resin injection hopper, complete with a water ejector system for resin make-
up. Resin injection hopper shall be sized to handle upto 150 litres of as
received new resins.

5) All internals, fittings and appurtenances for these vessels.

6) Common waste effluent header with one resin trap designed for in place
manual backwashing.

7) 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.

8) Each blower shall be complete with motor, V-belt drive with belt guard, inlet
filter/silencer, flexible couplings and discharge snubber, all mounted on a
single base. Relief valve(s) shall be provided as required.

9) Two (2) numbers of (1 Working +1 Standby) DM water pumps with electric
motor drives for water supply for chemical preparation & for dilution water
supply during dosing. These DM water pumps will take suction from DM
water storage tanks.

10) Two (2) numbers of (1 Working +1 Standby) DM water pumps with electric
motor drives for water supply and transfer of resin from service vessel to
regeneration vessels and vice-versa. These DM water pumps will take
suction from DM water storage tanks.

11) Bulk Acid & Alkali Storage Tanks and Acid/alkali unloading facilities (if
included in the scope of the Bidder as shown relevant tender drawing)

12) Acid solution preparation & dosing facility

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13) Alkali solution preparation and dosing facility

14) DM Water Storage tanks for regeneration system (if separately
identified/included in the scope of the Bidder) as shown in relevant tender
drawings.

15) Effluent neutralization system.

16) All necessary piping, valves & fittings i.e. All piping between the external
regeneration facility and the skids for chemical dosing and acid/alkali
preparation, demineralised water piping to the chemical dosing, acid/alkali
piping from external bulk storage tanks to respective preparation skids,
acid/alkali solution pipelines from preparation skids to respective dosing
skids, chemical solution piping for acid and alkali from the dosing skids to the
external regeneration facility, instrument air piping etc. These shall include all
drains, vents and sampling points with valves as specified and as required.
The entire installation shall be complete with all pipe supports, hangers, etc.

17) Complete instrumentation, controls etc necessary for automatic operation.

18) The equipment and system of external regeneration facilities described
above is indicative and for guidance only. Based on the regeneration process
offered, the contractor may make suitable modifications in the equipment to
make the system complete in all respect.

b) Free Board: The pressure vessels in the common external regeneration facility shall
be provided with adequate freeboards over the top of the settled resins, to minimize
resin loss during their use. Minimum freeboards to be are as follows:

(i) Mixed resin Storage vessel : 50%

(ii) Resin separation vessel : 75%

(iii) Cation regeneration vessel : 75%

(iv) Anion regeneration vessel and : 75%
activated carbon filter

However, if a vessel is used for more than one service, then the vessel design shall
be based on the service which gives maximum freeboard.

c) Design pressure of the condensate Polisher Service Vessels is indicated elsewhere.
For all other Pressure vessels the design pressure shall be at least 8 kg/sq. cm (g).

d) All equipment for dosing of acid and alkali solutions shall be rated to provide a
maximum dosing rate at least 20% in excess of that required from process
calculation.

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e) In order to facilitate erection at site chemical dosing preparation equipment shall be
mounted on structural steel skids and assembled (including piping) at the
manufacturers 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. Following is a recommended listing of the main equipment skids to be
furnished under this package. The Contractor may also supply and install these
equipments independently instead of assembling the skids.

(i) Alkali Solution Preparation skid (1 no):

This shall comprise one (1) alkali preparation tank complete with electrically
driven stirrer and dissolving basket, two (2) nos. (each 100% capacity) alkali
solution transfer-cum-recirculation pumps of suitable capacity and head to
meet the system requirements, one (1) nos. alkali day tank, one (1) no.
activated carbon filter for alkali, all interconnecting piping, valves and fittings
as required for the system. This facility shall be used for preparing alkali
solution from alkali flakes and prepared solution shall be either transferred to
the bulk alkali storage tanks or in day tanks.

(ii) Alkali Dosing Skid (1 no) & Acid Dosing skid (1 no):

The acid and alkali dosing equipment for regeneration of condensate
polishing resins shall be mounted on skid which shall consist of at least the
following:

1) Positive displacement type metering pumps with electric motor drive;
two (2) (1W +1S) for dosing hydrochloric acid (30% conc) and two
(2) (1W+1S) for dosing sodium hydroxide solution.

2) 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.

3) 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.

4) A hot water tank with electric immersion heater

5) Two (2) acid measuring tank of adequate capacity to hold acid for
one regeneration.

All the equipment, piping etc. shall be assembled on two structural steel skids one
for acid and one for alkali dosing equipment. The Contractor 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.
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5.00.00 TECHNICAL REQUIREMENTS OF EQUIPMENTS

5.01.00 Bulk Acid & Alkali Storage Tanks (applicable if included in scope of supply)

Description / Data Acid Storage tanks Alkali Storage Tanks

Numbers. required Two (2) Two (2)
Dimensions (diameter, length &
thickness) As per BS:2594
Location Outdoor
Useful capacity Each tank to store one Each tank to store one
months requirement of months requirement of all
all the units or the units or minimum as
minimum as specified specified in scope of supply
in scope of supply in in Part A of Technical
Part A of Technical Specification.
Specification.

Type & pressure class Horizontal, with dished (Torospherical) ends,
Atmospheric

Material of construction Mild Steel (as specified)

Internal Painting/ lining Rubber lining (4.5 mm thick)

External painting As specified elsewhere

Concentration 30-33% HCl 48% NaOH

Accessories Vent, overflow, Drain, sample connections,
Fume absorbers manholes, operating platforms etc

5.02.00 Acid & Alkali Unloading Pumps (applicable if included in scope of supply)

-------------------------------------------------------------------------------------------------------------------------
Description / Data Acid Unloading Pumps Alkali Unloading Pumps
and Alkali transfer cum
recirculation pumps
-------------------------------------------------------------------------------------------------------------------------

a) Numbers. required Two (One working + Two (One working +
one standby) one standby) unloading
pumps & Two (One
working +one standby)
alkali transfer pumps

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-------------------------------------------------------------------------------------------------------------------------
Description / Data Acid Unloading Pumps Alkali Unloading Pumps
and Alkali transfer cum
recirculation pumps
-------------------------------------------------------------------------------------------------------------------------

b) Type Horizontal, Centrifugal

c) Pump Speed Maximum 1500 rpm

d) Location Outdoor

e) Capacity & head of each pump 10 Cu.m/hr & 10 mWC 10 Cu.m/hr & 10 mWC
(minimum) (minimum)

f) Liquid to be handled 30-33% HCl 5 to 50% NaOH

g) Type of Shaft sealing Mechanical Seal Mechanical Seal

h) Material of Construction Polypropylene or Stainless Steel -316
equivalent suitable
for HCl

i) Reinforced Rubber hoses Minimum two numbers Minimum two numbers of
of size 80 mm NB of size 80 mm NB of minimum
minimum 10 meters 10 meters length with isolation
length with isolation valves
valves

j) Accessories Coupling gaurds, drain plug, vent valve, Suction hoses,
isolation valves, Y-type strainer etc.
--------------------------------------------------------------------------------------------------------------------------

5.03.00 Chemical Preparation Tanks
----------------------------------------------------------------------------------------------------------------------------
Chemical Tanks Alkali Preparation Alkali Day Tank Acid Measuring
Tank Tank
----------------------------------------------------------------------------------------------------------------------------
a) Number required One (1) One (1) Two (2)

b) Type Vertical Cylindrical, with dished end at bottom; Atmospheric

c) Useful capacity Minimum 10 Cu.m Each tank shall be adequate to hold
chemical for 125% of one regeneration

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----------------------------------------------------------------------------------------------------------------------------
Chemical Tanks Alkali Preparation Alkali Day Tank Acid Measuring
Tank Tank
----------------------------------------------------------------------------------------------------------------------------

d) Material M.S. with 4.5 mm thick rubber lining inside

e) External protection As specified elsewhere

f) Accessories Required Vent, Overflow, drain connection, motor driven stirrer (only
for alkali preparation tanks), dissolving basket in SS-316
construction (only for alkali preparation & day tanks),
fume absorber etc

5.04.00 DM Water Pumps

----------------------------------------------------------------------------------------------------------------------------
Description / Data DM Water (for Resin DM Water (for Regeneration)
Transfer) Pumps Pumps
----------------------------------------------------------------------------------------------------------------------------

a) Numbers. required Two (2 x 100% capacity) Two (2 x 100% capacity)

b) Type Horizontal, Centrifugal

c) Pump Speed Maximum 1500 rpm

d) Capacity & head As required As required

e) Liquid to be handled DM Water DM water

f) Type of Shaft sealing Mechanical Seal Mechanical Seal

g) Material of Construction

a) Casing ASTM A 351 CF 8M

b) Impeller ASTM A 351 CF 8M

c) Wearing rings As per manufacturers Standard

d) Shaft SS 316

e) Shaft Sleeves SS 410

f) Mechanical Seal As per manufacturers Standard
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----------------------------------------------------------------------------------------------------------------------------
Description / Data DM Water (for Resin DM Water (for Regeneration)
Transfer) Pumps Pumps
----------------------------------------------------------------------------------------------------------------------------

h) Recirculation line with motor Required
actuated regulating type
butterfly valve

i) Accessories Coupling gaurds, drain plug, vent valve, Suction
hoses, isolation valves, Y-type strainer etc

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

5.05.00 Dosing Pumps
----------------------------------------------------------------------------------------------------------------------------
Description / Data Acid Alkali
----------------------------------------------------------------------------------------------------------------------------

a) Number Two (2 x 100% cap) Two (2 x 100% cap)
b) Type Simplex positive displacement type;
hydraulically operated diaphragm type

c) Whether suction strainer required Yes -

d) Accessories :

i) Pressure Dampeners Two (2)-

ii) External safety relief valve (in
addition to inbuilt safety valve) Two Two

e) Maximum pump stroke speed 100 per minute

f) Material of construction

1) Liquid End (Pump Head, Valves, PVC AISI:316
Valve housing, valve spring etc.).

2) Diaphragm P.T.F.E.

3) Packing P.T.F.E.

4) Shaft Hardened steel EN 8 (BS:970)-------

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5) Worm & worm wheel Manganese Bronze
(If applicable)

6) Connecting rod Manganese Bronze

7) Cross head guide Bronze

8) Capacity & Head As per system requirement

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

5.06.00 Hot Water Tank (for alkali):

For heating of alkali diluent water, 2x50% electrical heating coil in a tank of mild steel rubber
lined 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 heater shall be controlled by the
temperature switches provided on the tank. The heaters shall be sized for heating the water
from a temperature of 15
o
C to 50
o
C at the outlet. The water shall be heated to the required
temperature within 5 hours.

5.07.00 Acti vated 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 not be less than 1 meter.

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%

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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.

5.08.00 Air Blowers

Each blower shall be complete with motor, V-belt drive with belt guard, inlet filter/silencer,
flexible couplings and discharge snubber, all mounted on a single base. Relief valve (s) shall
be provided as required.

5.09.00 DM Water storage tanks for Condensate polishing Plant (if included in scope of
supply):

5.09.01 Two numbers of DM Tanks shall be provided (if included in scope of supply in Part-A of
Technical Specification) and the tanks shall be of vertical cylindrical type in Mild steel
construction internally painted with epoxy. The design features of the tanks & accessories
shall be as per IS:803. However minimum thickness of shell plate, bottom plate and roof plate
shall be 8 mm, 10 mm and 6 mm receptively.

The tanks shall be provided with CO
2
absorber and over flow seal pit. Effective capacity of
each tank shall be equivalent to 1.5 times the DM water required for one regeneration
operation of one TG unit including resin transfer operations from Condensate Polishing Plant
to regeneration plant and regeneration plant to Condensate Polishing Plant and for
preparation of chemicals for one regeneration of one unit or as mentioned in Scope of Supply
in Part-A of Technical Specification whichever is higher. However, the DM storage tank
capacity shall be 450 cubic meter minimum.

Water inlet pipe shall led upto the bottom of DM tanks (preferably through perforated pipe) to
avoid turbulence / agitation

5.10.00 Effluent Neutralisation System

Neutralising pit of RCC construction with acid/alkali resistant tiles shall be provided to receive
drains from the regeneration. If separate pit is envisaged for Condensate Polishing Plant, (as
shown in relevant Tender drawing), Bidder shall design the system so that pit shall be
provided in two (2) sections and each section shall have a holding capacity of 1.5 times the
waste effluent from each regeneration of each vessel. For disposal of neutralized effluent
pumping, required number of pumps (as mentioned in Scope in Part-A of Technical
Specification & shown in relevant tender drawing ) shall be provided. Proven agitation system
like air agitation & venturi mixing shall be provided, in addition to recirculation from pumps.

The waste recirculation / disposal pumps shall conform to the following technical
requirements:

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Effluent re-circulation cum-disposal pumps

a) Number : Three numbers (one working, one standby
one maintenance standby)

b) Type : Horizontal centrifugal single stage with
priming system / or vertical pump mounted
on top of pit

c) Minimum Capacity and : Suitable to pump the total volume of one
total head of each pump section in 8 hours (Minimum 50 Cu.m/hr).
Head to suit the requirement

d) Suction condition : Suction from priming chamber / submerged
(suction from pit)

e) Casing and impeller material : Rubber lined, cast iron IS : 210 Grade FG
260

f) Shaft material : Stainless Steel -316

g) Number of priming chambers : Two (2)

Dosing of acid, alkali and lime shall also provided to neutralise effluents before disposal along
with all piping, valves etc. including lime solution preparation facilities for neutralization. One
number of lime tank of Stainless steel construction of effective capacity of minimum 2 Cum
shall be provided with dissolving basket, agitator (slow speed), platform/ladder, manhole,
overflow/drains etc. The tank shall be protected externally with chlorinated rubber paint.

5.11.00 Piping

a) Contractor 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.

b) 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 permit.

c) Complete supporting system for the pipeline shall be designed, fabricated and
supplied by the Contractor. 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 Contractor.

d) Routing of this pipe line shall be developed by the Contractor and shall be finalised in
coordination with the Employer, based on the space available and the final layout.
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e) 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.

f) The resin transfer pipeline shall be sized for a flow velocity of between 2.3 and 3.0
meters/sec. For other service design criteria in piping general design criteria. Pipeline
velocity for other services shall be generally in line with design philosophy described
in subsection titled Power Cycle & Low Pressure Piping System in Part-B of this
Technical Specification.

g) 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.

h) All lined vessel connections and connections in unlined vessels (25 Nb and larger)
shall be flanged to ANSI 125 lb class except the polisher service vessels which shall
be ANSI 300 lb class : Flat face flanges shall be used throughout. Nozzle material
shall be ASTM-106 Gr.B. Sch.80 pipe for all vessels. 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.

i) Material of construction for piping :

1) The resin transfer pipeline shall be of stainless steel type 304.

2) Piping handling DM Water & Alkali shall be of stainless steel 316 Sch-10
(Minimum).

3) Piping for Acid service shall be carbon steel polypropylene lined.

4) Piping for air service shall be of hot dip galvanized (heavy grade) steel.

5) Piping for condensate near condenser Polisher service unit shall be of
seamless carbon steel ASTM A-106 Gr B all welded construction with 300 lb
flange connection.

5.12.00 Val ves

1) The isolation valves on the resin transfer line shall be of eccentric plug type/ball valve
(full bore type) of stainless steel construction.

2) Emergency bypass control valve shall be of double flanged butterfly type. Isolation
valves of wafer (lugged) type butterfly valves (resilient material seated, to ensure
bubble-tight shut off) shall be provided on the upstream and down stream sides of
the control valve. The material of construction of Valves handling condensate in
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service vessel area shall be as described in subsection titled Power Cycle & Low
Pressure Piping System in Part-B of this Technical Specification.

3) Isolation Valves handling Acid, Alkali, Ammonia etc shall be diaphragm type in MSRL
(mild steel rubber lined) construction.

4) Isolation Valves handling DM water shall be Butterfly or gate or globe type and shall
be SS construction.

5) Non-return valves for DM Water & alkali shall be SS construction and for acid non
return valve shall be lined type or as per manufacturers standard practice.

6) All valves in service vessels area where pressure may attain same as service vessel
shall be designed for 300 lb class.

5.13.00 Pressure Vessels & Miscellaneous Items

a) 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.

b) 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
atleast 6 mm thickness.

c) All pressure vessels shall be fabricated from carbon steel plates to SA-515 / 516 Gr.
70 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.

d) 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).
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3) All internal fastener shall be of SS-316 and heavy duty locknuts shall be used
throughout.

e) 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 construction and internals (cord & screen) shall be
of J OHNSON 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.

6.00.00 CONTROL & OPERATION

6.01.00 General

a) It is not the intent to specify here the complete details of the control system. Basic
type of controls required has been specified below. The bidder shall submit with the
proposal the complete detail of the system offered by him like 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.

b) It shall be possible to operate 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 by operation of the
Control switches on the panel.

c) Close-Auto-Open control facility shall be provided from OWS/control panel for
solenoid valves. In Auto position, the valves shall receive close / open command
from the Control system.

d) Stop-Auto-Start Control facility shall be provided from OWS/control panel for the
various drives. In Auto position, the drives shall receive stop/start command from the
Control system.

e) On control system failure, it shall be possible to operate the valves by means of
manual operator of solenoid valves too.

f) 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.

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g) 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.

h) 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.

i) 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 in the OWS/control
panel.

j) A mimic shall be provided for the CPP scheme and Regeneration system scheme
shall be provided. Status of various vessels, drives, valves etc shall be indicated by
on the mimic.

k) 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 should not proceed further, and Alarm shall be
provided. Missing criteria, sequence, which is under hold up etc., shall be displayed.

l) 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.

m) Wherever standby equipments are provided, it shall be possible to select each of the
drive on standby duty.

n) The detailed logic for the sequence and for each of the drive shall be subject to the
Employers approval.

o) Start, progress and stop of each of the sequence shall be annunciated.

p) The status of vessels of Condensate Polishing Plants shall be available in all the
CPP panels of all TG units and as well as in the regeneration plant control panel.
Similarly the status of regeneration plant status shall be available in the panels of
Condensate Polishing Plants of all TG units.

q) Details of control system specification and configuration details shall be as
elaborated in the relevant C&I sub section of the technical specification

6.02.00 Control & Operation of the Condensate Polishing Unit

a) The regeneration system control system shall be linked with Balance of Plant control
system for data transfer through a two way link for both information and control.

b) It shall be possible to select each of the CPU vessel for any of the following
operations or mode :

(1) Standby (Applicable for where spare service vessel (s) are provided)

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(2) Service

(3) Isolation from service.

(4) Resin Transfer from CPU vessel to Regeneration plant.

(5) Resin Transfer from Regeneration plant to CPU vessel

(6) Rinse mode.

Each mode or operation is described as below:

c) Standby Mode :

(1) Among the vessels, any one of the vessels may be selected in this mode.

(2) Under this mode, the vessel, which was regenerated in previous cycle and
filled with regenerated resin, shall be kept ready for next Service cycle.

(3) The selection of any vessel for Standby mode shall be initiated by operator
and there shall be indication about the details such as Condition of the resin
; Whether it is filled with regenerated resin or exhausted resin, whether the
standby vessel has undergone rinse cycle or not, date and time of receipt of
regenerated resin and completion of rinse cycle etc

d) Service mode :

(1) Service flow rate for each polishing vessel shall be monitored. During periods
of low condensate flow the operator may select to remove one of the vessels
from service by a manually initiated automatic sequence.

(2) A differential pressure switch installed between the influent and effluent
headers will on a high signal cause an alarm and bypass system shall be
initiated as described elsewhere in this section.

(3) 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.

(4) 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 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 alarm will alert the operator to the need for regeneration of a
polishing vessel.

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(5) When the vessel under Service mode is ready for regeneration, the operator
shall change the same into Isolation mode in the panel. Subsequently the
Standby vessel shall be selected for Service mode from the OWS/control
panel. The selection shall follow, required sequences such as pressurization
of the vessel, checking of the effluent quality and putting the vessel in service
on satisfactory effluent quality.

e) Isolation from Service :

Normally Service Vessel once exhausted shall be isolated from service till the
Resin Transfer operation is initiated. In addition, provision to be kept for isolation of
one or all the vessels from service if required by operator from the panel.

f) Resin Transfer from CPU vessel to Regeneration plant:

(1) When a vessel in a service mode needs regeneration as stated above, the
resin transfer from the particular vessel to the regeneration plant shall be
initiated from the panel of the condensate polishing plant.

(2) The transfer of resin from the service vessel shall include operations such as
isolation of the service vessel, hydraulic transfer of the resin to the external
regeneration system (resin separation vessel) and the complete drain down
of the service vessel.

(3) The sequence of Resin Transfer operation shall be initiated from the
Control system in panel of CPP and shall be controlled in the regeneration
Panel.

(4) The completion of the operation shall be exhibited in the panel.

g) Resin Transfer from Regeneration Plant to CPU Vessel :

(1) When the regeneration is completed in the regeneration plant, the resin shall
be transferred to the empty vessel of Condensate Polishing plant.

(2) This shall be initiated by the operator from the control panel of condensate
polishing plant of the unit from which resin was transferred to the
regeneration plant in previous service. Provision shall also be kept to transfer
the regenerated resin to any of the empty vessel of the CPP of any of the TG
unit if required.

(3) The transfer of resin from the regeneration plant shall include operations
such as hydraulic transfer of the resin and the complete drain down of the
water.

(4) The sequence shall be initiated from the panel of CPP and shall be controlled
in the regeneration Control Panel.

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(5) The completion of resin transfer operation shall be exhibited in both the
Control panels.

h) Rinse mode :

(1) After transfer of regenerated resin from the regeneration plant to the empty
condensate polisher vessel, this rinse cycle shall be initiated from the Control
system of the respective unit so that the vessel may be rinsed and kept ready
for next service cycle.

(2) The rinse mode shall be a manually initiated full automatic sequence. This
sequence shall include the rinse down step using condensate at a suitable
rate until the unit effluent quality is acceptable for boiler feed water. Prior to
rinsing, the resin shall be given air scrub by means of air blowers provided
near the CPP.

(3) The effluent quality shall be determined by conductivity monitoring of the
rinse water outlet, which is returned to the condenser hotwell for recycle.

(4) Cation conductivity values shall be monitored and interlocked to prevent
advancing of the automatic sequence until the rinse down is complete.

(5) The completion of rinse operation shall be annunciated in the panel so that
the rinsed vessel may be selected for Standby mode or Service mode as
per requirement.

6.03.00 Regeneration Control System

6.03.01 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.

6.03.02 Physical cleaning of the resin shall consist of three steps, drain to level, air scrub and rinse.
The air scrub and rinse steps are of short duration, approximately 1 and 2 to 3 minutes
respective time. However the program will allow the operator to increase or decrease the
number of times the sequence is repeated to meet the requirements existing at that time.

6.03.03 The chemical regeneration is a many step sequence. This will include hydraulic
reclassification of the resins and the transfer of the resins to the respective regeneration
vessels. The Bidder may include a layer of inert, intermediate density resin to achieve a
better separation of the cation and anion resins, improve resin regeneration, and reduce
leakage. The separated resins are then back washed, regenerated with hydrochloric acid and
sodium hydroxide solutions respectively and then rinsed. Following the rinse step the resins
shall be given an air scrub followed by 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. The
quality of this discharge will determine if the regeneration has been effective. If the quality is
not satisfactory the regeneration sequence must be repeated . If satisfactory, the mixed resin
is transferred to the resin storage vessel.
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6.03.04 A resin mixing and final rinse may occur in the resin storage vessel provided that the system
design will permit direct return of the resins to the resin separation vessel in the event of an
unsatisfactory regeneration.

6.03.05 Upon satisfactory completion of regeneration, the status shall be annunciated audio-visually
in the regeneration system OWS/control panel and as well as in the Balance of Plant Control
System. This repeat annunciation in the CPP OWS/panel shall facilitate the operator to
initiate resin transfer operation from the regeneration plant to the desired vessel of the Unit in
which the service vessel is empty.

6.03.06 Upon resin transfer operation from regeneration plant as described by the operator from the I
Control System, the regeneration plant shall be ready to receive next batch of exhausted
resin from any of the CPP. The status of regeneration plant (Whether ready to receive resin
for regeneration or under regeneration etc) shall be available in the Control System of
CPP.

6.03.07 Demineralized water shall be used through out the regeneration process for backwashing,
diluting the regenerant, rinsing and resin transfer.

6.03.08 A conical bottom hopper having a water ejector will be used for resin make-up.

6.03.09 At any time only one of the sequence shall be in progress.

6.04.00 Interlocks

a) All interlocks for safe operation of the plant shall be provided. They shall specifically
include the following as minimum requirement.

b) Service vessels can be back in service, only after they have been pressurized.

c) Service vessels can be taken up for resin transfer only after they have been completely
isolated from the condensate system and depressurized.

d) Resin can be transferred to and from only one service vessel at a time.

e) Resin transfer between the service and the regeneration skids shall be permitted only
when the receiving vessel is initially empty.

f) Regeneration sequence can commence, only when the level in the waste neutralisation
pit is low enough to receive the entire waste quantity of waste water from the
regeneration operation.

g) 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
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over ride sequence, if required. 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.

h) 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.

i) 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.

j) Adequate diluent water flow shall be established before starting of the ejectors/ dosing
pumps for acid and alkali.

k) The immersion heater in the hot water tank can be put on only when there is adequate
water level in the tank.

7.00.00 PAINTING

7.01.00 All the Piping, Valves and Equipments of this system shall be protected against external
corrosion by providing suitable painting.

7.02.00 The surfaces of stainless steel, Gunmetal, brass, bronze and non-metallic components shall
not be applied with any painting.

7.03.00 The condensate pipelines and valves near the condensate polisher vessels shall be painted
as specified under Power Cycle Piping specification in Part-B of the Technical Specification.

7.04.00 All the condensate polisher vessels and other equipments, piping, valves and equipments in
the regeneration area shall be painted as follows:

(a) For all the steel surfaces inside the building (indoor installation), a coat of chlorinated
rubber based zinc phosphate primer of minimum DFT of 50 microns followed up with
undercoat of chlorinated rubber paint of minimum DFT of 50 microns shall be applied.
Then, intermediate coat consisting of one coat of chlorinated rubber based paint
pigmented with Titanium di-oxide with minimum DFT of 50 microns and topcoat
consisting of two coats of chlorinated rubber paint of approved shade and colour with
glossy finish and DFT of 100 microns shall be provided. Total DFT of paint system
shall not be less than 200 microns.

(b) For all the steel surfaces exposed to atmosphere (outdoor installation), one primer
coat of epoxy resin based zinc phosphate primer of having a minimum DFT of 100
microns followed up with undercoat of epoxy resin based paint pigmented with
Titanium Oxide with minimum DFT of 100 microns shall be applied. Thereafter
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topcoat shall be applied consisting of one coat of epoxy paint suitably pigmented of
approved shade with glossy finish and DFT of 75 microns. Additionally finishing coat
of polyurethane of minimum DFT of 25 microns shall be provided over the topcoat.
The paint may be applied in one coat, incase high built paint is used, otherwise two
coats shall be applied. Total DFT shall not be less than 300 microns.

(c) Specification for the application of Epoxy coating for internal protection of DM tank
shall be as follows :

Primer hardener : One coat of unmodified epoxy resin alongwith polymide.

Paint hardener : Two (2) coats unmodified epoxy resin alongwith
Aromatic adduct.

Total thickness of primer and paint should not be less than 400 microns.

SECTION-VI
PART-B
A - 6
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SECTION - VI
PART-B
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LOW PRESSURE PIPING
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LOW PRESSURE PIPING

1.00.00 EQUIPMENT SIZING CRITERIA

1.01.00 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.

1.02.00 For all L.P. 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.

1.03.00 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
and recirculation 1.2-1.8 1.8-2.4 2.1-2.5

(c) Header ------ 1.5-2.4 2.1-2.4

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) C.I 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.

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(b) Compressed Air Application
Compressed air - 15.0 m/sec.(under Average Pressure & Temp. conditions)
1.04.00 The pipes shall be sized for the worst (i.e. maximum flow, temp. and pressure values)
1.05.00 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.
1.06.00 Corrosion allowance of 1.6 mm will be added to the calculated thickness being considered.
1.07.00 Bend thinning allowance/manufacturing allowance etc. shall be as per the requirement of the
design code provision.
1.08.00 High points in piping system shall be provided with vents along with valves as per the system
requirement. Low points shall be provided with drains along with 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.
1.09.00 Material of construction for pipes carrying various fluids shall be as specified elsewhere.
1.10.00 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.
1.11.00 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.
1.12.00 Threaded joints shall be provided with Teflon sealant tapes.
1.13.00 Following types of valves shall be used for the system/service indicated.
SYSTEM TYPES 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 (if any) x x x x x
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1.14.00 Recirculation pipes along with 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 flow of single pump operation
or the recommended flow of the pump manufacturer whichever is higher.

2.00.00 TECHNICAL SPECIFICATION

2.01.00 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.
2.02.00 Pipes and fittings
2.02.01 All low pressure piping systems shall be capable of withstanding the maximum pressure in
the corresponding lines at the relevant temperatures. However, the minimum thickness as
specified in the following clauses and or respective codes for pipes and fittings shall be
adhered to. The bidder shall furnish the pipe sizing/ thickness calculation as per the criteria
mentioned above under LP piping equipment sizing criteria of this Technical Specification.
2.02.02 Piping and fittings coming under the purview of IBR shall be designed satisfying the
requirements of IBR as a minimum.
2.02.03 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.
2.02.04 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).
2.02.05 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.
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2.02.06 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.
2.02.07 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.
2.02.08 For rubber lined ERW pipes, beads shall be removed.
2.02.09 Inspection holes shall be provided at suitable locations for pipes 800 Nb and above as
required for periodic observations and inspection purposes.
2.02.10 At all intersection joints, it is Contractor's responsibility to design and provide suitable
reinforcements as per the applicable codes and standards.
2.02.11 For large size pipes/ducts, 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 where ever specified and required shall be conducted in
order to determine the location , number and size of the Air-Release valve on certain long
distance/high volume piping systems, if applicable within the scope of work of the package.
2.03.00 Material
2.03.01 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.
2.03.02 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.
2.03.03 All materials shall be new and procured directly from the manufacturers. Materials procured
from traders or stockists are not acceptable.
2.03.04 All materials shall be certified by proper material test certificates. All material test certificates
shall carry proper heat number or other acceptable references to enable identification of the
certificate that certifies the material.
2.03.05 Material of construction for pipes carrying various fluids shall be as follows:

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1 Raw water, ash water, circulating IS-2062 Gr. B/ASTM A-36/ASTM
Water, aux. cooling water, clarified A-53 type 'E' Gr.B / IS-3589
Water, service water, air pre-heater Gr. 410 /IS-1239 Heavy. For
Wash water, clarifier sludge and equipment cooling water system
Equipment cooling water including wherever DM water is used or
Both primary & secondary circuit alkaline solution is used for
(DMCW pH-corrected & ACW drain pipes 50NB and below, pipe
water material shall be stainless steel
to ASTM A312 Gr. 304 sch. 40
Seamless.

2 Demineralised water, (condenser Stainless steel to ASTM A-312,
Make up water, Boiler fill and Gr.304 welded for sizes above
Deaerator Fill water, equipment cooling 50mm NB
Water piping from overhead tank to
Suction header of DMCW pumps Stainless steel to ASTM A312,
and chemical dosing system to Gr. 304 sch. 40 Seamless for
Primary circuit of equipment sizes 50mm and below
Cooling water (DMCW System),
ECW overhead tank make-up water

3 Drinking water ASTM A-53 type E Gr. B
galvanized/ IS 1239 heavy
galvanized/IS 3589 Gr 410
Galvanized to IS- 4736 or
equivalent.

4. Instrument air & plant air. ASTM A-53 type E Gr. B
galvanized/ IS 1239 heavy
galvanized/IS 3589 Gr 410
galvanized to IS- 4736 or
equivalent.

5. (Condensate) spill water/ ASTM A 106 Gr. B
Deaerator Drain

6. Oil piping API 5L

2.03.06 In water lines, pipes upto 150mm 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 less than IS:1239 Grade
Heavy except for demineralised water, drinking water and condensate spill lines.
2.03.07 Pipes of above 150mm 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. 1000mm 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).
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2.03.08 In demineralised 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 65mm 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.
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.
2.03.09 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).
2.03.10 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.
2.03.11 Condensate lines shall be to ASTM A 106 Gr. B and dimension to ANSI B 36.10 schedule
"standard" as minimum to be maintained.
2.03.12 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.
2.04.00 Piping layout
2.04.01 Piping shall be grouped together where practicable and routed to present a neat appearance.
2.04.02 Piping routing shall be such as to provide sufficient clearance for removal and maintenance
of equipment, easy access to valves, instruments and other accessories. The piping shall not
encroach on the withdrawal space of various equipments.
2.04.03 Over head piping shall have a normal minimum vertical clearance of 2.5 meters above
walkways and working areas and 8m above roadways/railways. When several pipe lines are
laid parallel, flanged joints must be staggered. Welded and flanged joints should as far as
possible be located at one third span from supports. if the support is situated right under the
welded joints this joint must be reinforced with a strap. Flanged and welded joints must be
avoided in the middle of the span. Valves should be located in such a manner so as to
ensure their convenient operation from the floor or the nearest platform.
2.04.04 Pipe lines 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
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Manager to the installation of the field run pipe work. Based on these approved layouts the
Bidder shall prepare the BOQ of field run-pipes and submit to Employer for approval.
2.04.05 All piping shall be routed so as to avoid interference with other pipes and their hangers and
supports, electrical cable trays, ventilation ducting, structural members, equipment etc.
Adequate clearance shall be ensured with respect to the above to accommodate insulation
and pipe movements, if any.
2.04.06 Piping shall generally be routed above ground but where specifically indicated/approved by
the Project Manager the pipes may be arranged in trenches or buried. Pipes at working
temperature above the ambient shall however not be buried.
2.04.07 Sufficient up stream and down stream lengths shall be provided for flow measuring devices,
control valves and other specialties.
2.04.08 All local instruments shall be located on pipe lines as to render them observable from the
nearest available platforms.
2.04.09 Openings provided in the wall for pipelines must be closed with bricks and mortar with 10-12
mm clearance between brick work and pipe after taking care of insulation and thermal
movement, if any. The clear space must be filled with felt or asbestos or approved filling
compound.
2.05.00 Slope/Drains and Vents
2.05.01 Suitable slope shall be provided for all pipelines towards drain points. It is Bidder
responsibility to identify the requirements of drains and vents, and supply the necessary pipe
work, valves, fittings, hangers and supports etc. 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 for use during
hydrostatic test shall be plugged after the completion of the test. Vent shall not be less than
15mm size. Drains shall be provided at low points and at pockets in piping such that
complete drainage of all systems is possible. Drain shall not be less than 15mm for line size
up to 150mm, not less than 20mm up to 300mm and not less than 25mm for 350mm to
600mm pipes and not less than 50mm for 600mm and above pipes.
2.05.02 Air piping shall be sloped so that any part of the system can be drained through the shut-off
drain valve or drain plugs.
2.06.00 Pipe Joints
In general all water lines 65mm 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
50mm and below by socket welding unless mentioned otherwise specifically. All air lines
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2.06.01 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 and fittings are already galvanized before the above mentioned
fabrication then suitable application of Zinc-Silicate paste adequately at the welded
surface (both in side & out side) after welding with zinc rich electrode, along with the
nascent threaded metal portions 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 paste. 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
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galvanic protection has been impaired due to welding of pipe-to-pipe joint. Thus the
last erection joint shall be flanged joint.
2.06.02 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. J ointing by butt weld, or socket weld shall depend upon the respective piping
material specifications.
2.06.03 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.
2.07.00 Bends/elbows/mitre bends/ Tees/ Reducers & other fittings
2.07.01 Unless otherwise specified elbows shall be of long radius type.
2.07.02 For pipe sizes up to 65Nb, long radius forged elbows or seamless pipe bends shall be used.
Pipe bends, if used, shall be cold bent to a radius measured to the centre line of pipe of 3 to
5 times the pipe diameter.
2.07.03 For steel pipes 80 Nb and above, seamless long radius forged elbows shall be used. For
pipe size 350Nb and above mitre bends may be used for all pipes except rubber lined pipes.
The bend radius shall be 1 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 22 deg. Fabrication of
mitre bends shall be as detailed in BS 2633/BS534.
2.07.04 Mitre bends are not acceptable in case of rubber lined mild steel pipes.
2.07.05 For pipe fittings such as reducers and tees, the material shall be to astm-a-234 gr. WPB up
to 300 NB. For pipe reducers and tees above 300 NB, the fittings may be fabricated
conforming to parent pipe material. Provision of compensation pads shall be kept as per
ANSI B 31.1. The fitting shall conform to the dimensional standard of ANSI B-16.9.
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However, for pipes up to 150 NB, pipe fittings may be supplied with material and dimension
conforming to IS 1239 in case parent pipes also conform to IS 1239.
For pipes, above 1200 NB, reducer and tees shall be to dimensional standard of AWWA-C-
208.
2.07.06 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 up to and including 50mm 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.
2.07.07 In no case, the thickness of fittings shall be less than the thickness of parent pipe,
irrespective of material of construction.
2.08.00 Flanges
2.08.01 Flanges shall be slip on type. Welding of flanges in tension is not permitted.,
2.08.02 All flanges and-flanged drilling shall be to ANSI B 16.5/BS EN-1092 of relevant
pressure/temperature class. Flanges shall be fabricated from steel plates conforming to
ASTM A 105/IS 2062 Gr. B. 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.
2.09.00 Specific technical requirement of laying buried pipe with anti corrosi ve treatment
The pipe in general shall be laid with the top of the pipe minimum 1.0 (one) meter below
finished general ground level.
2.09.01 Trenching
(a) The trench shall be cut true to the line and level and shall follow the gradient of the
pipeline. The width of the trench shall be sufficient to give free working space on
each side of the pipe. Trenches shall conform to IS 5822.
(b) Free access shall be provided for the welding of the circumferential joints by
increasing the width and depth of the trench at these points. There should be no
obstruction to the welder from any side so that good welded joint is obtained.
(c) The free working space shall conform to IS: 5822. The trench shall be excavated so
as to provide minimum cover of 1000mm between the top of the pipe and finished
grade.
(d) Prior to lowering and laying pipe in any trench, the bidder shall backfill and compact
the bottom of the trench or excavation in accordance with is: 5822 to provide an
acceptable bed for placing the pipe.
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(e) Coating and Wrapping shall be done as under
2.09.02 Preparation and cleaning of piping
(a) The pipeline shall be thoroughly cleaned of all rust, grease, dirt, weld scales and
weld burrs etc. moisture or other foreign matter by power cleaning method such as
sand blasting, power tool cleaning, etc. Grease or heavy oil shall be removed by
washing with a volatile solvent such as gasoline. Kerosene 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 230mm for joints, which shall be coated manually at site after laying, welding and
testing the pipe.
(d) On the internal surface for pipes 1000 Nb and above, a coat of primer followed by a
hot coal-tar enamel or coal tar epoxy painting (cold) shall be applied.
2.09.03 Coating and wrapping
(a) Buried piping shall be coated and wrapped, as per specification, after completion of
welded and/or flanged connections, and after completion and approval of Hydro
testing. Materials to be used for coating and wrapping of underground pipelines are:
(1) Coating primer (coal tar primer)
(2) Coating enamel (coal tar enamel)
(3) Wrapping materials.
(b) All primer/coating/wrapping materials and methods of application shall conform to IS:
10221 except asphalt/bitumen material. Materials (primer/coating/wrapping) as per
AWWA-C-203 are also acceptable.
(c) Protective coating shall consist of coal tar primer, coal tar enamel coating, glass
fiber, tissue inner wrap followed by glass fiber or coal tar impregnated Kraft outer
wrap or finish coat
(d) Number of coats and wraps, minimum thickness for each layer of application shall be
as per IS-10221. Number of. Coats and wraps shall be decided based on soil
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corrosivity/resistivity as indicated in IS-10221. Soil data-for this purpose shall be
made available.
(e) Total thickness of completed coating shall not be less than 4.0 mm.
(f) Alternatively, the anti-corrosive protection can consist of anti-corrosive protection
Coal-tar tapes. Material and application of tapes shall conform to AWWA-C-203.
These-tapes shall be applied hot over the cold coal tar primer preferably in steps of
2mm thickness so as to cover the spiral edges of the first tape by the application of
second tape. The total thickness of the finished protective coating shall be 4.0 mm
minimum.
2.09.04 Trench bed preparation and back filling
Prior to lowering and laying pipe in any excavated trench, the bottom of the trench may
require to be back filled and compacted (or as the case may be) to provide an acceptable
bed for placing the pipe. Bed preparation in general shall be as per IS: 5822.
2.09.05 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 jointing Threaded
portion on either side of the socket joint shall be applied with Zinc silicate paste.
All the provisions for trenching' bed preparation' laying the pipe application of primer' coating'
wrapping with tapes 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.
2.10.00 Cleaning and flushing
2.10.01 All piping shall be cleaned by the Bidder before and after erection to remove grease, dirt,
dust, scale and welding slag.
2.10.02 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.
2.10.03 After erection, all water lines shall be mass flushed with water. The cleaning velocities in
water lines shall be 1.2-1.5 times the operating velocities in the pipelines.
2.10.04 All compressed air pipe work shall be cleaned by blowing compressed air.
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2.11.00 Surface preparation and painting
Pipes shall be cleaned both internally and externally thoroughly by blast-cleaning or power
tool cleaning method as indicated above.. In case of oil piping, cleaning will have to be done
by pickling. No painting is required on stainless steel pipe / equipment surface, galvanized
pipe surface or galvanized steel surface. However, necessary color banding for identification
as per color code shall be done. External surface of piping shall be cleaned and prepared as
indicated below.
2.11.01 Primer painting
(a) After the surface is prepared two coats of red oxide (zinc chromate/zinc phosphate)
primer conforming to IS-2074/IS-12744 or equivalent shall be applied. Primer coat
shall be immediately applied without any time lag after the surface preparation.
(b) Any equipment which has been given the shop coat of primer shall be carefully
examined after its erection in the field and shall be treated with a touch up coat of
primer wherever the shop coat has been abraded, removed or damaged during
transit/erection, or defaced during welding.
2.11.02 Finish painting
(a) Paint to be used shall be synthetic enamel paint conforming to IS-2932 or equivalent.
Finish painting shall be carried out in three coats consisting of one intermediate coat
and two finishing coats. Dry film thickness (DFT) of painting inclusive of primer
thickness shall be at least 150 micron.
(b) The primed surface shall be cleaned of dust/dirt/grease etc. without scratching or in
any way damaging the primer coat. The intermediate coat shall be allowed to dry
before applying the finish coat or as recommended by paint manufacturer.
(c) Paint shall be applied by brushing. It shall be ensured that brush marks are a
minimum and the requirements of workmanship is as specified in IS-1477.
(d) Paint used shall be stirred frequently to keep the pigment in suspension. Paint shall
be of the ready mix type in original sealed containers as packed by the paint
manufacturer. No thinners shall be permitted.
(e) No painting shall be done in frost/foggy weather or when the humidity is high to
cause-condensation on the surface to be painted.
(f) The dry film thickness (DFT) after the painting shall not be less than 150 microns.
2.11.03 Other requirements
(a) Paint manufacturers instructions shall be followed in method of application, handling,
drying time etc.
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(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.
2.11.04 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.
2.12.00 Specification for hangers and supports
2.12.01 All supports and parts shall conform to the requirement of power piping code ANSI B 31.1 or
approved equivalent.
2.12.02 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.
2.12.03 Hanger for piping 65mm 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.
2.12.04 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 pipe line movements as necessary. The structural steel work
shall be as per IS: 800/BS: 4360. Insulation protection saddles shall be used at support point
of all insulated piping.
2.12.05 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.
2.12.06 The maximum spans of the supports of straight length shall not exceed the recommended
values indicated in ANSI B 31.1.
2.12.07 All pipe supports shall be designed to provide an absolute minimum head room of 2.5 m from
floor in passages/walkways.
2.12.08 At all sliding surfaces of supports suitable arrangement is to be provided to minimize sliding
friction.
2.12.09 All components of hangers/supports 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.
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2.13.00 Design/Construction/Material Particulars of Gate/ Globe/Check Val ves/ Globe Stop
Valve/Butterfly val ve
2.13.01 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 minimum of maintenance
is required. For valves of size 350mm 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.
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(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 600mm 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.
(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 indicators; rising stem valves shall have only visual indication
through plastic/metallic stem cover for sizes above 50 mm nominal bore.
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(s) For Cl 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.
2.13.02 VALVE BODY MATERIAL
Valve body material for various services shall be as follows:
Valve body material for water application like circulating water, Secondary circuit auxiliary
cooling water of ECW system, Raw water, Ash water make-up, service water, clarified water,
DM cooling water (pH corrected) & drinking water shall be cast iron for sizes 65NB and
above; gun-metal for sizes 50 Nb and below.
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 along with SS internals.
Condensate: Cast Carbon Steel / Forged Carbon Steel.
2.13.03 The design, material, construction, manufacture, inspection, testing and performance of
valves shall comply with all currently applicable statutes, regulations and safety codes in 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.
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.
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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.
2.13.04 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)
2.13.05 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).
2.13.06 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.
2.13.07 All gun metal body valves shall have screwed ends.
2.13.08 All flanged end valves/specialties. shall be furnished along with matching counter flanges,
fasteners, gaskets etc. as required to complete the joints.
2.14.00 Check Valves
2.14.01 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.
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2.14.02 Drilling on flanges of flanged valves must correspond to the drilling on flanges of the piping
system on which the valves are to be installed.
2.14.03 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.
2.14.04 Counter flanges to be installed on air pipes shall be screwed-on type irrespective of size.
2.15.00 Globe Valves
2.15.01 The globe valves shall have the following characteristics:
Straight conveyed flow.
Right angle
Preferably, the valves shall be of the vertical stem type.
2.15.02 Globe valves shall preferably have radiused or spherical seating and discs shall be free to
revolve on the spindle.
2.15.03 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.
2.15.04 For the regulating valves, valves with regulating plug & parabolic outline disc type is
preferred.
2.15.05 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.
2.16.00 Gate val ves
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.
Gate valves shall be of the solid/elastic or articulated wedge disc and rising stem type.
2.17.00 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.
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(b) The valve shall efficiently discharge the displaced air automatically from ducts/pipes
while filling them and admit air automatically into the ducts/pipes while they are being
emptied. The valve shall also automatically release trapped air from ducts/pipes
during operation at the normal working pressure.
(c) Body material of automatic air release valves shall comply generally with BS 1452
Gr. 14/IS: 210 Gr. FG 260. and spindle shall conform to high tensile brass.
(d) Air release valves shall not have any integral isolation device within them. Each Air
release valve shall be mounted, preceded by a separate isolation gate/ butterfly
valve.
2.18.00 Butterfly valves
2.18.01 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 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
CLAUSE NO.

STAGE II (2X660 MW)
SECTION - VI
PART-B
A-6
LOW PRESSURE PIPING
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PAGE
21 OF 29

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 300mm 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-350Nb and above shall have pressure equalizing bypass valves,
wherever system parameters warrant the same.
Valves-350Nb 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
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STAGE II (2X660 MW)
SECTION - VI
PART-B
A-6
LOW PRESSURE PIPING
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PAGE
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torque It shall be designed to hold the valve disc in intermediate position
between full open and full closed position without creeping or fluttering.
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 along with suitable space heaters for motor actuated valves,
which may be either for On-Off operation or inching operation with position
transmitter.
2.18.02 Material of Construction (Butterfl y Valves)
Materials and other design details shall be as indicated below :
(a) Cast Iron Butterfly Valves
Body & Disc ASTM A48, Gr. 40 with 2% Ni/
IS: 210. Gr. FG-260, with 2%
Ni and epoxy coated
Shaft BS 970 431 S: 291 / EN 57, or
AISI-410 or AWWA-permitted shaft
material equivalent to EN-57/AISI-410 or better.
Seat ring 18-8 Stainless steel
Seal Nitrile Rubber
(b) Stainless Steel Butterfly Valves
Body & Disc ASTM A 351, Gr. CF8M / ASTM-A-182-Gr.304.
Shaft ASTM A 182, Gr. 316 / ASTM-A-479 Gr.316/Equivalent
Disc & Seat Rings EPT/BUNA-N/Neoprene
(c) Carbon steel Butterfly Valves
Body & Disc ASTM A 216, Gr. WCB
Shaft ASTM A 182, Gr. 304 / ASTM-A-479 Gr.304/Equivalent
Disc & Seat Rings EPT/BUNA-N/Neoprene
2.18.03 Proof of Design Test (Type Test) for Butterfl y Valves
Proof of Design (P.O.D.) 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
P.O.D. test shall be conducted by the bidder in the presence of Employer's representative.
CLAUSE NO.

STAGE II (2X660 MW)
SECTION - VI
PART-B
A-6
LOW PRESSURE PIPING
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PAGE
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All valves that are designed and manufactured as per AWWA-C-504 shall be governed by
the relevant clauses of P.O.D test in AWWA-C-504. For Butterfly valves designed and
manufactured to EN-593 or equivalent, the P.O.D. test methods and procedures shall
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 P.O.D. test of AWWA-C-504.

2.19.00 MATERIAL OF CONSTRUCTION (GATE/GLOBE/CHECK VALVE)

(a) The materials shall generally comply with the following:

(1) Cast Steel Val ves
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

(2) Stainless steel val ves

Body & Bonnet ASTM A 351 Gr. CF 8M/
ASTM A 182 Gr. 304

Disc -do-

Trim. ASTM 182 Gr. F. 316
/ASTM-A-479Gr.316 or Integral with body
(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 val ves

Body and bonnet IS 318 Gr. 2/ Equivalent
Standard

Trim. -do-

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STAGE II (2X660 MW)
SECTION - VI
PART-B
A-6
LOW PRESSURE PIPING
SYSTEM
PAGE
24 OF 29

(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.
2.20.00 Float operated val ves
(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.
(g) Valves shall be suitable for flow velocities of 2 to 2.5m/sec.
(h) The valves shall have flanged connections.
2.21.00 PAINTING OF VALVES:
Two (2) coats of primer followed by three (3) coats of enamel 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 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.
2.22.00 Tanks and Accessories
2.22.01 The designer and manufacturer of storage tanks shall comply with and obtain approval of all
currently applicable statutory regulations and safety codes in the locality where the
equipment will be installed. The tanks shall conform to IS 803/IS804/IS 805/ IS 2825/ API
650/ IS 4049/ IS 4682 (part-I) and IS 4864 to 4870/ ASME B & PV code Sec.-VIII as the case
may be.
CLAUSE NO.

STAGE II (2X660 MW)
SECTION - VI
PART-B
A-6
LOW PRESSURE PIPING
SYSTEM
PAGE
25 OF 29

2.22.02 DESIGN AND CONSTRUCTION
(a) Design of all vertical atmospheric storage tanks containing water, acid, alkali and
other chemical shall conform to IS:803 & API 650.
(b) Design of all horizontal atmospheric storage tanks containing water, acid, alkali and
other chemicals shall generally conform to IS:2825 as regards to fabrication and
general construction taking care of combined bending, shear & hoop stresses
developed due to supporting arrangement.
(c) Design temperature of vessels shall be 10 deg.C higher than the maximum
temperature that any part of the vessel is likely to attain during the course of
operation.
(d) Tank shall be made from mild steel plates to BS 4360/IS-2062 Gr.B (or equivalent).
(e) The joint efficiency factors to be adopted for design calculations shall be in
accordance with the specified design code.
(f) Tank shall be provided with suitable supporting joints. All vessels shall be provided
with lifting lugs, eye bolts etc. for effective handling during erection.
(g) The material for flanges shall be of ASTM A 105/ IS-2062 Gr.B.
(h) For cylindrical tanks, the plates shall be cold rolled through plate bending machine by
several number of passes to true curvature.
(i) Vessel seams shall be so positioned that they do not pass through vessel
connections. For cylindrical vessel consisting of more than two sections longitudinal
seams shall be offset.
(j) Tanks shall be provided with float operated level indicators/level gauges/level
transmitters and level switches, as required, with complete assembly. Suitable
flanged pads for level switches mounting shall also be provided. The level indicator
can be top or side mounted as the case may be.
(k) In addition to inlet and outlet nozzles, the tanks shall be provided with vents,
overflow, drain nozzles complete for various connections on tanks. Overflow lines
from storage tanks is to be routed to the nearest surface drains. For tanks containing
dm water, alkaline water or power cycle water the vent to atmosphere shall be
through carbon-di-oxide absorber vessel suitably mounted on the tank. CO2
absorber vessel shall be provided with the initial fill of chemicals. Similarly for
equipment cooling water overhead tank, the overflow & drain from tank shall be
combined together and shall be led to nearest drain (at zero level) via. a seal-trough
so as not to come directly in contact with atmosphere.
CLAUSE NO.

STAGE II (2X660 MW)
SECTION - VI
PART-B
A-6
LOW PRESSURE PIPING
SYSTEM
PAGE
26 OF 29

(l) Tanks shall have suitable stairs/ladders on inside and outside of the tanks,
manholes/inspection covers as required and also platform suitably located.
(m) Tank supporting arrangement as approved by Employer shall be provided with all
plates/angles/joints/flats and supporting attachment including lugs, saddles, legs etc.
(n) Piercing nozzles/pipes from tank body / dish ends shall be adequately compensated
as per relevant code.
(o) Tank fabrication drg. and design calculations shall be approved by the Project
Manager.
2.22.03 Corrosion protection
(a) A corrosion allowance, applicable to surface in contact with corrosive media, when
required, shall be taken into consideration.
(b) Manholes shall be provided for easy access into the vessels. The size shall be
minimum 500 mm and will be with cover plate, nuts bolts, etc. to ensure leak
tightness at the test pressure.
(c) Each tank shall be provided with drilled cleats welded to the tank for electrical
grounding. Material of cleats shall be same as that of the shell.
(d) Epoxy-coating shall be provided on the inside of vessel in three coats (minimum)
resulting in total thickness of not less than 150 micron in which ever case required,
such as equipment cooling water overhead tank, sodium hydroxide tank, condensate
storage tank, condensate surge tank etc.
2.22.04 Cleaning & Painting
(a) Inside surface of all tanks shall be protected by anti-corrosive paints as required.
(b) For tanks/vessel requiring epoxy painting, all inside surface shall be blast cleaned
using non-siliceous abrasive after usual wire brushing.
(c) Outside surfaces of all vessels shall be provided with two coats of primer with three
(3) coats of epoxy resin based paint of approved color.
2.23.00 RUBBER EXPANSION JOINTS
2.23.01 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.
2.23.02 The expansion joints shall be single bellow rubber expansion joints. The arches of the
expansion joints shall be filled with soft rubber.
CLAUSE NO.

STAGE II (2X660 MW)
SECTION - VI
PART-B
A-6
LOW PRESSURE PIPING
SYSTEM
PAGE
27 OF 29

2.23.03 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.
2.23.04 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.
2.23.05 Reinforcement, consisting of solid metal rings embedded in carcass shall be provided.
2.23.06 Expansion joints shall be complete with stretcher bolt assembly. The expansion joints shall
be suitable to absorb piping movements and accommodate mismatch between pipe lines.
2.23.07 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.
2.23.08 The expansion joints shall be adequately reinforced, with solid steel rings, to meet the
service conditions under which they are to operate.
2.23.09 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.
2.23.10 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.
2.23.11 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.
2.23.12 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.
2.23.13 Each joint shall have a permanently attached brass or stainless steel metal tag indicating the
tag numbers and other salient design features.
2.23.14 Bidder to note that any metallic part which comes in contact with DM /corrosive water shall
be of Stainless Steel material.
CLAUSE NO.

STAGE II (2X660 MW)
SECTION - VI
PART-B
A-6
LOW PRESSURE PIPING
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PAGE
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2.24.00 STRAINERS
2.24.01 Simplex type
The strainers shall be basket type and of simplex construction. The strainer shall be provided
with plugged drain/blow off and vent connections. The free area of the strainer element shall
be at least four (4) times the internal area of the connecting pipe lines. The strainer element
shall be 20 mesh. Pressure drop across the strainers in new condition shall not exceed 1.5
MCW at full flow. Wire mesh of the strainers shall be suitably reinforced, to avoid buckling
under operation. Strainer shall have screwed blow off connection fitted with a removable
plug. The material of construction of various parts shall be as follows:

(a) Body IS: 318, Gr. 2 up to 50 mm Nb, and IS: 210 Gr.
FG 260 above 50 mm Nb. (For DM water/ -Body: AISI
316 or equivalent)

(b) Strainer Stainless steel (AISI 316)
Element

(c) End connection Screwed upto 50 mm Nb, and
Flanged above 50 mm Nb

2.24.02 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 or ASTM-A-515 Gr. 75/IS-2062
Gr. B and internally epoxy-painted above 50 mm NB.

Strainer element Stainless steel (AISI 316)

End connection Screwed up to 50mm Nb, and
Flanged above 50 mm 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.
CLAUSE NO.

STAGE II (2X660 MW)
SECTION - VI
PART-B
A-6
LOW PRESSURE PIPING
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PAGE
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(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.
2.24.03 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.

SECTION-VI
PART-B
A - 7
NOT USED
SECTION-VI
PART-B
A - 8
A-8
HYDROGEN
GENERATION PLANT
PAGE
1 OF 7
SECTION-VI
PART-B
STAGE-II (2X660 MW)
1.00.00 GENERAL PLANT DESIGN CRITERIA
1.01.00 To be designed for continuous, as well for as two shift or one shift operation.
1.02.00 The scheme shall be based on manufacturer's standard. The scheme & construction
details of equipment are described for hydrogen generation plant of unipolar design in
this section. However, Bipolar designs are also acceptable, provided the same are of
proven design from reputed manufacturers. Some of the components specified herein
may not be applicable for bipolar design. For bipolar deisgn, the same need not be
supplied if it is not applicable as per manufacturer's standard practice. However, for
such bipolar design, all safety measures shall be provided in line with specification/
schematic drawing.
1.03.00 Total Plant Capacity to be sized as follows :
1.03.01 Leakage rate per generator = "A" NM3/day
1.03.02 Requirement of one generator filling = "B" NM3.
1.03.03 Number of TG Units = C
1.03.04 Hydrogen generation plant Capacity = [C*1.5* A + B/30 ]/12 NM3/hr
1.03.05 However total plant capacity shall not be less than 12 NM
3
/hr with two streams of
50% Capacity each of minimum 6 NM
3
/hr.
1.04.00 Hydrogen purity to be maintained at gas manifolds 99.9%.
1.05.00 Moisture content in hydrogen :- 0.05 gm/m
3
(max.)
1.06.00 The Complete Hydrogen generation plant system, equipments, layout etc. shall be
designed as per the Explosives Authority and the bidder shall obtain the approval from
Chief controller of Explosives - India and other statutory authorities for the design and
installation of the plant.
2.00.00 GENERAL OPERATIONAL CRITERIA/PHILOSOPHY
2.01.00 To be designed for Continuous duty.
2.02.00 To be designed for parallel operation of both streams.
2.03.00 Flexibility to operate electrolyser in part load.
2.04.00 Complete operation from remote control panel/OWS.
A-8
HYDROGEN
GENERATION PLANT
PAGE
2 OF 7
SECTION-VI
PART-B
STAGE-II (2X660 MW)
2.05.00 To trip the plant in case of high hydrogen level inside the building suitable numbers of
hydrogen gas detectors to be provided by the bidder for each of the room.
2.06.00 Set pressure to be maintained with help of back pressure regulation valve.
2.07.00 Automatic operation of standby compressor as and when required.
2.08.00 To provide alarm & tripping of compressor based on suction conditions.
3.00.00 CONSTRUCTION DETAILS OF EQUIPMENT
3.01.00 Electrolyser
3.01.01 Modular type. Both bipolar and unipolar type of electrolysers are acceptable.
3.01.02 Cells in electrolyser shall be connected to each other. Further for unipolar design there
shall be provision to isolate any one of the cells in electrolyser. The cells in
electrolyser shall be of corrosion resistant material.
3.01.03 The electrolyser to be designed to operate at part load of normal capacity without any
disconnection and operation interruption and shall produce the hydrogen gas of specified
purity and dryness.
3.01.04 All measuring instruments, controllers and control valves shall be provided.
3.01.05 Safety devices are to be provided on each collecting pipe to release gas pressure in
case it goes above the limits.
3.01.06 To be designed so that it can be dismantled, cleaned, and reassembled easily.
3.01.07 Proper sealing shall be provided by the Bidder while crossing the wall to avoid any
gas leakage to Rectifier Room.
3.01.08 Each electrolyser shall be fitted with the following instrumentation.
(a) In unipolar design one explosion proof temperature switch in each cell for
electrolyser temperature high alarm on the control panel. In case of bipolar
design one explosion proof temperature switch in each generator module for
electrolyser temperature high alarm on the control panel.
(b) A local pneumatic temperature controller, controlled through PLC, to maintain
the electrolyser temperature to a preset value by controlling cooling water flow
to the electrolyser through the temperature control valve.
(c) One temperature gauge for local indication for electrolyte temperature.
(d) One off-line specific gravity measuring instrument.
A-8
HYDROGEN
GENERATION PLANT
PAGE
3 OF 7
SECTION-VI
PART-B
STAGE-II (2X660 MW)
3.02.00 Rectifier
3.02.01 Two nos, of rectifier (one for each electrolyser) to cater the load of each of the
electrolyser. The rectifier equipment shall be complete in all respects with air-cooled
rectifier transformer, thyristor converter, electronic control and annunciation, fillers choke
etc mounted in suitable panels.
3.03.00 Gas washing Tanks (if applicable)
3.03.01 One for each electrolyser with manometers at inlet and outlet, temperature gauge, level
switches for controlling the level of DM water in the tank etc.
3.04.00 Demineralised water tank
3.04.01 One number tank of Capacity adequate for 5 days normal requirement of hydrogen gas
generation on continuous basis at rated capacity of (minimum) 12 NM/hr.
3.04.02 To be fitted with removable drain connections, level switches/ transmitters, level
indicators etc.
3.05.00 Caustic solution mixing tank
(i) Capacity - Suitable to fill one electrolyser
(ii) Material - High Density PVC
(iii) Accessories - Removable cover, motor operated pump,
instrument as required
(iv) Pump (if applicable) - Suitable to pump alkali upto the cells with
discharge flexible hose, differential pressure
gauge across suction filter, pressure gauge at
pump discharge etc.
3.06.00 Hydrogen gas Holders (if applicable)
(i) Number Two (2) numbers (one for filling, one for supply
to compressor)
(ii) Capacity Each Gas holder shall be equal to that of
hydrogen generation plant capacity or minimum
of 12 NM/hr (whichever is higher).
(iii) Material IS-2062/2002 or equivalent
(iv) To be designed for outdoor duty
A-8
HYDROGEN
GENERATION PLANT
PAGE
4 OF 7
SECTION-VI
PART-B
STAGE-II (2X660 MW)
(v) To provided with two (2) Seal pots for each gas holders
(vi) Accessories such as Wire rope, Counter weight, guide pulley required to
suspend the gas holders, steel stairs four-way motorised valves, flame proof low
& high level switches for interlock and control, float type level indicators, etc.
vii) Venting of hydrogen shall be through flame arrestor.
3.07.00 De-oxy unit (if applicable)
3.07.01 One number De-Oxy unit shall be provided to handle both the streams and capable to
remove oxygen as impurity. The unit should have accessories such as heater with
temperature control device, gas cooler, filter, necessary instruments etc
3.08.00 Hydrogen compressors and drives,
(i) Number 3x50% as specified in the scope (two
working & one standby)
(ii) Capacity of each compressor shall be 125% of each stream capacity
(iii) Design delivery Pressure 150 kg/cm2 (g)
(iv) Type Preferably Oil free, Piston or Diaphragm type.
(v) Piston type Of proven design
(vi) Diaphragm type Triple diaphragm failure detection system. The
side and oil side diaphragms shall be of
stainless steel.
(vii) Drive cage As speciifed in relevant subsections (Electrical)
of Technical Speciifcations.
(viii) Activated carbon filters 2 x100% and required in case of oil lubricated
compressor
(ix) All metal to metal joints shall be provided with "O" rings of suitable grade
material.
(x) To provide auxiliaries such as built in relief valves, Pressure and temperature
gauges after every compression stages, mechanical lubricator, built in automatic
unloader devices, Water cooled inter coolers after every compression stage, flow
switches, pressure gauges in coolant line, sight flow indicators in coolant line,
V belt drive with pulleys, a transfer switch to allow operation of standby
A-8
HYDROGEN
GENERATION PLANT
PAGE
5 OF 7
SECTION-VI
PART-B
STAGE-II (2X660 MW)
compressor automatically, suction filters, scrubber to remove any traces of
entrapped electrolyte, separator and filters, suitable protection device to prevent
suction of water from gas holders as a back-up to low level switch provided on
the gas holders for compressor TRIP, Mist Eliminators One number on-line
hydrogen purity analyser at the suction etc.
(xi) To make arrangement for continuously monitoring hydrogen purity before
compressor and before filling of gas into cylinders and to provide suitable alarm
and automatic tripping of plant in case, hydrogen purity falls below the preset
level.
3.09.00 Drying system for Hydrogen gas
3.09.01 To provide twin tower Moisture separating columns of Regenerative design alongwith
instruments.
3.09.02 To provide valves arrangement to suit operation of one Column & another under
regeneration. The operation shall be automatic based on PLC/microprocessor command.
3.10.00 Back Pressure regulating valve
3.10.01 Spring loaded disc operated self actuating type back pressure regulating valve to
maintain 150 kg/cm
2
(g) pressure on the compressor discharge.
3.10.02 To be provided with accessories such as Pressure sensing element, controller etc.
3.11.00 Cylinder Manifold
3.11.01 To provide one dual cylinder filling manifold, arranged for two banks of minimum four
cylinders each.
3.11.02 To provide accessories such as Isolating valves, safety valves, Pressure gauges,
pressure switch (To shut-off compressors beyond set pressure) "ON-LINE" Hydrogen
purity analyser, trace oxygen analyser, moisture analyser at cylinder manifold, records
of hydrogen purity and moisture content, & one number PORTABLE hydrogen gas
purity testing kit.
3.12.00 Flushing System
3.12.01 To be provided with necessary connection with proper isolation devices, nitrogen
cylinders, valves, manifolds piping etc to enable purging the system with nitrogen
commissioning and each maintenance work.
3.13.00 Piping
3.13.01 All Pipe to conform to ASA pressure piping code, and seam less type.
A-8
HYDROGEN
GENERATION PLANT
PAGE
6 OF 7
SECTION-VI
PART-B
STAGE-II (2X660 MW)
3.13.02 All high pressure joints shall of ferrule/ welded construction.
3.13.03 All vents to be fitted with flame arrestor.
3.13.04 All high pressure drains to be terminated through H2 traps and all low pressure drains
to be terminated through U-bends.
3.13.05 Cooling water pipe be minimum 80 NB size.
4.00.00 VENTILATION SYSTEM
4.01.00 It shall consist of adequate number of roof exhausters, wall mounted exhaust fans,
ducting (if required), drives & other electrical accessories ducting supports and
supporting system, rain protection cowl, bird screens, vibration isolators nuts & bolts,
grouting frame, transition piece etc. as required to complete the system.
4.02.00 The air quantity of ventilation system shall be estimated based on equipment and solar
heat load and the temperature rise inside the building shall be restricted to maximum
of 3 deg.C over design ambient. However, in no case the number of air changes shall
be less than 30 air changes per hour. The exhaust air shall be discharged at a
suitable height from the room.
4.03.00 Bidder to provide louvers for fresh air supply the building layout.
4.04.00 Bifurcated type of axial flow fans for exhausting air/fumes shall be provided for hydrogen
generation plant area and shall be of flame proof construction with inlet and outlet
dampers. However, ducts and all other parts like blades etc. shall be epoxy painted.
5.00.00 HYDROGEN AND CO
2
GAS CYLINDERS
5.01.00 Adequate quantity of gas cylinders shall be supplied and installed as described in
relevant Electrical Sub-Sections of technical specification.
6.01.00 All electrical devices like switches/transmitters/controller/analyzer/solenoid valves which
are located in the hydrogen generation plant shall be made intrinsically safe by
providing suitable type of transformer isolated barrier/ Zenner barrier of standard make.
Otherwise such instruments shall be provided with explosion proof enclosure suitable for
hazardous areas describd in National Electric Code (USA), Article 500, Class-I, Division-
I or EN60079-14 or shall comply with the essential requirements of ATEX directives. All
fittings, cable glands etc. shall be strictly as per NEC recommendation article, 500 to
503.
A-8
HYDROGEN
GENERATION PLANT
PAGE
7 OF 7
SECTION-VI
PART-B
STAGE-II (2X660 MW)
7.00.00 PAINTING
7.01.00 All the Piping, Valves and Equipments of this system shall be protected against
external corrosion by providing suitable painting.
7.02.00 The surfaces of stainless steel, Gunmetal, brass, bronze and non-metallic components
shall not be applied with any painting.
7.03.00 The steel surface to be applied with painting shall be thoroughly cleaned before
applying painting by brushing, shotblasting etc as per the agreed procedure.
7.04.00 For all the steel surfaces, one primer coat of epoxy resin based zinc phosphate primer
of having a minimum DFT of 100 microns followed up with undercoat of epoxy resin
based paint pigmented Titanium di-oxide with minimum DFT of 100 microns shall be
applied. Thereafter topcoat shall be applied consisting of one coat of epoxy paint
suitably pigmented of approved shade with glossy finish and DFT of 75 microns.
Additionally finishing coat of polyurethane of minimum DFT 25 microns shall be provided
over the topcoat.
The paint may be applied in one coat, incase of high built paint is used, otherwise
two coats shall be applied. Total DFT shall not be less than 300 microns.
7.05.00 Painting of imported items shall however be as per manufacturer's standard practice.
SECTION-VI
PART-B
A - 9
SERVICE ELEVATORS
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SECTION - VI
PART-B
A-9
SERVICE ELEVATORS
PAGE
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1.00.00 SERVICE ELEVATORS

1.01.00 DESIGN CRITERIA AND OPERATIONAL SPECIFICATION

1.01.01 Design
Elevator shall be of conventional for Service Building and for TG building and of panoramic
type with five glass panels on rear side for Administration Building. The elevator shall meet
the quality of international standard. The quality of glass panel on rear should be of highest
grade from safety point of view and should meet the best standard.

1.01.02 No. of floors to be served shall be as per the specification and tender drawing of the
Employer. Bidders shall quote variation in price for addition/deletion of one landing level in
the relevant schedule of Forms and Procedures. However, bidder shall quote for above
indicated landing levels in his base offer. No of floors and landing elevations are tentative
only. The final landing elevations for all buildings shall be subject to approval by the
Employer after award.

1.01.03 Elevators shall be designed based on following criteria :

i) Design/construction/installation codes. : Latest edition of IS: 14665 (all
parts)

ii) Load carrying capacity : a) 884 kgs. (equivalent to 13
persons) for passenger
elevator for service building ,
TG building and
Administration Building.

iii) Rated speed : 1.0 m/sec.

iv) Position of machine room : Directly above the elevator shaft.

v) Machine room : Machine room shall be provided
by NTPC. However window air
conditioner of minimum 2T
capacity per elevator shall be
provided by bidder.

1.02.00 CONSTRUCTION

Construction of the elevators shall specifically meet all requirements of the codes indicated
and shall have following additional features:

i) Flooring of Cabin : Vitrified ceramic tiles of mat finish.

ii) Car enclosure & car panels

: Stainless Steel

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iii) Handrails on 3 sides : Mirror Stainless Steel

iv) False ceiling : Powder painted

v) Car opening & Hoist way
opening
: Protected by central opening sliding Stainless
Steel door

vi) CABIN ACCESSORIES

: The following accessories shall be provided :
a) Recessed fluorescent light fittings on car
floor.

b) Car control station

c) Emergency stop switch.

d) 5/15A, 3 pin plug socket with switch on top
of lift car.

1. AUTOMATIC RESCUE DEVICE (ARD) - (BATTERY DRIVE):

Bidder to provide a modern Advanced electronic drive system of RESCUING
Passenger Trapped in a ELEVATOR.

2. EMERGENCY SAFETY DEVICES :

The lift shall be provided with safety Device attached to the lift car frame and placed
beneath the car. The safety device shall be capable of stopping and sustaining the
lift car up at governor tripping speed with full rated load in car.

1.02.01 All steel embedment for fixing landing doors/indicators etc. to the Elevator well shaft and
fascia plate shall be supplied by the Bidder.

1.02.02 Guide rails complete with supporting brackets for the car and counter weights.

1.02.03 Elevator drive machines complete with electric motor, reduction gear unit, suspension ropes,
buffers for the cars and the counter weights and other drive and control mechanism. All
foundation anchor bolts, sleeves, anchoring steel and any item required to complete the job
satisfactorily shall be provided by the bidder. The bidder shall also provide for the grouting of
anchor bolts, sleeves, anchoring steel, etc. and other anchorages. Bidder shall provide hoist
and hoisting beam in the machine room ceiling.

1.02.04 Any other steel works as well as all other accessories/components not specified in the
specification but necessary for making the Elevator complete.

1.02.05 All minor building work including the supply of steel items, associated with installation of
equipment in the machine room hoist way, hoist way door, frames and Elevator pit, shall form
part of bidders scope of service, Employer will provide the Elevator-well complete with
foundation and brick walls around the lit-well together with overhead machine room including
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PART-B
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SERVICE ELEVATORS
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trap door and entry door for machine room. The machine room will be provided with R.C.C.
floor slab with necessary pockets for anchor bolts and slots.

1.03.00 OPERATION

1.03.01 Elevator shall have provisions to meet following operational requirements :

a) Selective Duplex collective, automatic operation with or without attendant through
illuminated push button station located inside the lift car.

b) Door operating shall be automatic door operation and electronic door protection
system for opening/closing of car and landing doors.

c) Bidder shall provide car operating panel with luminous buttons, car position
indication in car (both visual and audio) combined with direction arrows, overload
warning indicator, battery operated alarm bell and emergency light and fan & hands
free speaker telephone set with suitable battery, charger & controls.

d) Bidder shall provide emergency indicator to indicate the location of elevator in case
of elevator being stuck up between the floors through automatic flashers (both audio
& visual)

e) Bidder shall provide electronic door detector (Infra red curtain type).

f) Two push buttons, one for upward movement and the other for downward movement
at each intermediate landing and one push button at each terminal landing shall be
provided in order to call the car. Digital hall position indicator at all floors, tell lights at
all floors shall also be provided by the bidder.

g) For facilitating the movement of visually & hearing impaired persons, hall lantern and
car arrival chimes shall be provided in service building and TG building elevators.

h) All fixtures shall be in stainless steel face plates.

i) Push buttons shall be fixed in the car for holding the doors open for any length of the
time required.

j) All other safety/protection/operation interlocks as required by IS:14665 (latest
edition).

1.04.00 Elevator Electricals:

1.04.01 Electric motor:

The driving motors shall conform to I.S 325 and suitable for the Variable Voltage Variable
Frequency (VVVF) application. All motors shall be squirrel cage induction type, suitable for
operation at 415V (+/- 10% variation) , 3 phase, 3 wire, 50HZ (+3% to -5% variation) supply.
Motors shall be provided with thermal class 130 (B) or better insulation.

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1.04.02 Controls:

The controls shall be Variable Voltage and Variable frequency type and shall provide smooth
and constant acceleration and retardation under all conditions of operation . Suitable control
panel shall be provided in the machine room.

1.04.03 Cables and wiring:

All the cables except trailing cables shall be as per IS:1554-1 or IS-7098-I. the PVC outer
sheath of these cables shall be flame retardant, low smoke (FRLS) type with the following
FRLS properties.

a) Oxygen index of min. 29 (as per IS:10810 Part-58)

b) Acid gas emission of max. 20% (as per IEC-754-I).

c) Smoke density rating shall not be more than 60% (as per ASTMD-2843).

The circular trailing cables shall be either in accordance with IS 4289 Part-I (Elastomer
insulated) or IS-4289 Part-II (PVC insulated). The flat type trailing cables if offered shall be in
accordance with IEC-60227-6.
All wiring / cabling between the equipments in the lift machine room and that between the
machine room and equipments in the lift well and at the landings shall be wired in HDP
conduits/ galvanized steel conduits to be supplied by the contractor. Alternatively armored
cables may be used.
1.04.04 Earthing:

The elevator structures and all Electrical equipment, including metal conduits shall be
effectively earthed with the earth conductors provided in the machine room as per IS: 3043.

SECTION-VI
PART-B
A - 10
POWER CYCLE PIPING
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SECTION - VI
PART-B
A-10
POWER CYCLE PIPING
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POWER CYCLE PIPING
1.00.00 EQUIPMENT SIZING CRITERIA
1.01.00 GENERAL
(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 parameter fluctuations and cycling which can be
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.
1.02.00 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 listed below.
Feed Water Suction 2.0-3.0 M/sec
Feed water Discharge 4.0-6.0 M/sec.
Extraction steam (Super heated) 60 M/sec
Extraction steam (Saturated) 30 M/sec
Condensate suction 1.5 M/sec
Condensate discharge 3.0-5.0 M/sec
Auxiliary steam 40 M/sec
Other piping As per good engg. practice
(b.) Inside diameters thus calculated for various piping systems shall be checked for the
allowable pressure drop as per the HBDs.
(c.) Pipe shall be sized for the worst (i.e. maximum flow, temperature and pressure
values) operating conditions for each system considering the maximum occasional
pressure and 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 the
pump NPSH requirement under worst operating conditions.
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(d.) The design pressure for BFP discharge piping up to 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 B31.1.
(i) Discharge Pressure corresponding to Turbine driven BFP trip speed at shut
off head flow condition, If TDBFP characteristics is governing for calculation
of boiler feed discharge piping design pressure.
(ii) Discharge pressure corresponding to Motor driven BFP trip speed
(frequency 51.5Hz) at shut off head flow condition If MDBFP characteristics
is governing for calculation of boiler feed discharge piping design pressure.
However, contractor may consider 20% higher stress as per the provision of ASME
B31.1 (for the piping up to downstream valve at feed regulating station only) for
which the requirement of special provision as per the stipulation of clause no. 520 of
IBR shall be met as a must by the contractor. 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 emergency point of BFP operation. However,
pressure relief valve across the HP heaters shall be provided, as per the tender
drawing, so that the piping and valves beyond feed regulating station are not
subjected to shut-off head condition.
1.03.00 Material Selection
Piping system shall be of carbon steel for design temperature upto 400 deg.C and alloy steel
for design temperature above 400 deg. C.
1.04.00 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 then 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 heavier commercial wall thickness shall then
be selected from thickness schedules (eg. sch.40, sch 80, etc) as contained in ASME B36.10
for OD controlled pipes and from manufactures schedules for ID controlled pipes.
However, in such cases where the calculated thickness for OD controlled pipe falls beyond
the thickness corresponding to the listed schedule nos as given in ANSI B36.10 for the pipe
size, both ID and OD controlled pipes to manufactures schedules are acceptable.
OD controlled pipes shall be to the dimensional standards ANSI B36.10 for carbon & alloy
steels pipes and ANSI B36.19 for stainless steel pipes.
To account for losses due to corrosion, erosion etc. during the plant service life, an allowance
of 1.6 mm/0.75mm shall be considered in the minimum wall thickness calculation of pipes as
per ASME B31.1/IBR respectively.
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Further, the design pressure and temperature, down-stream of any pressure reducing valve
upto and including the first block valve shall be the same as that at up-stream of pressure
reducing valve. The piping at down stream of de-superheater shall be designed for spray
failure condition. The length of piping system considered for spray failure condition shall not
be less than the length required for proper spray mixing as recommended by de-superheater
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 B36.19.
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 the 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 for pipe sizes above 50 Nb, but below 300 Nb and
(b.) Sch. STD for pipe sizes 300 Nb and above.
1.05.00 Layout
(a.) All high points in piping system shall be provided with vents. All low points shall be
provided with drains. Provisions 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 pipe routing shall be such that clear headroom of not less than 2.5 meters above
the walkways/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. The piping shall not encroach
on withdrawal space of various equipment and walking space.
(d.) Wherever there is possibility of ingress of rainwater through floor/ceiling opening at
points where any pipe passes through floor/ceiling suitable weather protection hood
shall be provided.

1.06.00 Stress Analysis
(a.) Flexibility and stress analysis for various piping systems shall be carried out by the
contractor as per the requirement of ASME B31.1. Analysis results shall satisfy the
following.
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(1.) Calculated stresses in the piping system shall be within the allowable limits
stipulated in ASME 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 systems that
there will be no requirement of cold pull for meeting allowable reaction/stress values.
All hangers and supports shall be erected such that they are vertical when the 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
manufacturer(s).
1.08.00 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.) Personnel protection.
(b.) Design for personnel protection
For the piping and the equipment with surface operating temperature of 60 deg.C
and above, the personnel protection insulation shall be applied such that the temperature of
protective cladding shall not exceed 60 deg.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.
Design ambient temperature 40 Deg.C for inside and
45 Deg.C for outside the
Main plant building.
Maximum cladding temperature 60 Deg.C

Wind speed 0.5m/sec. for inside and
0.25m/sec for outside the
Main plant building
Emissivity of cladding 0.2
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Pipe/Equipment wall temp. Maximum operating
temperature.
Thickness calculation As per ASTM C-680 or
equivalent
1.09.00 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 variation in drain 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 submit design
calculation for flash tanks and basis of design parameter selection for Employers
review.
(b.) However the minimum design pressure and temperature for the flash tanks shall be
3.5 Kg/cm2 (g) and 210 deg.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 flash 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 manifolds 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 flash tanks open to atmosphere continuous
spray through an orifice shall also be acceptable.
2.00.00 SPECIFIC REQUIREMENTS : PIPES AND FITTINGS
2.01.00 Manufacturing tolerances on pipe diameter (for both ID and OD controlled pipes) and
thickness shall be as per ASTM A-530/ A999M, as applicable.
2.02.00 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 pipe wall thickness.
2.03.00 Steel pipes and fittings shall in general be provided with butt welding ends as per ANSI B
16.25. Pipe fittings of size 50 Nb and below shall be socket welded as per ANSI B 16.11.
However, in certain cases edge preparations on pipe welding end may be required to be
done to match equipment terminals, valves etc.
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2.04.00 All stubs welded to the pipe including welded thermowells and instrument source tappings
shall be installed on the pipe prior to stress relieving.
2.05.00 Instrument tubing upto and including the root valves and all line drains & vents shall be
generally of the same pipe material as that of the main pipe on which they are located unless
& until specified otherwise elsewhere.
2.06.00 Wherever ASTMA 106 Gr. B/Gr. C or A - 105 material are used the maximum carbon content
shall be limited to 0.30% (Max.).
2.07.00 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.
2.08.00 Non-destructive examinations for butt welds of NPS over 50 mm and for welded branch
connections of branch size over 100 mm NPS shall be as 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 and as per Regulation 360 of IBR or table 136.4 of ANSI B 31.1, whichever is
more stringent, for piping under purview of IBR.
3.00.00 SPECIFIC REQUIREMENTS : VALVES AND SPECIALITIES
3.01.00 For all globe and check valves, the direction of flow shall be clearly stamped on the body of
the valve.
3.02.00 All globe valves shall be capable of being closed against the design pressure.
3.03.00 Where globe valve has been specified for regulation purpose, the disc shall be tapered plug
type and suitable for controlling throughout its lift.
3.04.00 All gate and globe valves shall have bonnet-back seating arrangement.
3.05.00 Check valves shall have full floating and accurately guided discs.
3.06.00 All gate, globe and check valves shall be designed for reconditioning seating surfaces and
replacement of stem and disc without removing the valve body from the line.
3.07.00 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.
3.08.00 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.
3.09.00 Valves of 65 mm 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 mm and below in vacuum service shall have extra deep gland
packing without requiring water gland sealing. All gate and globe valves of size 65 mm Nb
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PART-B
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and above in vacuum services shall have adequately deep gland packing and shall be
equipped with lantern rings to admit pressurized water for gland sealing.
3.10.00 Where floors and extension spindle arrangements is required for valves, the height of floor
stand shall be about one meter from the floor/platform. The floor stand shall be sturdy
construction with column, nut plate and hand wheel made of the cast iron conforming to
material 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 on platform shall be provided.
3.11.00 All valves shall be provided with proper name plates indicating complete information about
the valves.
4.00.00 INTEGRAL BY PASS VALVES
(a.) The requirement of integral bypass valves shown in P&IDs, is the minimum required.
The final requirement shall be worked out, as per process requirement, during
detailed engineering.
(b.) If integral bypass valve selected is of size 50 mm Nb and below, then 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 Nb and above, only cast steel
gate valves with butt weld ends as per ANSI B 16.25 shall be provided.
(c.) Bypass pipe shall be of seamless construction and thickness corresponding to
minimum of schedule 80 and shall be of the same material class as the main pipe.
(d.) Integral bypass shall be motor operated if main valve is motor operated.
5.00.00 SPECIFIC REQUIREMENTS: FABRICATION
5.01.00 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 connections 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.
5.02.00 Where welded pipe and fittings are used the longitudinal weld seams of adjoining sections
shall be staggered by 90 deg.
5.03.00 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.
5.04.00 Bends and Elbows
(a.) Elbows shall be generally of long radius type.
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(b.) Bends for piping 65 mm Nb and above shall be made hot and for piping 50 mm Nb
and smaller may be made cold.
(c.) Bends shall be made in accordance with PFI-ES-24/ ISO/ Other international
standards. Bends shall be supplied with the minimum tangents except 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.Heat treatment of bends shall be done as per material specification.
(d.) All bends 65 mm Nb and larger shall be ultrasonically examined as per PFI-ES-20.
(e.) Where examination 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 150 mm 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 welds shall not be used in the area of the bend. Longitudinal
welds, where bends are formed from welded pipe shall be located on the bends
neutral axis.
5.05.00 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 B31.1/IBR.
5.06.00 All materials that are bent, forged or formed shall be subject to heat treatment after the
forming operations as required by the original material specification. For alloy steel materials
the preferred heat treatment process is full annealing.
5.07.00 Cleaning and Protection
(a.) All fabricated piping shall be cleaned as per relevant SSPC cleaning
technique/practice such that both inside and outside surfaces 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.
(c.) After descaling, the pipe shall be protected by applying internally with a water-soluble
preservative.
(d.) Following cleaning and preservation, the fabricated sections shall be covered, boxed,
capped, or others shielded from further contamination or corrosion.
5.08.00 MARKING
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5.08.01 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.
5.08.02 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 0.8 mm.
5.08.03 Items 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.
6.00.00 SPECIFIC REQUIREMENTS ERECTION
6.01.00 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
6.02.00 Field run piping shall be erected only after completion of erection of all other piping system,
structures and equipment unless otherwise approved/directed by the Employer.
6.03.00 When C clamps are tack welded to the pipe for the purpose of alignments of a joint,
preheating for the tack welding shall be performed if the main joint adjacent to it to be
preheated as per the requirements of this specification, otherwise preheating for the tack
weld may be omitted. After the joint is completed, all tack welds shall be removed, flushed
with the adjacent surface of pipe by chipping and/or grinding. The areas where c clamps
were attached shall be subjected to stress relieving as required.
6.04.00 The hydrostatic testing of the piping system shall be done after proper installation of all
permanent hangers/supports. Spring hangers shall be locked during hydrostatic test. Prior to
steam blowing all hangers which had been locked for the hydrostatic testing shall be
unlocked.
6.05.00 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 restraints 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, hanger readings/clearances shall be logged by
the contractor in proper format and a joint protocol be made.
6.06.00 The contractor shall monitor the behaviour of all hangers, supports, restraints etc. during the
initial stages of plant operation. When the piping system(s) have attained their rated
temperature the contractor shall log , hanger readings, snubber deflections, restraints/limits
stop clearances, as specified elsewhere.
6.07.00 All gaskets shall be asbestos free material and suitable for the service application.
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7.00.00 SPECIFICATION FOR PIPING AND FITTINGS
Al loy Steel Carbon Steel
A. PIPES

Material
ASTM A335 Gr.P91

ASTM A335 Gr.P22
(See Note below)
ASTM 106 Gr. B / ASTM 106 Gr.C

[A 106 Gr. C for BFD design parameters,
CRH design parameters and above.
Alternate material for BFD design
parameters-15NiCuMoNb5 (EN 1.6368)
/ ASTM A335 Grade P36 (See Note
below) ]

ASTM A 672 Gr. B60
CLASS-12/22
(See Note below)

Construction

Seamless
(See Note below)

Seamless
(See Note below)

B. Fittings
a) Material for
65 NB &
Above

ASTM A234 Gr.WP91

ASTM A234 Gr.WP22
ASTM A234 Gr. WPB with A 106 Gr.B
piping and ASTM A234 Gr. WPC for
A106 Gr.C piping

And

15NiCuMoNb5 (EN 1.6368) / ASTM
A335 Grade P36/ ASTM A234 Gr. WPC
for alternate BFD pipe material
[ See Note below ]
b) Material for
50 NB and
Below
ASTM A182 Gr. F91
ASTM A182 Gr. F22
ASTM A105
See note below See note below
c) Basic
standards
ANSI B16.9,
ANSI B16.11
ANSI B 16.25 &
ANSI B 16.28
ANSI B16.9,
ANSI B16.11
ANSI B 16.25 &
ANSI B 16.28
d) Construction Seamless
(Forged for 50 NB & below)
Seamless
(Forged for 50 NB & below)
See note below
e) Rating/Wall/
Thickness

To match with that of pipe To match with that of pipe
C. WELDING
Backing Rings Not permitted Not permitted
D.MATERIALL ANALYSIS
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Al loy Steel Carbon Steel
Mandatory
Requirements
and
supplementary
requirements:

(a)Mandatory requirements:
All tests, as given in respective material code (other than supplementary
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 be carried out
when specified by the purchaser or any such indication, in the code.

(b)Optional tests/ Supplementary requirements (Applicable for
15NiCuMoNb5 (EN 1.6368) / ASTM A335 Grade P36) :

(i) Optional tests for 15NiCuMoNb5 (EN 1.6368)

Product Analysis (Option 3), Wall thickness measurement away from tube end
(Option 15), NDT for the detection of transverse imperfection (option 8) and
laminar imperfection (option 9) as indicated in EN 10216-2 and tensile test at
room temperature to be done per heat as an additional test.

(ii) Supplementary tests for ASTM A335 Grade P36

S1,S2,S3,S4 & S5 as indicated in ASTM A335.

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 subject to regulation 374 of IBR. However, non-
destructive testing in lieu of hydrotest is also acceptable subject to
regulation 343 (3) of IBR
After Erection All piping systems shall be hydro tested at 1.5 times the design
pressure subject to regulation of 374 IBR. However, for such
systems where it is practically not possible to do hydro tests, the
tests as called for in ANSI B31.1& IBR in lieu of hydro test 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 isolating valves up to TP either by blanking or providing a temporary
valve. NDT as per the provision of IBR & ASME B31.1 can be carried out for the joint at TP
between SG & TG contractor.
(2) Non-IBR Piping Systems:-
At Shop

All piping including fabricated piping shall be hydro tested at 1.5 times
the design pressure subject to regulation 374 of IBR. However, non-
destructive testing in lieu of hydrotest is also acceptable subject to
regulation 343 (3) of IBR
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After
Erection
All piping systems shall be hydro tested at 1.5 times the design
pressure subject to regulation of 374 IBR. However, for such systems
where it is practically not possible to do hydro tests, the tests as called for
in ANSI B31.1& 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 550
NB and above. The fitting shall correspond to ASTM A 234 with Grade corresponding
to the pipe material. Welded construction fittings 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 fittings.

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.

3. Materials for fittings, specialties and valves shall be corresponding to piping material.

4. For Boiler Feed Discharge piping, material conforms to 15NiCuMoNb5 (EN
1.6368)/ASTM A335 Grade P36 are acceptable as an alternate material to the
specified material ASTM A106 Grade C. subject to meeting the following conditions:

(a). Bidder/ Package contractor to obtain necessary IBR approvals for using material
15NiCuMoNb5 (EN 1.6368) or ASTM A335 Grade P36 for boiler feed discharge
piping from Central boiler board, New Delhi and furnish the same to employer
prior to the scheduled date for start of detailed engineering & material
procurement. However, in case IBR does not accept the material 15NiCuMoNb5
for Boiler feed Discharge piping or there is delay in getting IBR approval, the
bidder/package contractor shall have to necessarily use material ASTM A106
Gr.C as specified in NTPC Technical specification.

(b). Bidder/Package contractor to also obtain necessary IBR approvals for design,
manufacture, testing, inspection, erection etc.. as required by IBR regulation.

(c). For material 15NiCuMoNb5 (EN 1.6368) or ASTM A335 Grade P36, pipe
thickness shall be calculated based on the procedure and formulae given in ASME
B31.1, Indian Boiler regulations -1950 (IBR) and DIN standard (for 15NiCuMoNb5)
and the highest thickness obtained from all these calculations shall be used as the
calculated bare minimum thickness ( excluding tolerance).

5. Material for stubs, laterals, Boss etc. which are to be welded on to the main pipe
(15NiCuMoNb5 (EN 1.6368)/ ASTM A335 Grade P36) shall corresponds to
either the pipe material or ASTM A105.

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8.00.00 SPECIFICATION FOR VALVES
8.01.00 Cast Steel Valve (Gate/Globe/Check 65 NB size & above)
Carbon Steel Alloy Steel Stainless
Steel
Sl.
No.
Description
600 Lbs
& below
Above 600
Lbs
600 Lbs
& below
Above
600 Lbs
400 Lbs &
below
1.0 Basic Standard ANSI B16.34
2.0 Construction
a Bonnet/Cover Bolted
type
Pressure
Seal
Bolted
type
Pressure
seal
Bolted Type
Disc
Globe valves Throttling type plug
Check valves Twilting/swing type
Solid/flexible wedge below 100 NB
b
Gate valves
Flexible wedge for 100 NB & above
c Seat Integral type
3.0 Material
a Body & Bonnet
Cover
ASTM 216
Gr. WCB
(Refer
note
below)
ASTM 216
Gr. WCC
(Refer
note
below)
ASTM A217Gr. WC9
ASTM A217Gr. C12A

ASTM A351
CF8
b Stem 13% Chrome Steel ASTM-A-182 Gr.F6a ASTM 182
F316/F304
c Hinge pin(for
check valves)
13% chrome steel ASTM A-182 Gr F6a ASTM 182
F316/F304
ASTM
A216 Gr.
WCC
Refer note
below)
ASTM A217 Gr.WC9
ASTM A217Gr. C12A

ASTM 182
F316/F304
d Disc and seat
ring
(heat treated &
hardened)
ASTM
A216 Gr.
WCB
Minimum
Hardness
250 BHN
Refer note
below)
Seating surface hard faced with stellite 350 BHN

e
Back seat/ stem
guide Bushing
ASTM A 182, Gr. F6a
13% Cr. SS with stellite hard facing

ASTM 182
F316/F304

8.02.00 Forged Steel Valves (50 mm NB & below - Gate/Globe/Check)
Sl.
No.
Description Carbon Steel Alloy Steel Stainless
Steel
1.0 Design Standard : ASME B 16.34
2.0 Construction
a Bonnet/cover Bolted type for 600/800 lbs
Seal welded type for 900 lbs and above

Seal welded/
Bolted type for
600/800Lbs.
Sealed welded
above 800lb
Disc:
Gate Solid wedge type
Globe As per manufacturing std
b
Check Piston lift
c Seat Integral type
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Sl.
No.
Description Carbon Steel Alloy Steel Stainless
Steel
3.0 Material
a Body & Bonnet
Cover
ASTM A-105 ASTM A-182 Gr.F22
ASTM A-182 Gr.F91

ASTM 182
F316/304
b Stem 13% chrome steel ASTM-A-182 Gr.F6a

ASTM 182
F316/304
c Disc and
seat ring
ASTM A105 hard faced
with stellite minimum
hardness 350 HB
ASTM A182
Gr.F22/F91 hard
faced with stellite
minimum hard ness
350 HB
ASTM 182
F316/304 hard
faced with stellite
Minimum
hardness
350 HB
8.03.00 Angle Globe Valve
Alloy Steel `Carbon steel
Design
Standard
ASME B16.34 ASME B16.34
Material:
Body &
Bonnet
A182 Gr.F22/F91 or better A105 or better
Spindle/Disc 17% Chrome steel or better 17% Chrome steel or better
Disc Seat Stellited Stellited
Body Seat &
back seat
Stellited Stellited
Gland
Packing
Graphite Graphite
Constuction:
Valve type Outside Screw & Yoke Type
Body
&Bonnet
Forged body with integral /welded bonnet construction
Disc type Taper plug or Parabolic type to suit system requirement
End
Connection
Socket weld end ( ANSI B16.11) for sizes 50 NB & below and
Butt weld end (ANSI B16.25) for sizes above 50 NB.
Pressure rating To suit the service condition. However, minimum pressure rating shall
be corresponding to ANSI Class 1500
8.04.00 Other Valves (65 mm and above)
SAFETY VALVE S.
NO.
DESCRIPTIO
N
ALLOY
STEEL
CARBON
STEEL
RELIEF
VALVE
BF VALVE
1.0 Basic standard ANSI B16.34 AWWA
C-504
2.0 Pressure Class 400 lbs & below 75 B and above
3.0 Accumulation 10% (max.) -
4.0 Blow down 5% (max.) 10% to
15%
-
5.0 Construction
5.1 General Spring loaded with weld end
inlet, pop up type
Spring
loaded
with
flanged
inlet &
outlet
Long body, butt
welded
5.2 Bonnet Bolted type -
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SAFETY VALVE S.
NO.
DESCRIPTIO
N
ALLOY
STEEL
CARBON
STEEL
RELIEF
VALVE
BF VALVE
5.3 Seat bushing Renewable type screwed on and held in
position by pin
-
5.4 Shaft seat - - - O ring type
6.0 Materials
6.1 Body &
Bonnet/ cover
ASTM A-217
WC9/C12A
ASTM A216 Gr. WCB /
WCC

ASTM A216
Gr.WCB
6.2 Spindle/Shaft Stainless steel ASTM A182
Gr.304
6.3 Disc, nozzle,
seat ring
ASTM A182 F316 ASTM A 216 Gr.
WCB

Seal & O- Ring:

-EPT/BUNA-N/
Neoprene
for water service
-EPT/EPDM for
steam service
6.4 Spindle guide 17% chrome steel or monel, heat treated and hardened to
minimum hardness 250 HB
6.5 Spring Stainless steel
or Tungsten
steel
Carbon steel --
6.6 Retainer Rings
and internal
bolts Etc
-- -- -- SS 304

6.7 Bearing -- -- -- Sleeve type, self
lubricated
NOTE: The material of body, bonnet/cover & disc shall be corresponding to that of
pipe material on which the valve is installed.
8.05.00 Specific Requirements
1. Valves 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. Valves shall be tested in accordance to ANSI B 16.34. However, for butterfly
valves, the requirements of AWWA C-504 shall also be met.
4. All gate and globe valves shall be with outside screw and yoke with rising stem.
5. Gate valves below 100 NB shall be solid wedge/flexible wedge type, valves of
size 100 NB and above shall be of flexible wedge type. However, for sizes 100
mm NB and above for temperatures above 300
o
C, parallel slide valves are also
acceptable.
6. Specification for valve actuators shall be as indicated in C&I Subsection
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7. Stem for all valves shall be heat treated and hardened - minimum, hardness 200
HB 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 reinforced
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 wheels 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. Valve closure test shall be as per ANSI B16.34 and MSS-SP-61. Acceptable
maximum seat leakage shall be 2 ml of water per hour per 25 mm of nominal
pipe size.
13. Safety and Relief valves shall be supplied complete with discharge elbow and
drip pan along with drain.
14. For valves of size 65 NB and above in vacuum service, water gland-sealing
arrangement shall be provided. For valves 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
9.00.00 SPECIFICATION FOR HANGERS/SUPPORTS
9.01.00 Design and Manufacture of Hangers/Supports shall conform to ANSI B 31.1, MSS-SP-58,
MSS-SP-89.
9.02.00 Where hanger rod angularity exceed 4 degrees 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.
9.03.00 The Contractor shall furnish detailed arrangement sketches for each support, restraints,
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.
9.04.00 Hangers support tag no. shall be marked on all pipe hangers/supports, restraints and anchor
assemblies. The design loads, hot and/or cold loads shall be stamped on respective constant
and variable springs.
9.05.00 TECHNICAL REQUIREMENTS
(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.
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(c.) Hanger support rods of less than 10 mm diameter for supporting pipes of 50 Nb and
smaller and less than 12 mm 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.) Attachments 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 5 mm for weather protected
locations and 6 mm for locations exposed to weather.
(h.) Beam clamps shall be forged steel equipped with a rod to fix a nut.
(i.) All sliding surfaces of supports and restraints shall have teflon lining on one surface
coming in contact with stainless steel lining on the other surface.
(j.) All pipes 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.
9.06.00 Spring Hangers
(a.) 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%.
(b.) 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 mis-alignment or failure.
(c.) Constant load hanger shall have a minimum field adjustment range of 15% of the load.
The total travel for constant load hangers shall be design travel plus 20% but in no
case shall the difference between total travel and design travel be less than 25 mm.
The supporting effort variation throughout the travel range of constant load hangers
shall not exceed 6%.
(d.) Variable spring hangers shall have supporting effort variation of not more than 25%
throughout the total travel range.
(e.) All springs shall remain under compression throughout their operating regime and
never under tension.
(f.) Spring hangers shall have provision for locking the hangers in any position of the
travel.
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(g.) 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.
(h.) All spring hangers shall be locked before performing the hydro test. The locking shall
be removed before the line is placed under operation.
9.07.00 SNUBBERS
a Snubbers shall be designed to allow normal movement of pipe due to thermal
expansion and shall require minimal maintenance.
b Snubbers shall be designed to withstand twice the rated load without loss of structural
integrity and shall have convenient means for determining rod extension.
c Snubbers shall be of hydraulic type of Lisega/ITT Grinell, West Germany or Employer
approved equivalent.
d Axes of snubbers/restraints shall be parallel to the direction of the expected reaction
force in operating condition.
9.08.00 Restraint & Anchors
(a.) All anchors shall be designed for direct rigid fastening to the structural steel member.
(b.) Anchors, guides and restraints shall be capable of withstanding the forces and
moments due to thermal expansion and dynamic effects.
9.09.00 Testing and Inspection
(a.) All shop tests shall be conducted in accordance with ANSI standards and other
applicable codes/standards.
(b.) Each Constant load hanger shall be tested before delivery to ensure that the variation
in supporting capacity provided through specified range does not exceed 6%.
(c.) Each variable load spring hangers shall be tested before delivery for its spring
stiffness.
(d.) Material test and analysis
All materials shall be furnished in strict accordance with the applicable codes. All sources of
materials shall be disclosed and relevant test certificates giving precise details of
identification of material for the physical and chemical properties shall be submitted to the
Employer/Project Manager.
(e.) All hangers\supports\restraints etc on piping shall be inspected for the conditions
mentioned elsewhere in the specification and log reports to be submitted to employer
for their review
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10.00.00 STEAM TRAPS AND STRAINERS
10.10.01 Steam traps shall be of inverted bucket/thermo static type with integral or separate Y-type
strainers.
10.10.02 Traps shall have stainless steel internals.
10.10.03 All Y-type strainers shall 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.
10.10.04 Strainers shall have screwed blow off connection with removable plug.
10.10.05 All traps and strainers shall have socket weld ends as per ANSI B 16.11 for size 50 mm Nb
and smaller and butt weld ends as per ANSI B 16.25 for sizes 65 mm Nb and larger.
10.10.06 Y-type strainers shall be provided along with each steam trap in case the strainer does not
form an integral part of the trap.
11.00.00 SPECIFICATION FOR THERMAL INSULATION
11.01.00 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 continuously 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 layers 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. thickness shall not
be less than 25 mm & number of layers shall be min. & the innermost layer shall be
thickest.
11.02.00 Insulation Materials
(a.) Rock/glass wool 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.
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(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.
11.03.00 Others Accessories
The Contractor shall also provide other accessories such as ceramic boards, sealants and
washers as required.
11.04.00 Installation
(a.) All surface to be insulated 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 at 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 shall be filled with finishing cement, suitable for the
equipment operating temp. so as to form a smooth base for the application of cladding.
11.05.00 Insulation Materials

STAGE II (2X600 MW)
SECTION - VI
PART-B
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Type #1 Type #2 Type #3 Type #4 Type #5 Type #6
Type Lightly resin Bonded
mineral (rock) wool
Lightly resin bonded
mineral (rock) wool
Bonded glass wool Resin bonded mineral
(rock) wool preformed
pipe section
Resin bonded glass
wool preformed pipe
section
Calcium silicate
preformed block
type
Apparent
Density

120-150 Kg/M 100 Kg/M 64 Kg/M 140-150Kg/M 60-80Kg/M 200-250Kg/m

Mtl.
Standard
IS:8183 IS:8183 IS:8183 IS:9842 IS:9842 IS:8154

Applicable
Service
Piping system &
equipment with
operating temp.
above 400
0
C
Piping system &
equipment with
operating temp. in range
of 60-400 deg.C
Piping system &
equipment with
of 60-400 deg.C
Piping system of 350
NB and below with
temp. in range of 60-
650 deg.C
Piping system of 350
NB and below with
of 60-400 deg.C
Piping system &
equipment with
operating temp. in
range of 400-650
deg.C

Testing
Requirement
As per IS:8183 8183 8183 8183 IS:9842 IS:8154

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11.06.00 Cladding Material & Accessories shall be as specified here under.
Sl.No. I tem Basic Specification Description
1. Cladding Aluminium ASTM B-209-1060 temper H14 or IS:737 Gr.19000/H2 Thickness of sheathing

(a) 18SWG (1.219mm) for diameter for insulated
surface 450 mm and above and for flat
surfaces
(b) 20 SWG (0.91 mm) for diameter of insulated
surface 150 mm and above upto 450 mm.
(c) 22 SWG (0.71 mm) for diameter of insulated
surface 150 mm and below.
2. Binding &
lacing wire
Galvanised Steel wire to IS:280 for temp. below 400
o
C and stainless
to IS:6528 for temp above 400
o
C
28 SWG for all insulation interface temperature
3. Straps &
Bands
(i) Aluminium where interface temperature are below 400 deg.C
(ii) Stainless steel where temperatures are above 400 deg.C
Band shall be 20 mm wide and 0.6 mm thick for
securing Aluminium Sheathing anodised aluminium
bends shall be used.
4. Screws Stainless steel Self tapping, chese headed
5. Hexagonal
wire mesh
(i) (i)Galvanised steel wire to IS:280 mesh for interface
temperature upto 400 deg.C.
(ii) Stainless steel wire for temperature above 400 deg.C

Wire mesh netting shall be 10 to 13 mm aperature at
least 0.56 mm diameter wire.
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11.07.00 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 rings.
(b.) Longitudinal joints of insulation mattresses sections 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 layers shall be staggered by atleast 150 mm and
longitudinal joints shall be staggered by at least 50 mm.
(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.) Where 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 the 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 550 mm and with metal bends for insulation
surfaces with diameter over 550 mm. The fastening shall be done at intervals of 250
mm except where specified otherwise. The ends of the binding wires shall be hooked
and embedded in the insulation. The straps shall be mechanically stretched and
fastened with metallic clamping seals of the same materials as the strap.
(i.) Insulation for 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 through floors/walls.
(k.) All pipe attachments coming on horizontal pipes, inclined pipes and bends shall be
insulated alongwith 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.
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(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 personnel protection.
11.08.00 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 provisions 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 aluminium sheets of thickness same as the connected pipe
cladding. Adjoining pipe insulation shall be beveled back to permit removal bolts and
nuts or bands. 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 valves/flanges shall
be applied after the finishing has been applied over the connected piping. The cladding
shall be applied in such a 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.
11.09.00 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 surfaces of insulation layers, applied on horizontal cylindrical vessels shall be
securely fastened by bands upto vessel/tank outer diameter of 150 mm and below.
Where vessel/tank outer diameter exceeds 1500 mm, binding wire passing through
insulation clips provided both longitudinally and circumferentially at 500 mm centers
shall be used. Gaps in the insulation shall be filled with loose mineral wool and
finished with finishing cement so as to obtain a smooth surface for the application of
cladding. The contractor shall provide support ribs/lugs on the surface of the
vessel/tank as necessary. 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 requirement 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
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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 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. Alternatively, wire loops may be tack welded at 250 mm centers to
hold the insulation in place
11.10.00 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 50 mm and shall be located at
45 deg. or more below the horizontal for horizontal equipment. J oints shall be made
with cheese headed self tapping galvanised steel screws at 150 mm centers.
(c.) All circumferential joints shall have a minimum overlap of 100 mm and shall be held in
position by stainless steel or anodised 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 sealed 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 monel metal.

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11.11.00 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.
12.00.00 SPECIFICATION FOR HYDROSTATIC TEST OF PIPING SYSTEMS
12.01.00 On completion of installation/erection of the piping systems a hydraulic test in accordance
with the requirements of the Indian Boiler Regulations/ASME B31.1, as applicable , 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 discussed and
finalized during detailed engineering stage.
12.02.00 Cutting/welding/edge preparation and re-welding required for blanking, temporary piping
connection and/or for replacements by spool pieces including reinstallation of
components/piping systems after hydraulic testing shall be the responsibility of contractor.
12.03.00 The water for hydraulic test shall be made alkaline by addition of suitable chemicals. After the
test, high pressure external piping shall be suitably drained and preserved.
12.04.00 All blank flanges/blanks, Caps, removable plugs, temporary valves, pipes & fittings, spools,
blanking inserts/hydraulic kit for stop valves/control valves, other accessories & services etc.,
as applicable, for carrying out hydraulic testing of pipings shall be furnished by the
Contractor. The pressurization equipments including water piping as needed for the above
test shall also be furnished by the Contractor. Any defect noticed during the testing shall be
rectified and the unit shall be retested by the Contractor.
12.05.00 In case any piping (in others scope) connection to/from the contractors scope of piping are
not ready or not erected at the time of hydro testing of contractors scope of piping, then the
contractor to provide necessary blanking arrangement as required at these branch
connections / tap-off locations to complete the hydro testing of his scope of piping.
12.06.00 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.
13.00.00 SPECIFICATION FOR CHEMICAL CLEANING OF PIPING SYSTEMS AND EQUIPMENTS
13.01.00 It is intended to chemically clean the following piping system
(a.) Boiler feed piping
(b.) Heater drains piping
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(c.) Main condensate piping
(d.) Extraction steam piping
(e) Reheater spray piping
(f.) Any other piping system in contractors scope to be cleaned through chemical
cleaning as per the procedure prepared by contractor and approved by
employer during detail engineering.
The following equipment which form a part of the above system shall also be
included in the cleaning operation.
(i.) H.P. Heaters
(ii.) L.P. Heaters
(iii.) Deaerator
(iv.) Gland steam cooler
(g.)
(v.) Drain cooler
(vi) Any other equipment in contractors scope to be cleaned through
chemical cleaning as per the procedure prepared by contractor and
approved by employer during detail engineering.
13.02.00 Before introducing chemicals, all the piping systems and equipment listed above shall be
water flushed. Water flushing will be followed by alkaline cleaning acid cleaning and
passivation.
13.03.00 However, the Bidder shall submit alongwith the offer his usual procedures and practices for
chemical cleaning of the piping and equipment specified. The Bidder shall submit all
schematics, write up, details of chemicals to be used etc. and detailed procedures he intends
to follow. These schematics and procedures shall be subject to the approval of the Employer.
13.04.00 Pre-Cleaning Procedure
Prior to starting any phase of cleaning operation the following procedures 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 acceptable 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
locations for sampling of the cleaning solution during cleaning.
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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 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.
13.05.00 General Cleaning Procedures
(a.) Seal water lines to pump shall be broken and flushed.
(b.)

Where pipeline 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 neturalise 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 alongwith
necessary first aid kits as required for handling the chemical and for carrying out
the cleaning operation.
14.00.00 SPECIFICATION FOR STEAM BLOWING OF PIPING SYSTEMS
14.01.00 Steam blowing of contractor's scope of piping systems shall be performed by the contractor.
Contractor shall submit their recommended procedure for steam blowing operation of these
piping systems along with scheme/ layout/ drawings giving step by step procedure for
performing steam blowing of each these piping systems to the Employer for their approval.
However, for purposes of bidding, the bidder shall make an estimate based on his
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experience for the piping system defined below, taking into consideration all temporary
piping, consumables etc. required
14.02.00 Steam blowing shall include engineering, supply and installation of all temporary piping,
valves, fittings including quick actuating valves (for puffing purposes), supports, blanking
plates, blow tools, valve head/valve blanking cover plate, pipe spools, target plates, devices
for protection of valves/equipment in steam blowing circuit, instruments, controls and all other
accessories & services required to complete the cleaning process as specified herein.
14.03.00 Steam blowing shall also include reinstatement of cleaned piping systems and
dismantling/removal of all temporary piping, equipment and other materials etc. from site. All
temporary piping, valves, equipment and materials shall be taken back by the contractor
upon satisfactory completion of cleaning/steam blowing and shall be removed from the
Employer's premises.
14.04.00 Engineering involved regarding temporary piping shall include the following:
a Selection of temporary piping including disturbance factor calculation.
b Preparation of layout of temporary piping and performing stress analysis as per ASME
B 31.1.
c Selection of temporary hangers and supports as required.
14.05.00 The following piping systems shall be cleaned through steam blowing operation.
1. Main Turbine gland sealing system
2. Boiler Feed Pump Drive Turbine gland sealing system
3. Steam lines feeding turbines of boiler feed pumps and their exhausts to condenser.
4. Steam lines to Deaerator
5. Any other piping systems in contractors scope to be cleaned through steam blowing
(as finalised during detailed engineering).
14.06.00 Steam blowing shall be carried out for removal of particles (rust, scales, weld splatter etc.)
from various piping systems to avoid damage to turbine. Cleanliness of system shall be
checked by means of test plates made of steel which will be installed in the centre line of the
piping system.
14.07.00 Cleaning shall be achieved by steam purging i.e. by blowing of steam through the piping
such that the momentum of flow is greater than that of steam flow during normal operation of
unit (at MCR). The disturbance factor during steam blowing (ratio of momentum of flow
during purge to that during MCR) shall be more than 1.4.
14.08.00 The blow off shall be done with steam which is exhausted through adequately sized, open
ended temporary piping. Temporary piping and motor operated valves shall be installed for
steam blowing operation. Piping shall be warmed before release of steam by quick opening
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of motor operated valve located on temporary piping. The cycle shall be repeated until steam
from the blow out pipe is determined to be clean.
If erected already flow nozzles and control valves etc. shall be removed and replaced by
spool pieces before steam blowing. The removed flow nozzle and control valves etc. shall be
put back after steam blowing. Installation of thermowells prior to steam blowing shall be as
per recommendations of respective thermo well supplier or employer.
The motor operated valves used for steam blowing shall have special characteristics like
minimum loss of pressure, resistance to wear during grave working conditions (high velocity
and carry over of water and solid particles), quick opening time, minimum effort on electric
actuator etc.
14.09.00 The steam blowing termination criteria will be :
(i) Acceptable target plate condition
(ii) Measured D.F. (disturbance factor) more than 1.4
The required values to calculate actual D.F. will be measured at site. The criteria for
acceptable target plate condition shall be finalised during detailed engineering
15.00.00 SPECIFICATION FOR FLASH TANKS
15.01.00 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.
15.02.00 Number and Sizing
Flash tanks 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 as per tender drg. Requirement
/details of various flash tanks are given below :
a High pressure (HP) flash tank for accommodating high pressure (above and
including hot reheat design pressure) steam drains and HP heater emergency
drains, as indicated in the tender drawing.
b Low pressure (LP) flash tank for accommodating low pressure (below hot reheat
design pressure) steam drains and LP heater emergency drains as indicated 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.
d In lieu of the HP & LP flash tanks mentioned above at a) & b) above, bidder may
also offer flash boxes attached to condenser, if it is a standard & proven practice of
the bidder. However, number of flash boxes shall be as indicated in the tender P&ID.
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15.03.00 Constructional Features
a Flash tanks shall be vertical, cylindrical design and of welded construction with
torispherical or hemispherical heads.
b Drain/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 case the
contractor finds better alternate arrangement, the same can be submitted for the
Employer acceptance & approval.
c The drain and 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 drain if required.
d A manhole shall be provided on the flash tanks for inspection purpose. It shall be of
diameter 500 mm minimum. The manhole shall be of devit type and shall be provided
with grip.
e The flash tanks shall be located on the ground/mezzanine floor of the powerhouse.
Necessary structural supports including anchor bolts shall be provided. Three (3)
support legs at 120 degree spacing shall be provided on each flash tank. Necessary
lifting lugs for handling by the TG hall EOT crane shall be provided.
f The flash tanks shall be provided with a full length level indicating gauge glass complete
with protective rods, isolation valves and drains. Temperature indicators and
temperature switches shall be provided on the flash tanks.
g The flash tanks shall be provided with access ladders, if required for access to the
instruments, valves, main holes etc
15.04.00 Schedule of Materials
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
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However the material as per ASTM A 516 Gr. 60 or IS 2062 Gr. B shall also be acceptable
subject to the relevant codes / standards permitting so for the design parameters of various
flash tanks.
16.00.00 SPECIFICATION FOR METALLIC EXPANSION JOINTS
16.01.00 The expansion joints shall be of metallic multi-bellows construction and shall be used to
reduce the reactions (forces and moments) at the connected equipment terminals due to
thermal expansion/connection and/or vibration of connected equipment and piping.
16.02.00 The design, material, construction, manufacture, inspection, testing and performance of the
expansion joints shall comply with the currently applicable requirement of EJ MA, Boiler and
Pressure Vessel Code Section III, ANSI B-31.1 and all statutes, regulations and safety
codes.
16.03.00 Construction Details
(a) Bellows
i The bellow shall be hydraulically or roll formed from perfect cylinders of
single ply, 304 grade stainless steel.
ii The number of longitudinal weld seams shall be minimum and there shall
be no circumferential weld seam.
iii Cold formed stainless steel bellows shall not be heat treated.
iv All bellow elements shall be pickled after forming.
v Equalising rings, where required, shall be either from high quality castings
of from fabricated metal.
vi Flanged expansion joints shall be provided with adequate pipe stubs.
vii Butt welded expansion joints shall have adequate length of pipe so that
site welding does not impair or reduce the joints efficiency.
(b) Sleeves
i Expansion joints will be furnished with internal sleeves of the same
material as the bellows and installed with sufficient clearance to allow full
rated deflection. The sleeves shall be welded on the flow inlet end of the
joint only.
ii Bellow shall have external sleeves with an arrow indicating the direction of
flow on the outside. The external steel covers provided to protect bellows
from physical damages, shall be suitable for supporting insulation where
necessary and shall be detachable.

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(C) Tie Bars
i J oints 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 rods on pressure balanced type expansion joints shall be adequately
sized to prevent buckling in vacuum services or services with other
external loads .
14.04.00 Type test of Metallic Expansion joints
Following tests (Type tests) shall be carried out for metallic expansion joints as per the
procedures given in EJ MA.
a) Life Cycle Test
b) Meridional yield-rupture testing
c) Squirm testing
14.04.01 For the purpose of carrying out type tests; metallic bellows shall be grouped based on the
parameters as given below. The bellows conforming to same combination of these
parameters shall constitute one group. Type test shall be carried out on one or more bellows
(as required) for the successful completion of all the type tests specified above.
i. Material of bellow: Based on material of bellow, bellows shall be categorized into
three category namely Carbon steel, stainless steel (Eg. SS304, 316, 321etc.) &
High alloy steel (Eg. Inconel).
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 &
including 1600 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:
Design pressure from full vacuum up to 5 kg / sq.cm (g).
Design pressure above 5 kg / sq.cm (g) and up to 10 kg / sq.cm (g) with or
without vacuum.
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14.04.02 Number of cycles
For the life cycle test, the number of test cycles shall be minimum 10,000 cycles.
14.04.03 Other tests for metallic expansion joints shall be carried out as per the approved QP / QA
Section. Further, other terms and conditions for type test shall be as specified elsewhere in
the specification.
17.00.00 SPECIFICATION FOR SURFACE PREPARATION & PAINTING
17.01.00 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 the
substitute material.
17.02.00 All paints shall be delivered to job site in manufacturers sealed containers. Each container
shall be labeled by the manufacturer with the manuacturers name, type of paint, batch
number and colour.
17.03.00 Unless specified otherwise, paint shall not be applied to surfaces of insulation, surfaces of
stainless steel/nickel/ copper/brass/ monel/ aluminum/ hastelloy/lead/ galvanized steel items,
valve stem, pump rods, shafts, gauges, bearing and contact surfaces, lined or clad surfaces.
17.04.00 All pipelines shall be Colour coded for identification as per the NTPC Colour-coding scheme,
which will be furnished to the contractor during detailed engineering..
17.05.00 SURFACE PREPARATION
17.05.01 All surfaces to be painted shall be thoroughly cleaned of oil, grease and other foreign matter.
Surfaces shall be free of moisture and contamination from chemicals and solvents.
17.05.02 The following surface schemes are envisaged here. Depending upon requirement any one or
a combination of these schemes 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 cleaning/ abrasive blast cleaning to SA21/2 (near white
metal) 35-50 microns
SP5 Phosphating
SP6 Emery sheet cleaning/Manual wire brush cleaning.
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17.06.00 APPLICATION OF PRIMER/PAINT
17.06.01 The paint/primer manufacturers 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 specified herein.
17.06.02 Surfaces prepared as per the surface preparation scheme indicated herein shall be applied
with primer paint within 6 hours after preparation of surfaces.
17.06.03 Where primer coat has been applied in the shop, the primer coat shall be carefully examined,
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.
17.06.04 Steel surfaces 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 primed and finish painted before the grating is permanently secured.
17.06.05 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 Aluminum paint to IS-13183 Gr.-I (for temperature
400
o
C - 600
o
C) , IS-13183 Gr.-II (for temperature 200
o
C - 400
o
C)
and IS-13183 Gr.-III (for temperature upto 200
o
C)
PS13 - Rust preventive fluid by spray, dip or brush.
PS14 - Weldable 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.
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STAGE II (2X600 MW)
SECTION - VI
PART-B
A-10
POWER CYCLE PIPING
PAGE
36 OF 38

17.06.06 All weld edge preparation for site welding shall be applied with one coat of weldable primer.
17.06.07 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.

STAGE II (2X600 MW)
SECTION - VI
PART-B
A-10
POWER CYCLE PIPING
PAGE
37 OF 38

17.07.00 Primer/Painting Schedule
Primer Coat Intermediate Coat Finish Coats Sl.
No
Description Surface
Preparation System Coat Min. DFT /
coat
(Microns)
System Coat Min.
DFT/
Coat
(Microns
)
System Coat Min. DFT/
Coat
(Microns)
Total Min.
Painting
DFT
(Microns)

Colour
Shade
1. All insulated Pipings, fittings/
components, Pipe clamps,
Vessels/Tanks, Equipments etc.
SP3/SP4 PS 9* 1 20 - - - PS9* 1 20 40
Design
temperature
<60
o
C

SP3/SP4 PS 5 2 25 - - -
PS 4
3
$
35
$
155
$

Design
temperature
60
o
C-200
o
C
SP3/SP4 PS 9* 1 20 - - - PS9* 1 20 40
2. All un-
insulated
Piping,
fittings/
components,
Pipe clamps,
Vessels/Tanks
, Equipments
etc.
Design
temperature
>200
o
C
SP3/SP4 PS9* 1 20 - - - PS9* 1 20 40
3 Constant Load Hanger (CLH),
Variable Load Hanger (VLH)
and other supports
SP4* PS19 1 40 - - -
PS17

1

30

70

Val ves

Design
temperature <60
o
C

SP1/SP2/SP
3
PS4/PS
9
1 40 Polyami
de
Epoxy
1 100 PS17 1 40 180
Design
temperature 60
o
C-
200
o
C

SP1/SP2/SP
3
PS 9* 1 20 - - - PS9* 1 20 40
4.

Cast
/Forged
Design
temperature >200
o
C

SP1/SP2/SP
3
PS9* 1 20 PS9* 1 20 40
5. All Structural
Steel
components
Outside TG
building and
in SG
envelope
SP4* Inorgani
c Ethyl
Zinc
Silicate
1 75 PS18 1 75 a))Epoxy
coat

b)Final
coat of
paint
PS17
2

1
35

30

250

As per
NTPC
Colour
shade/
coding
scheme

STAGE II (2X600 MW)
SECTION - VI
PART-B
A-10
POWER CYCLE PIPING
PAGE
38 OF 38

Within TG
building
SP4* -do- 1 35 PS18 1 35 a))Epoxy
coat

b)Final
coat of
paint
PS17
2

1
25

30
150
6. Weld Edges SP6
(Hand
cleaning by
wire
brushing)
PS13
(Welda
ble
primer)
1 25 - - - - - - -
$ The first 2 finished coats (total min.DFT of 70 microns) shall be done at shop and the 3
rd
finish coat (min.DFT 35 Microns) shall be applied at site.

17.00.00Testing 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.

SECTION-VI
PART-B
A - 11
SECTION-VI
PART-B
A-11
OTHER CRANES AND
HOISTS
PAGE
1 OF 2
CRANES/ HOISTS / MONORAIL
1.00.00 CRANE, HOIST
1.01.00 Suitable EOT Crane/HOT Crane/Monorail beams with hoists/Chain Pulley Blocks of
adequate capacity, to meet the erection and maintenance requirements are to be
provided by the vendor for the various areas/equipment. Some of the areas/equipment
not covered by TG hall EOT cranes are indicated below. For balance areas/equipment,
not listed hereinafter, the requirements of Specification shall be followed.
(a) Feed water heaters & deaerators.
(b) Various pumps & Heat Exchangers.
(c) Condenser Water Boxes (front & rear)
(d) Vacuum Pumps
(e) CW Butterfly Valves
(f) Control Fluid Room
(g) Auxiliary cooling water (clarified) pumps and DM cooling water pumps of ECW
systems.
(h) Central Lube Oil System room.
(i) Any other equipment.
The above requirement is indicative only, the requirement given in the respective chapter
is to be adhered to.
1.02.00 The EOT cranes shall be designed as per IS-3177 (Latest edition) class -2 duty and
the monorail hoists (hand operated ) shall be designed to duty class 2 to IS 3832.
Electrical wire rope hoist shall be designed as per IS:3938 (latest).
1.03.00 The design, manufacture inspection and testing of the crane shall comply with the
requirment of latest version of IS:3177
1.04.00 The stipulations of all statutory codes like Indian Electricity Act, Indian Electricity Rules,
Factory Acts, Local Municipality Act etc. shall however prevail over the specification
requirements, incase any conflict arises between this specification and the statutory
codes.
1.05.00 For the hoists with more than 2.0 tonne lifting capacity or more than 06.0 M lift,
motor operated hoist block for both long travel and lift shall be provided. Other hoist
blocks shall be of hand operated type for both travel and lift. However, all monorails
coming out of the building shall be provided with electric hoist block, irrespective of
load and lift.
SECTION-VI
PART-B
A-11
OTHER CRANES AND
HOISTS
PAGE
2 OF 2
For hand operated hoists, the hoists shall be suitable for operation from floor level.
Hand chain shall be provided for long travel of trolley and the Hoisting mechanism.
The operator shall be able to control the movement of the monorail hoist with the help
of floor operated pendant. The creep speed for vertical movement shall also be provided
as per the system requirement.
SECTION-VI
PART-B
ELECTRICAL SYSTEMS
SECTION-VI
PART-B
B - 1
GENERAL AND AUXILIARIES
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PART-B
B - 1
GENERATOR AND
AUXILIARIES
PAGE
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GENERATOR & AUXILIARIES
1.00.00 GENERAL REQUIREMENTS
1.01.00 For the purpose of design of equipment/systems, an ambient temperature of 50 deg.
Centigrade and relative humidity of 95% (at 40 deg C) shall be considered. The
equipment shall operate in a highly polluted environment.
1.02.00 All equipment shall be suitable for rated frequency of 50Hz with a variation of +3% &
-5%, and 10% combined variation of voltage and frequency unless specifically
brought out in the specification.
1.03.00 Contractor shall provide fully compatible electrical system, equipment, accessories
and services.
1.04.00 Standard : IEC-60034
1.05.00 Paint shade : RAL 5012
1.06.00 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.
2.00.00 TYPE AND RATING
2.01.00 Type : Three phase, horizontal mounted, indoor installed, two-pole, Thermal Class
155 (F) winding insulation, Stator water/Hydrogen cooled, cylindrical hydrogen /
water cooled rotor type.
2.02.00 GENERATOR RATING
2.02.01 Generator and its excitation system shall have a capability at least matching the
declared maximum continuous rated output of the associated steam turbine (for the
secondary cooling water temperature of 39 deg C) at all power factors between 0.85
lagging and 0.95 leading with +3% to -5% frequency variation, terminal voltage
variation of +/- 5% and combined voltage & frequency variation of 5%. It shall be
ensured that when the Generator is working at this capability and cooling water
temperature is 39 deg C, no part of the Generator shall attain a temperature in
excess of the temperature limits specified for Thermal Class 130 ( B ) insulation as
per IEC-60034.
2.02.02 Also the generator and its excitation system shall be capable of continuous stable
operation without any excessive temperature rise at the peak output of the
associated steam turbine under VWO & HP heater out condition, etc. as available
for the secondary cooling water temperature of 39 deg. C, at all power factors
between 0.85 lagging and 0.95 leading with +3% to -5% frequency variation,
terminal voltage variation of +/- 5% and combined voltage & frequency variation of
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PART-B
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GENERATOR AND
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5%. Temperature of different parts may exceed those permissible for Thermal Class
130 (B) insulation under such operating conditions, but shall be lower than those
permissible for Thermal Class 155 (F) insulation as per IEC-60034.
2.02.03 Rated Parameters :
1. Power Factor 0.85 (lagging)
2. Terminal voltage In the 18 TO 24 KV range
3. Frequency 50 Hz
4. Speed 3000 rpm
5. Short circuit ratio Not less than 0.48(without negative tolerance)
3.00.00 SYSTEM OF COOLING
1. Stator winding Closed loop system using Hydrogen or using
demineralised water flowing through the hollow
conductors.

2. Rotor winding Directly cooled by hydrogen, Alternatively
manufacturer's standard & proven arrangement of
rotor cooling with water is also acceptable.
Bidder shall furnish complete details of water
cooling system alongwith the bid.

3. Stator core By hydrogen flowing through suitable ventilating
ducts or water cooled.

4. Configuration for Hydrogen Shaft driven Hydrogen blower and machine
Cooling mounted Hydrogen to water heat exchanger.
Secondary cooling water details as indicated
elsewhere in technical specification.

5. Capacity with one Gas
cooler out Capable of delivering at least two third of the
rated and max. continuous MVA with one cooler
out of service and ten (10) percent of tubes
plugged in remaining coolers that are in service
without exceeding the temperature limits of
Thermal Class 130 (B) and Thermal Class 155
(F) respectively.

4.00.00 INSULATION : Thermal class 155 (F) for Stator and Rotor
winding
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GENERATOR AND
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5.00.00 OPERATIONAL REQUIREMENTS FOR GENERATOR

1. Voltage Variation +/-5% continuously at rated power factor.
Reduced MVA operation at 110% of the rated
voltage. (to be indicated by the Bidder)

2. Frequency Variation 47.5 HZ to 51.5 Hz.

3. Combined voltage and 5%
frequency variation

4. Power factor variation 0.85 (lag) to 0.95 (lead)

5. Operation under unbalanced As specified in IEC 60034-1
load
6. Operation under unsym- Negative sequence current I
2
expressed in per
metrical short circuit unit of rated current for a duration of 't' second
such that the value of I
2
2
t shall comply to IEC
60034-1
7. Voltage Wave form The Total Harmonic Distortion (T.H.D) shall be
within the limit specified in IEC 60034-1.
8. Short Circuit withstanding Capable of withstanding of 3 phase short circuit at
capacity the generator terminals when operating at rated
MVA and power factor with 5 % over voltage for a
period of not less that 3 seconds.
9. Special operating conditions Capable of withstanding the electrical, mechanical
and thermal stresses developed during fast
reclosing of high voltage line, transmission line
switching, faults, out of step operation and out of
phase synchronisation etc.
10. Line Charging Capability Not less than 30% of its rated MVA at zero pf.
11. Generator Neutral Earthing Non-effectively earthed through a distribution
transformer, loaded with a resistor. The core
design to permit the flow of earth fault current of
at least 15 amperes for one (1) second without
any core damage
12. Impulse level & Surge To be suitable for test voltage of 4U+5 KV.
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PART-B
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GENERATOR AND
AUXILIARIES
PAGE
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Protection (where U is rated line to line voltage in KV).
Lightning arrestor of suitable rating shall be
provided by Employer for the surge protection of
generator winding. In case surge capacitors are
recommended, the value of the same shall be
mentioned in the offer.
6.00.00 DESIGN AND CONSTRUCTIONAL FEATURES
1) General
a) All components of the generator to be designed to avoid resonance at any
of the frequency in the operating range and their multiples.
b) All components requiring inspection and maintenance to be designed for
easy access and replacement.
2) Stator Body
a) Enclosure To withstand without any residual deformation,
any internal hydrogen explosion.
b) Handling Four number of trunions to be provided for
handling the stator by means of crane. The Bidder
to clearly bring out in the proposal the features
provided in the generator body construction to
enable generator stator to be lifted/dragged in
case of non-availability of suitable crane.
c) Transportation The dimensions of the generator stator body to be
within the maximum permissible rail / road
transportation dimensions within the country
taking into account the special wagons
available/being made available for transporting
such heavy over sized consignment.
d) Manholes At suitable locations with proper sealing
arrangements etc. to facilitate the inspection of
back of the core, end winding area and terminal
connections.
3) Stator Core
a) Material High permeability, low loss, cold rolled silicon
sheet steel segmental punchings.
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PART-B
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GENERATOR AND
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b) Core assembly Assembled on core bars in an interleaved
manner. To rest on flexible support system such
that radial and tangential magnetic vibration of
the stator core due to electro magnetic loading
transmitted to the outer frame is minimum.
c) End packets To be adequately strengthened to minimise the
magnetic vibration due to end leakage flux.
d) Fastening elements used in generator shall be non - magnetic & shall
be used with proper locking arrangement.
4) Stator Winding

a) Winding The stator winding shall consist of three phase,
Configuration double layer, short chorded, bar type winding
having two parallel paths. The elementary
conductors shall be Roebel transposed in the slot
portion.

b) Winding Insulation Epoxy thermo-setting type and rated for Thermal
Class155(F) insulation. Adequate semiconducting
protection shall be provided on the winding and
slots to avoid Partial Discharges.

c) Ripple springs To be provided in stator slots. However bidders
standard arrangement of conductor support shall
be subject to owners approval.

5) Distillate Headers (wherever applicable)

a) Inlet and outlet Stainless steel
water headers

b) Insulation The headers and header connections shall be
suitably insulated from the stator body. It shall be
possible to measure the insulation resistance of
the stator winding after simply removing the
outside water pipe connection. It shall also be
possible to measure the insulation resistance
between the water header and casing after
disconnecting the header grounding.

c) Connection of High quality heat resistant and high strength
bars teflon (P.T.F.E) hoses. Single pass cooling
arrangement shall be preferred.
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PART-B
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GENERATOR AND
AUXILIARIES
PAGE
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6) Winding Connection and Terminal Bushings

a) Winding Star connected. Three (3) phase and the three (3)
neutral terminals brought out. In case the stator
winding is double-star, a machine with six (6) or
nine (9) terminals will be acceptable. All stator
terminal lead connections inside the generator
shall be suitably supported to contain vibration.

b) Overhang Portion The over hang portion of the winding shall be
of winding suitably braced and supported so as to withstand
- 3 phase short circuit at its terminals as stipulated
in IEC-60034 when the machine is operating at
rated MVA, power factor and permissible
maximum over voltage.

c) Bushing housing Bushing to be housed in stator frame in a non
magnetic steel terminal box.

d) Bushing Porcelain or epoxy based material with non-
hygroscopic property. The terminal bushing shall
be cooled by suitable arrangement with cooling
medium/system envisaged for the generator.

e) Terminal connector Silver coated copper as per standard and proven
design of the bidder, suitably designed for
temperature rise of 55 deg C at rated current for
connection to the busduct through flexible.

7) Rotor Machined from a single alloy steel forging to give
the required mechanical, metallurgical and
magnetic characteristics. To have an adequate
margin between critical speed and the operating
range of speed to ensure smooth running.

8) Rotor Winding

a) Conductor Coils made of hard drawn silver bearing copper.

b) Insulation Epoxy glass based material rated for Thermal
Class 155 ( F ) insulation.

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PART-B
B - 1
GENERATOR AND
AUXILIARIES
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9) Retaining Rings and Nuts

a) Retaining rings The retaining ring shall be provided to prevent the
movement of rotor winding in the radial/ axial
direction due to centrifugal/ thermal stresses.
Retaining ring shall be machined from high
strength, non-magnetic alloy steel forging, with
broad material specification of 18Mn-18Cr,
resistant to stress corrosion. Floating type shrunk
on the rotor body.

b) Locking nuts/ snap rings: High strength non-magnetic alloy steel forging
shall be provided on the retaining rings to prevent
any axial movement. However bidders standard
arrangement of locking the retaining rings shall be
subject to owners approval.

c) Centering rings To be mounted at the end of the retaining rings to
support it in position

10) Bearings Self aligning type sleeve bearings either mounted
on separate pedestals or on the end shields. The
bearing housings as well as bearing shells shall
be of split construction. The bearing shells shall
be lined with tin based babbitt metal. All the
intermediate support pieces of the bearing shall
preferably be interchangeable with those of
similar type and size of TG bearing.

a) Seal Labyrinth shaft seals / Oil Deflectors shall be
provided.

b) J acking Arrangement The hydrostatic jacking arrangement in line with
turbine bearings

c) Bearing insulation At least one of the bearings shall be suitably
insulated. Arrangements shall be provided to
measure the insulation of the generator bearing.
Insulating material used for the purpose shall be
non-hygroscopic epoxy glass laminate.

d) Bearing instrumentation Redundant pick-ups/ transducers for bearing
metal temperature, bearing drain oil temperature
and bearing vibration..

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PART-B
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GENERATOR AND
AUXILIARIES
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11) Shaft Seals (if applicable)

a) Type Ring type, to be provided at both ends and
designed in such a way that minimum oil comes
in contact with hydrogen during operation to
minimise contamination.

b) Sealing ring lining The face of the sealing ring shall be lined with
babbitt metal. Any other material as per bidders
standard practice shall be subject to owners
approval.

c) Insulation The shaft seals and associated piping shall be
adequately insulated to prevent circulation of
shaft current.

12) Rotor Earthing and Shaft Voltage Pick-ups

a) Rotor winding insulation Through a brush, suitably mounted and sliding on
and shaft voltage an oil free surface, shall be provided.
monitoring

b) Earthing brushes To be provided at the turbine end bearing
pedestal. It should be possible to increase the
brush pressure while generator is working. In
case any other arrangement for shaft earthing
offered by bidder, the same shall be subject to
owners approval.

13) Hydrogen Coolers To be provided with 10% excess tubes. Cooler
shall be designed for at least 10 Kg/sq.cm. gauge
pressure on the gas side irrespective of a lower
normal operating casing pressure.

a) Cooler tubes Corrosion resistant with integral fins and arranged
in the stator casing so as to avoid the direct fall of
water during leakage, if any, on the winding
insulation.

b) Water pressure Shall be maintained below the operating
in coolers hydrogen pressure in the generator casing.

c) Temperature control Necessary control system including temperature
sensing elements, control valves and devices
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GENERATOR AND
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shall be provided. Adequate number of
temperature and pressure gauges shall also be
provided on inlet and outlet of cooling water, in
case water cooled machine is offered.

14) Generator drying Complete with all electrical/ mechanical drives/
arrangement equipment, accessories and controls to enable
drying out operation of the generator with hot air
circulation shall be provided. The system shall be
complete with necessary pressure, temperature
and flow gauges as well as thermostats as
required. However bidder's standard and proven
system of generator drying arrangement is also
acceptable.

15) Generator Instrumentation The following minimum instruments shall be
provided for each generator. For the requirements
regarding type, make etc. of instruments and
sensors, refer stipulations under relevant Sub-
sections of Control & Instrumentation.

A) Resistance temperature detectors (RTD)

a) Temperature Detectors Resistance temperature detectors (RTD) to be
duplex four / three wire type 100 ohms platinum,
calibrated as per DIN standard and located at
points where highest temperature is likely to occur
during operation. The bidder may also offer
thermo-couple (TC) or duplex RTDs. In case
simplex RTDs are provided they shall be double
in quantity of those specified as below.

b) Number and location i) Atleast Twelve (12) detectors, four per
phase and uniformly distributed along the
circumference of the stator and located at
the hottest possible zones. viz. the point of
exit of stator water from winding in a water
cooled machine. Preferably all stator slot
temperatures shall be measured.

ii) Detectors for monitoring water temperature
of each winding bar in case of water cooled
machine. Alternatively, monitoring water
temperature of converged water flow of top
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PART-B
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GENERATOR AND
AUXILIARIES
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and bottom bar of each slot using two (2)
detectors shall also be acceptable.

iii) Twelve (12) detectors for stator core out of
which four (4) shall be located in the end
zones where maximum temperatures are
expected.

iv) Two (2) detectors per H2 gas cooler section
for measurement of inlet and outlet gas
temperature.

v) Two (2) detectors per H2 gas cooler section
for measurement of inlet and outlet water
temperature.

vi) Two (2) detectors per bearing for
measurement of babbitt metal and drain oil
temperature.

vii) Sets of detectors for generator shaft
sealing, Hydrogen gas and stator water
systems required for monitoring the
temperature of oil, water and Hydrogen at
different salient locations in the system.

c) Termination of RTD At terminal box after grouping of signals.
leads

d) Location Terminal box for RTDs shall be at an easily
accessible position so as to enable
maintenance/testing of the devices when the
machine is under operation.

e) Terminal box Dust and vermin proof (IP54)
construction

f) Interface All the above temperature measurement devices
shall be connected to TG C&I part of DDCMIS.

B) Termination Arrangement All the instrumentation wiring coming out of the
Generator shall be routed through a common
terminal plate with suitable sealing arrangement.
However bidders standard termination
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arrangement shall be subject to owners
approval.

C) Rotor winding Temper- To be monitored in TG C&I part of DDCMIS.
ature measurement and
monitoring

D) On line water temperature Complete with all software and hardware required
Monitoring for Individual to detect any abnormalities in the temperature at
stator winding bars any given generator operating point and shall
(Applicable for water be sensitive to generator loads, header flows,
system) pressure, etc. This shall be realised in TG C&I
part of DDCMIS.

E) Vibration monitoring At least six (6) numbers of optical sensor type
System vibration pickups at each end of over hang portion
of the winding shall be provided, symmetrically
located around the periphery with connection to
Turbine Supervisory system for vibration
monitoring and trend recording. The connection
between the pickups and Turbine Supervisory
system for vibration monitoring shall be of optic
fiber type.

F) Liquid leakage detector Shall be provided at all the low level points inside
the generator casing including end shields
alongwith provisions of indication and alarm
during leakage of liquid in generator in case of
water cooled machine.

G) Online partial
discharge (PD) monitoring: The system offered shall be applicable to the
Turbo Generator of large rating confirming to
IEEE-1434 / IEC 60034-27 2006.

Permanently connected Independent sensing unit
for each generator shall be provided along with
necessary terminal equipment. However
evaluation unit for all generators shall be common
and portable. Latest software shall be provided to
interpret the PD result. It shall also be suitably
connected to TG MMI. The sensors (e.g.
combination of slot coupler or coupling capacitors
etc.) shall be located as per the recommendation
of supplier of PD Analyser.
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H) Rotor flux monitoring system: Permanently connected independent sensing
unit for each Generator shall be provided along
with necessary terminal equipment to detect turn
to turn shorting in field winding of Generator. It
shall also be suitably connected to TG MMI to
facilitate alarm.

7.00.00 GAS SYSTEM (FOR HYDROGEN & WATER COOLED MACHINES)

1) Description Each generator shall be furnished with hydrogen
and carbon dioxide supply system including
hydrogen and CO2 gas manifold, CO2 heating
system, gas cylinders, hydrogen pressure
regulator, interconnecting piping, fittings, valves,
gauges, thermometers, pressure transmitters and
other instruments, control panels, etc.

2) Number of gas cylinders Equal to total requirement of Hydrogen cylinders
and CO
2
Cylinders for one start up and number of
CO
2
cylinders required for shut down of a unit
plus those required to be connected on manifolds
of all units plus total requirements for seven days
consumption of all units. The total CO
2
cylinders
shall be supplied duly filled up, however hydrogen
cylinders are to be supplied in empty condition.

3) Purity Purity of hydrogen from 97-99%.

4) Piping & Valves Seamless steel tubes shall be used for valve
piping. Valves shall be of glandless diaphragm
type, wherever possible.

5) Purging During purging, filling and emergency operating
conditions, the gases shall be expelled to the
atmosphere (outside the TG hall) through a
manually operated vent valve.

6) Hydrogen Safety relief valve To be provided at hydrogen manifold

7) Driers 2x100% duty to maintain the hydrogen inside the
machine dry with zero deg C dew point at
operating pressure.

Type : Refrigeration type

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8) Gas circulation at Standstill
during long shut down A suitable hot air blowing system complete with
blower, heater and thermostatic control etc. shall
be provided to prevent condensation during long
shut down. However bidder's standard and
proven system of generator drying arrangement
during long shutdown is also acceptable.

9) Valve interlocking Three way valve used along with the drier for
interconnecting the hydrogen and air line (as
applicable) shall preferably have mechanical
interlocking such that closing of the hydrogen side
port is positively ensured before opening of the air
side port.

10) On line dew point On line dew point monitoring system shall be
measurement provided across the inlet and outlet lines to the
drying system along with alarm/annunciation in
case of high moisture content in the generator
casing hydrogen.

11) Nitrogen capping During the transportation and storage the
machine shall be kept under nitrogen
atmosphere. Contractor shall bring out the
requirement of nitrogen gas during the normal
operation. The complete nitrogen system as
applicable along with the necessary nitrogen
cylinders shall be furnished for each machine.
However bidder's standard and proven system to
prevent ingress of moisture during transportation
and storage shall be acceptable.

12) Gas Analyser Thermal conductivity type and shall continuously
analyse the gas discharged from the casing
during purging and shall also analyse samples of
the casing hydrogen during normal operation.
The analyser shall measure the gas purity under
the following three conditions :

a) Normal % of purity of Hydrogen in air in the
generator casing. Purity range shall include
a low purity alarm.

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b) % of Hydrogen in CO2 leaving the casing
when Hydrogen is being admitted or
expelled.

c) % of air in CO2 leaving the casing when
CO2 is being admitted or expelled.

13) The local Generator auxiliary panel (located at 0.0m) shall be complete with all
lamps, indicators, power supplies etc. Further following instruments shall be
provided.

i) Pressure indicator / local gauge for gas pressure inside the generator.

ii) Gas purity indicator.

iii) Temperature indicator for cold hydrogen inside casing.

iv) Dew point indicator for casing hydrogen across drier inlet and outlet lines

14) Alarms in TG MMI and i) Hydrogen pressure in generator casing
Low/
annunciation contacts for High.
use in station DDCMIS
shall be provided for ii) Hydrogen pressure in hydrogen cylinders-
Low
these conditions
iii) Pressure of cooling water hydrogen coolers
Low/High.

iv) Purity of hydrogen in generator casing-Low.

iv) Liquid level in the generator casing - High.

vi) Temperature of cold/hot gas in the
generator - High.
vii) Dew point level, in hydrogen gas across the
drier inlet and outlet lines - High.
viii) Hydrogen leakage into cooling water.

15) Portable gas analyser Similar as detailed above under clause "Gas
Analyser" shall be provided for supervision of the
gas purging operation.

16) Hydrogen pressure and To be monitored and annunciated in TG MMI.
purity
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8.00.00 SEAL OIL SYSTEM (FOR H2 / WATER COOLED MACHINES)

a) General A complete seal oil supply and control system
including AC and DC motor operated pump sets,
cooler, filters, pressure regulators, oil tanks, de-
gasification tanks, regulating and control valves,
gauges, thermometers and other instruments,
interconnecting piping including hangers and
supports, valves and control panel complete with
all interlocking relays shall be provided. Blowers
for venting out Hydrogen gas liberated from oil
shall be provided suitably mounted at places
where such gas accumulation is likely to occur.

b) Number of pumps Two (2) number 100% AC motor driven pumps.
One (1) number 100% DC motor driven pump.

c) Pump starting interlock The auto starting of standby seal oil pumps shall
be interlocked with seal oil pressure.

d) Emergency condition During short time emergency which may arise due
to non availability of both AC & DC pumps, unit
may be tripped and seal oil supply for such
coasting down period shall be from a suitable
arrangement from lubrication oil system or a
damper tank. Alternatively, standard practice of
bidder regarding connection between seal oil
system and lubrication oil system/ damper tank
shall also be acceptable subject to owners
approval.

e) Pipes Seamless steel piping shall be used in the
system.

f) Seal oil pressure The seal oil pressure shall be maintained at a
pressure suitably in excess of the generator
casing hydrogen pressure. The differential
pressure shall be kept constant, once set at the
time of commissioning, at all hydrogen pressures
and all regimes of generator operation. The
pressure regulator or the regulating valve used for
the purpose shall be adjustable type.

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The seal oil system shall be so designed that it is
possible to run the machine at no load in air
medium at a slightly positive air pressure without
any modification in the system.

g) Oil level Monitoring To be provided in the different tanks. For
indication and alarm along with level gauge

Necessary hydraulic sealing arrangement shall be
provided in H2 side oil discharge line to prevent
circulation of gas due to any possible difference of
heads developed by fans mounted at the end of
the generator rotor.

h) Coolers Two (2) number 100% duty seal oil coolers along
with necessary 3 way valves for isolating or
bringing one cooler in service, shall be provided.
These coolers shall be shell and tube type or
Plate type suitable for using D.M. water of
condensate quality.

i) Cooler tube / Plate redundancy Seal oil coolers shall be designed to have 15%
excess tube or plate surface area over and above
designed tube or plate surface area required for
the rated load conditions while maintaining the
design pressure drop on cooling water side.

j) Water pressure The oil pressure in the cooler shall be greater
than water pressure under all operating
conditions.

k) Filters Suitable filters of 2x100% duty shall be provided.
It shall be possible to carry out cleaning and
maintenance of any cooler and filter when the
machine is in operation.

l) Temperature/Flow Temperature gauges and flow meters shall be
Measurement provided at all appropriate locations.

m) Pressure monitoring Pressure gauges and Transmitters shall be
provided at least at the following locations

i) At the inlet and outlet of pumps.

ii) At the outlet of the cooler
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iii) At the inlet and outlet of the pressure
regulators and filters.

iv) At the oil supply header.

n) Control The system shall be controlled as part of turbine
control system at CCR. The local Generator
auxiliary panel (located at 0.0m) shall be
complete with all lamps, indicators, power
supplies etc. Further following instruments shall
be provided:

i) indicators for seal oil-hydrogen differential
pressure.

ii) indicators for temp. of seal oil at the seals.

p) Alarms in TG MMI & i) Pressure of seal oil-Low.
Annunciation contacts for
use in station DDCMIS ii) Pressure of thrust oil-Low (if applicable)
shall be provided for these
conditions iii) Oil level in damper tank-Low (if applicable)

iv) Oil level in damper tank-(if applicable
Emergency)

v) Oil level in hydraulic seal-High. (if
applicable)

vi) Oil level in hydraulic seal-Low (if applicable)

vii) Automatic switching on of AC standby oil
pump.

viii) Automatic switching on of DC emergency
oil pump.

ix) Differential pressure between oil and
hydrogen-High.

x) Differential pressure between oil and
hydrogen-Low.

xi) AC seal oil motor power supply failure.

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xii) DC seal oil motor power supply failure.

xiii) AC/DC seal oil motor control faulty.

xiv) Seal oil temperature -high.

9.00.00 STATOR WATER COOLING SYSTEM (AS APPLICABLE)

9.01.00 General Cooling shall be provided with a closed loop
stator water cooling system. The system shall
generally include but not be limited to the
following.

a) Primary water tank One (1) number, mounted on the stator frame on
anti- vibration pads and covered by the generator
cladding. However primary water tank mounting
above the generator level as per standard and
proven practice of bidder is also acceptable. The
empty space in primary water tank may be filled
with Nitrogen or hydrogen (or air in case of
oxygen rich type system) to minimise water
evaporation. The Bidder shall indicate and
provide devices to detect, trap, monitor and
release the hydrogen, that leaks in to the stator
water cooling system, to a safe place outside the
building through suitable safety valves.

b) Make up water Make-up water for primary water system shall be
tapped off from condensate extraction pump
discharge header (before and after the
condensate polisher) and from DM water make-
up line to the condenser. The level in the tank
shall be maintained by means of suitable valves
in the make up line.

c) Water to water Two (2) 100% capacity shell and tube type or
heat exchangers plate type.

The water to water heat exchanger shall be
designed to accept secondary D.M. water
(condensate quality). The system shall be so
designed that the pressure of primary DM water
inside the cooler is always greater than that of
secondary DM water (condensate quality) The
exchanger shall be designed to have 10% excess
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tubes or plate surface area as applicable over and
above the designed requirements for the rated
load condition while maintaining the design
pressure drop on cooling water side.

d) Filters Two (2) 100% capacity fine wire mesh filters with
magnet bars of unlimited life for removal of all
magnetic particles. The permanent magnet bars
shall be protected by sleeves of stainless steel. It
shall be possible to clean easily the ferromagnetic
particles adhering to the magnet bars during
capital maintenance.

e) Circulating water pumps Two (2) 100% capacity A. C motor driven.
Standby pump shall cut in automatically in case
the working pump fails or the pressure of
circulating water drops below a certain preset
value.

f) Demineraliser One (1) mixed bed demineraliser (MBD) of
adequate capacity to maintain the required quality
of water. The MBD shall remain continuously in
service in order to retain high purity of stator
cooling water with its associated electrical
resistivity. The Bidder shall indicate in the
proposal the capacity of MBD necessary to
maintain the quality of water at the desired level
for a time duration of six months or more. It shall
be designed that the MBD could be taken out of
service for refilling without untoward effect on the
system which could necessitate load
reduction/rejection.

g) Piping Set of stainless steel piping including hangers and
supports, valves and other fittings for the
complete water system.

9.02.00 Instrumentation The following minimum instrumentation shall be
provided

i) Set of conductivity meters in the main water
circuit and after the demineraliser.

ii) Set of flow measurement (at least two nos.)
to monitor low distillate condition and flow
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transmitters/meters for primary water to
stator winding and main bushing, make up
water etc.

iii) Sets of pressure gauges at the inlet and
outlet of stator water filters, pressure
gauges at the inlet and outlet of stator
winding, differential pressure switches for
the filters, differential pressure gauge
across stator winding and pressure
transmitters as required.

iv) Set of resistance temperature detectors,
local indicators for primary water before and
after the generator winding, bushing and
cooler.

v) Set of dial type thermometers for cooling
water at the inlet and outlet of the cooler.

vi) Water level gauge, transmitters, for high
and low level alarms and other accessories
for primary water tank.

9.03.00 Control system The system shall be controlled as part of turbine
control system at CCR. The local Generator
auxiliary panel (located at 0.0m) shall be
complete with all lamps, indicators, power
supplies etc. At least the following instruments
shall be provided :

i) indicator for primary water flow in the stator
winding.

ii) indicators for primary water conductivity at
the inlet of winding and after the
demineraliser.

iii) indicator for stator winding differential
pressure.

9.04.00 Alarms in TG MMI & i) Water level in the primary water tank- low.
Annunciation contacts for

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use in station DDCMIS shall ii) Water level in the primary water tank- high
be provided for these conditions
iii) Temp. of primary cooling water at the outlet
of stator winding - high.

iv) Temp. of primary cooling water at the inlet
of stator winding - high.

v) Flow of primary cooling water to the stator
winding - Low.

vi) Conductivity of primary cooling water at the
winding inlet - high.

vii) Flow of primary cooling water to the stator
winding - very low.

viii) Conductivity of primary cooling water at the
winding outlet-high.

ix) Pressure of primary cooling at the inlet of
winding - Low.

x) Differential pressure across the primary
water filter - high.

xi) Stator water cooling pumps tripped on
overload.

xii) Reserve control supply failure for stator
water cooling.

xiii) Differential pressure across stator winding -
high.

xiv) Primary stator bar water temperature - high.

9.05.00 Alkaliser Alkaliser unit required for ensuring a corrosion
free operation shall be provided alongwith stator
water system. However alkaliser is not mandatory
for oxygen rich stator water system or stator
winding with SS hollow conductors.

9.06.00 On line dissolve oxygen To be provided for stator water system which
monitoring System operates in low oxygen regime at neutral pH.
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9.07.00 Stator coolant flow To be monitored in TG MMI.

9.08.00 Generator auxiliary system valves, piping, tanks and coolers etc. shall be designed
for at least 10 Kg/sq.cm gauge pressure irrespective of a lower operating pressure.

The maximum continuous rating of the pump and motor at specified ambient
temperature shall be at least the maximum load demand of the driven equipment in
its entire range of operation including run out flow condition when operating at
frequency variations from 47.5 Hz to 51.5 Hz.

9.09.00 The turbine generator control VDU in the central control room should have graphical
display of various generator subsystems, process/flow diagrams such as stator
cooling water, seal oil, hydrogen, lube oil, generator stator and rotor parameters
along with display of generator capability curves and operating point, generator
stator & rotor temperatures and vibration parameter etc. These should have limit
values alarm/trips tag numbers etc. clearly displayed on VDUs. In addition operator
help features for control of these systems and historical and reference data shall
also be made available for efficient operator guidance of these systems.

10.00.00 GENERATOR EXCITATION SYSTEM

10.01.00 A complete generator excitation and voltage regulating system shall be provided
with the generator. The system shall be a completely static excitation system to
meet the requirement specified herein. The excitation system offered shall be of
proven design and shall have a satisfactory field service record on machines of
similar size and construction incorporating the type of excitation.

10.02.00 Characteristics The excitation system shall have matching
characteristics suitable for satisfactory parallel
operation with other generators in the plant.

10.03.00 Fail safe requirement The various change over relays and other
equipment associated with supply system other
than AVR control supply, electronic circuits of
either channel etc., shall be such that the loss of
their control supply does not lead to the excitation
system outage.

10.04.00 Interface The necessary inputs and interface equipment
shall be provided with Generator Excitation and
Automatic Voltage Regulator for hooking up with
Turbine Automatic Run up system and Electro
Hydraulic Governing System.

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10.05.00 Equipment design & sizing criteria

10.05.01 General When the generator is subjected to a sudden loss
of rated output at rated power factor, the system
shall be capable of restoring the voltage of within
2% of the nominal preset value within negligible
time, so as not to initiate the protection
equipment.

10.05.02 Redundancy The excitation system shall have two (2x100%)
AVR channels including complete independent
power supplies and controls. Each channel shall
be equipped for 'Auto Operation' with the facility
for selecting either channel in 'Auto' or 'Manual'
mode.

10.05.03 Margin Each excitation system channel shall be designed
to continuously carry currents of at least 10%
above the field current requirement at generator
MCR condition and higher currents for short time
duty. Short time duty as mentioned above shall be
on MCR base as per clause 1.14 of part III in VDE
530.

10.05.04 Excitation system <0.5 sec
response time as per
IEEE 421 A

10.05.05 Excitation response ratio >2

10.05.06 Excitation system ceiling voltage >1.5 times rated load excitation voltage.

10.05.07 Field forcing capability Each excitation system channel shall be capable
of supplying without damage to any of the
components, the field forcing voltage and current
of the system for a period of 10 seconds without
exceeding the limits of temperature for rectifier
junction and heat sink, when the equipment starts
at normal operating temperature.

10.06.00 Voltage regulator The excitation system shall be designed in such a
manner that due to any fault in AVR firing circuit
pulse transformer, rectifying elements in any
channel etc. excitation system shall be available
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with its full capacity. All rectifying elements shall
have over voltage and short circuit protection.

10.06.01 Number of channel Two numbers fully equipped automatic channels.
Either channel shall be capable of being the main
or standby. Either channel shall be capable of
being selected as manual also.

10.06.02 Type Automatic voltage regulators shall be either of
solid state type or microprocessor/PLC based as
per manufacturer's standard and having negligible
dead band suitable for a large interconnected
system.

10.06.03 Input to AVR Current transformer secondary 5A potential
transformer secondary 110V phase to phase.

10.06.04 Characteristics

a) Auto control range +/- 10% of rated terminal voltage in all modes for
voltage level adjustments of generator operation.

b) Frequency range of 47.5 to 51.5 Hz
operation

c) Accuracy at which Better than 0.5% of the set value over the whole
generator voltage to be held load range of the
machine.

d) Range of transformer 0 to 15%
drop compensation

e) Max. change in generator Less than 0.5%
voltage when AVR is
transferred from auto
to manual under all
conditions of excitation.

f) Manual control range 70% of no load to 110% full load excitation.

10.06.05 Technical features Voltage regulator shall have the following
provisions.
a) Maximum and
minimum excitation
limiter.
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b) Channel reference control Either solid state or microprocessor control.

c) Ramp generation circuit To enable gradual rise of reference signal applied
to the circuit to avoid sudden voltage build up.

d) Transformer drop Suitable feedback proportional to transformer
compensation drop to be provided for compensation

e) Power system stabiliser PSS shall be suitable for damping the various
(PSS) modes of electro-mechanical oscillations at all
frequencies in the range of 0 to 3 Hz under
varying generator loading and power system
network configurations. PSS shall be adaptive to
varying operating conditions with features to
compute optimum stabilising signal along with
suitable scheme for identifying external reactance
of the generator. Facility for remote manual switch
off-on alongwith indication shall be incorporated.
Automatic supervision and blocking/switch off
facility alongwith indications, etc. shall also be
provided.

f) Rotor angle limiter A rotor angle limiter shall be incorporated in the
system. This shall enable to keep the angle
between the direct axis of the machine and
network vector within the set reference value as
determined by stability, by adjusting the
excitation. Alternatively bidders standard AVR
scheme to ensure machine operation within
capability curve limit shall be subject to owners
approval.

g) Stator current limiter The stator current limiter shall act immediately in
under-excited range. The time delay in over-
excited range shall enable a temporary
overloading of the machine.

h) Rotor Current limiter The regulator shall act with time delay, so that the
regulation dynamics are not impaired in case of a
fault.

i) Voltage/frequency(V/Hz) To limit the ratio of generator voltage and
limiter frequency at all operating conditions to such a
value that the maximum generator transformer
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core flux density does not exceed the value
specified.

j) Follow up In order to avoid a sudden change in generator
voltage when voltage regulation is transferred
from 'Main' to 'Standby', or 'Auto' to 'Manual', a
suitable arrangement shall be provided to follow
up changes in 'Auto' mode alongwith follow up
indication in UCB. An alarm and visual indication
shall be provided to indicate change over from
Auto channel-1 to Auto channel-2 or 'Auto' to
'Manual'.

k) Automatic changeover Shall be possible in case of trouble in the running
from Auto-1 to Auto-2 or channel.
vice versa

l) Automatic changeover Automatic change over shall be possible
from Auto to manual from 'Auto' to 'Manual' in case of : Generator
protection circuit operation i.e. after field forcing
and over excitation condition with a time delay.

Loss of terminal voltage feedback by way of any
of the VT fuse blowing up Faulty over excitation
condition.

- Loss of automatic channel reference signal

- Power supply failure in the automatic channel

- Manual intervention

- Any other condition as considered necessary
by the Contractor

10.06.06 All the above conditions and the conditions of limiter operations shall be annunciated
in local panel as well as in TG MMI. Local regulator panel shall be complete with
necessary facia window sequence logic, power supplies, accept reset test push
buttons, indicating lamps, control switches, local/remote switches, auxiliary relays
and programmable logic controllers, etc.

10.06.07 At least following instruments and control devices shall be provided for mounting on
unit control panel. Further, it shall be possible to exchange information with station
DDCMIS.

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- A center zero balance indicator to indicate the channel difference signal.

- Generator field current indicator.

- Rotor winding temperature recorder.

- Auto channel-1 to Auto channel-2 & auto/manual changeover indications.

- Generator field breaker/exciter field breaker control & instrumentation.

- PSS control and instrumentation.

- Auto and manual channel control of excitation level.

- Field flashing (for Static Excitation System) and field forcing condition
indications.

11.00.00 FEATURES OF STATIC EXCITATION SYSTEM (If applicable)

11.01.00 General Description The excitation system shall broadly consist of:

a) Rectifier transformer

b) Regulator cubicle

c) Thyristor convertor cubicles alongwith firing
controls.

d) DC excitation cubicle housing :

- A field circuit breaker.

- A main field flashing device.

- An over voltage protection.

e) Interconnecting cables/busbars between
different equipment/panels of the system.

11.02.00 Rectifier Transformer

a) Type Indoor, epoxy moulded dry type, 3 phase step
down transformer with Thermal Class 155 (F)
insulation complete with flanges and terminal lugs
for connection to the generator terminals through
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isolated phase bus ducts. The transformer shall
conform to IEC-60076-11.

b) Temperature rise 90 deg.C over an ambient temperature of 50
deg.C.

c) Fault rating Withstand through fault current for the time
duration equal to de-excitation time of the
generator field current for such faults under
AVR/manual operation.

d) Housing Sheet steel cubicle

e) Protection A set of CTs to be provided in the primary of
rectifier transformer for overload protection. Hot
spot temperature measurement in each limb of
the transformer alongwith indication as well as
alarm and trip contacts shall be provided.

11.03.00 Power Thyristor Convertor

a) Type Fully controlled three phase, full wave bridge type
facilitating fast and high ceiling performance.
Suitable to ensure trouble free service of the cells
under all fault conditions. The convertor shall
have N+2 redundancy where N is the number of
bridges required to deliver rated excitation current
and N+1 number of bridges shall be able to
deliver the ceiling voltage/current as mentioned
elsewhere in the specifications.

b) Protection The thyristors shall be selectively protected
against over- loads by ultra high speed fuses.
Suitable lamps indication or alarms shall also be
provided to indicate the defective 'thyristor'.

11.04.00 Gate Firing Circuit The firing circuit shall have the following essential
features :

a) It shall produce a gate pulse for every
thyristor once in a cycle.

b) It shall be able to shift the gate pulse in the
time over a range of about 150 electrical
degrees under a signal from the regulator.
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c) It shall provide a linear relationship between
the regulating inputs volts and rectifier
output.

d) The firing circuit shall have negligible time
lag.

e) It shall fire the thyristors correctly for any
situation of input voltage, depression or
unbalance coupled with high or low field
currents

11.05.00 Pulse Transformer There shall be a pulse transformer between the
individual gates of the parallel connected
thyristors and between the main current circuit
and the control circuit. Their amplitudes shall be
depending upon the trigger characteristics,
approximately +3 to +20V peak against cathode.

11.06.00 Field Flashing The initial field flashing shall be from the station's
415 V auxiliary AC supply. Suitable rectifier filters,
etc. required for converting this ac supply to the
required DC supply shall be housed in the
excitation system cubicle. Suitable protection
interlock with desired time delay shall be provided
so that when the AC terminal voltage of the
generator is built up to the required level for the
main excitation rectifier system to take over, the
field flashing circuit is switched off.

In case the main excitation system fails to take
over after a predetermined time of field flashing,
the field breaker should trip automatically. An
annunciation for field flashing failure/main field
breaker trip due to field flashing failure shall be
incorporated. All the components of field flashing
system shall be continuously rated irrespective of
its short time duty requirement so as to guard
against any failure in case of it's prolonged mal-
operation.

11.07.00 Field Application & Suppression Arrangement:

a) Field breaker The generator field breaker shall be of DC,
multipole or single pole air break type, suitable for
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operation from local panel as well as from UCB.
The breaker shall have arc quenching
arrangement for both the main poles as well as
the discharge contacts. Breaker shall be designed
to carry currents for continuous as well as short
time duty of the excitation system. Breaking
current capacity of the breaker shall match with
the fault level at the output DC bus. Discharge
contacts shall be rated to discharge the field
energy corresponding to the highest field current
which may come during its entire operating range.
The breaker shall be complete with control
switches, indication lamps, local/remote selector
switch, etc.

b) discharge resister Non-inductive for quick discharge of inductive
energy and thereby controlling the voltage across
the field.

c) Option Separate breakers for field application and
suppression may also be considered if it is
Contractor's standard arrangement.

d) Interlocks Suitable interlock shall be provided to prevent
closing of the field breaker unless the regulator
reference signal is at/near the minimum setting
and minimum machine speed of 95% is attained.
Adequate number of normally open and normally
closed field circuit breaker auxiliary contact for
remote position indication and interlocking with
generator and field flashing circuit shall be
provided.

e) Collector rings, Brush gears and Brushes

i) Enclosure For static excitation system, a suitable brush gear
with brush assembly, in a well ventilated
enclosure shall be provided. However for
brushless excitation system the same is not
applicable.

ii) Collector rings Insulated helically grooved, alloy steel collector
rings shrunk on the rotor. For cooling the slip
rings, if required, suitable fans shall be provided
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either on the collector rings or on the rotor shaft
adjacent to it.

iii) Brush position Located only on the upper two third periphery of
collector rings. The brushes shall be staggered
along the length of collector ring to avoid any non-
uniform ring wear.

iv) Access doors and To be provided to enable replacement and
inspection windows inspection of brushes while the machine is in
operation

v) Brush holders Constant pressure type which can be adjusted as
per requirement. Suitable insulation shall be
provided to prevent passage of current through
pressure device.

12.00.00 STABILITY STUDIES

The Contractor shall be required to carry out the detailed computer studies
considering single machine with infinite bus so as to confirm the suitability of the
Turbine generator and its excitation system in the grid for maintaining the power
system stability under dynamic and transient conditions and tune the PSS
parameters at site for all the machines. The data and worst possible conditions
pertaining to Employer's system shall be discussed and finalised between Employer
and the Contractor, in accordance with the system modeling techniques and depth
of modeling. The Contractor shall furnish the details of simulation technique and
method which he proposes to use for this purpose.

13.00.00 TYPE TESTS

13.01.01 The contractor shall carry out the type tests as listed in this specification on the
equipment to be supplied under this contract. The bidder shall indicate the charges
for each of these type tests separately in the relevant schedule of Section - VII-
(BPS) and the same shall be considered for the evaluation of the bids. The type
tests charges shall be paid only for the test(s) actually conducted successfully under
this contract and upon certification by the employers engineer.

13.01.02 The type tests shall be carried out in presence of the employers representative, for
which minimum 15 days notice shall be given by the contractor. The contractor shall
obtain the employers approval for the type test procedure before conducting the
type test. The type test procedure shall clearly specify the test setup, instruments to
be used, procedure, acceptance norms, recording of different parameters, interval of
recording, precautions to be taken etc. for the type test(s) to be carried out.

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B - 1
GENERATOR AND
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13.01.03 In case the contractor has already conducted such specified type test(s), he may
submit during detailed engineering the type test reports to the owner for waival of
conductance of such type test(s). These reports should be for the tests conducted
on the equipment similar to those proposed to be supplied under this contract and
test(s) should have been either conducted at an independent laboratory or should
have been witnessed by a client. The owner reserves the right to waive conducting
of any or all the specified type test(s) under this contract. In case type tests are
waived, the type test charges shall not be payable to the contractor.

13.01.04 Further the Contractor shall only submit the reports of the type tests as listed in
"LIST OF TESTS FOR WHICH REPORTS HAVE TO BE SUBMITTED" and carried
out within last ten years from the date of bid opening. These reports should be for
the test conducted on the equipment similar to those proposed to be supplied under
this contract and the test(s) should have been either conducted at an independent
laboratory or should have been witnessed by a client. However if the contractor is
not able to submit report of the type test(s) conducted within last ten years from the
date of bid opening, or in the case of type test report(s) are not found to be meeting
the specification requirements, the contractor shall conduct all such tests under this
contract at no additional cost to the owner either at third party lab or in presence of
client/owners representative and submit the reports for approval.

13.01.05 All acceptance and routine tests as envisaged in QA section shall be carried out.
Charges for these shall be deemed to be included in the equipment price.

13.01.06 The type test reports once approved for any projects shall be treated as reference.
For subsequent projects of NTPC, an endorsement sheet will be furnished by the
manufacturer confirming similarity and No design Change. Minor changes if any
shall be highlighted on the endorsement sheet.

13.02.00 LIST OF TYPE TESTS TO BE CONDUCTED

13.02.01 The following type tests shall be conducted under this contract on one generator of
each type and rating

a) Instantaneous short circuit test to determine transient and sub-transient
reactance parameters and to ensure stability of winding during sudden short
circuit condition.

b) Determination of negative sequence and zero sequence impedance.

c) Determination of voltage waveform factor and Total Harmomic Factor.

d) Short circuit heat run test at two third of rated stator current at rated pressure
and cooling parameters with one cooler out of service and ten (10) percent of
tubes plugged in remaining coolers that are in service. In case of
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unsymmetrical cooler configuration, test with all possible variants of one
cooler out of circuit shall be carried out.

e) Vibration measurement on all planes on stator overhang winding at suitable
locations on each end and at other critical locations to be decided by Owner
for the following conditions :

i) Open circuit operation.

ii) Short circuit operation.

iii) Sudden short circuit conditions.

iv) Stand still condition - with Hammer test.

Minimum six (6) readings shall be taken for each end of the Generator. The
test results of above shall prove that the values are within the normal
operating limits for long satisfactory performance and that there are no
components or parts which have natural frequency of resonance near
operating frequencies or 100Hz.

The above type tests shall be carried out keeping all conditions/ parameters as
close as possible to site conditions with all the built-in instrumentation (like RTD etc.)
suitably wired and the readings recorded. During various tests, bearing & shaft
overhang vibrations shall also be measured with and without excitation. Recording of
various parameters of bearing , seal oil system, gas system , stator water cooling
system and environmental conditions (like temperature etc.) shall also be done.

14.02.02 Static excitation system

Following type tests shall be conducted

a) All type and special tests on excitation transformer as per IEC-60076-11.

b) Type tests on field breaker as per IEEE/ANSI C-37-18.

c) Temperature rise test of converter panel at MCR rating. Ceiling duty
condition of excitation system shall also be demonstrated.

d) If busducts are used, the same shall be tested for material. One section shall
be tested for temperature rise, dynamic and short time current test, degree of
protection test and one minute power frequency high voltage withstand test
as per IS:8084 / ANSI IEEE-37.23 / IEC 60439-2,60529 & 62271.

e) Test for estimating the discharging capability of the field discharge resistors
in succession for at least two discharges. Alternatively, tests on field
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discharge resistors as per sub-supplier standards and applicable standards
shall be subject to owners approval.

f) Input and output surge withstand capability test:

The Oscillatory SWC tests shall be conducted as per ANSI / IEEE C37.90.1-
2002

The Fast transient SWC tests shall be conducted as per ANSI / IEEE
C37.90.1-2002 / IEC 60255-22-04-2008.

14.03.00 LIST OF TESTS FOR WHICH REPORTS HAVE TO BE SUBMITTED

14.03.01 Static Excitation system

(a) Excitation panels

i) Soak test for Electronic module.
ii) Dry heat test as per IEC-68-2-2 or equivalent for electronic modules
iii) Damp heat test as per IEC-68-2-3 or equivalent for electronic
modules

(b) Degree of protection test for Excitation system panels.

(c) Tests on thyristors as per relevant IS.

15.00.00 TRAINING

Contractor shall provide training on Generator, Excitation system including AVR,
Generator On-Line partial discharge system, Generator end winding vibration
monitoring system and Rotor flux monitoring system for Employers personnel. The
duration of the training shall be as elaborated in Part-C, Section-VI of technical
specifications.

SECTION-VI
PART-B
B - 2
MOTORS
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SECTION - VI
PART-B
B - 2
MOTORS
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MOTORS
1.01.00 For the purpose of design of equipment/systems, an ambient temperature of 50 deg.
Centigrade and relative humidity of 95% (at 40 deg C) shall be considered. The
equipment shall operate in a highly polluted environment.
1.02.00 All equipments shall be suitable for rated frequency of 50 Hz with a variation of +3%
& -5%, and 10% combined variation of voltage and frequency unless specifically
brought out in the specification.
1.03.00 Contractor shall provide fully compatible electrical system, equipments, accessories
and services.
1.04.00 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.
1.05.00 The auxiliary AC voltage supply arrangement shall have 11kV, 3.3 kV and 415V
systems and DC voltage shall be 220 V. It shall be designed to limit voltage
variations as given below under worst operating condition :
(a) 11kV, 3.3 kV +/- 6%
(b) 415/240V +/- 10%
(c) 220 V DC -15% to +10%. However the nominal
continuous DC power supply shall be 242V.
1.06.00 The voltage level for motors shall be as follows :-
a) Upto 0.2KW : Single phase 240V AC / 3 phase 415V AC
b) Above 0.2KW and upto 200KW : 3 phase 415V AC
c) Above 200KW and upto 1500 KW: 3.3 kV
d) Above 1500 KW : 11 kV

1.07.00 Fault level shall be limited to 40kA RMS for 1 second for 11kV & 3.3 kV system and
45 kA RMS 1 second for 415V system. 415V system shall be solidly grounded and
220 VDC system shall be isolated type.

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MOTORS
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1.08.00 Paint shade shall be as per RAL 5012 (Blue) for indoor and outdoor equipment.
1.09.00 The responsibility of coordination with electrical agencies and obtaining all
necessary clearances shall be of the contractor.
1.10.00 Degree of Protection
Degree of protection for various enclosures as per IS:4691, IEC60034-05 shall be as
follows :-
i) Indoor motors - IP 54
ii) Outdoor motors - IP 55
iii) Cable box-indoor area - IP 54
iv) Cable box-Outdoor area - IP 55
2.00.00 CODES AND STANDARDS
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) Energy Efficient motors : IS 12615, IEC:60034-30
3.00.00 TYPE
3.01.00 AC Motors:
a) Squirrel cage induction motor suitable for direct-on-line starting.
b) Continuous duty LT motors upto 160 KW Output rating (at 50 deg.C ambient
temperature), shall be Energy Efficient motors, Efficiency class-Eff 1,
conforming to IS 12615, or High efficiency (IE2) as per IEC:60034-30.
c) Crane duty motors shall be slip ring/ squirrel cage Induction motor as per the
requirement.
3.02.00 DC Motors Shunt wound.
4.00.00 RATING
(a) Continuously rated (S1). However, crane motors shall be rated for S4 duty,
40% cyclic duration factor.
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PART-B
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MOTORS
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(b) 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.
(c) For BFP motors starting MVA shall be restricted to 80 MVA.
5.00.00 TEMPERATURE RISE
Air cooled motors
70 deg. C by resistance method for both thermal class 130(B) & 155(F) insulation.
Water cooled
80 deg. C over inlet cooling water temperature mentioned elsewhere, by resistance
method for both thermal class 130(B) & 155(F) insulation.
6.00.00 OPERATIONAL REQUIREMENTS
6.01.00 Starting Time
6.01.01 For motors with starting time upto 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.
6.01.02 For motors with starting time more than 20 secs. and upto 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.
6.01.03 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.
6.01.04 Speed switches mounted on the motor shaft shall be provided in cases where above
requirements are not met.
6.02.00 Torque Requirements
6.02.01 Accelerating torque at any speed with the lowest permissible starting voltage shall
be at least 10% motor full load torque.
6.02.02 Pull out torque at rated voltage shall not be less than 205% of full load torque. It
shall be 275% for crane duty motors.

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PART-B
B - 2
MOTORS
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6.03.00 Starting voltage requirement
(a) 85% below 110 KW
(b) 80% from 110 KW to 200 KW
(c) 85% above 200 KW to 1000 KW
(d) 80% from 1001 KW to 4000 KW
(e) 75% above 4000KW
Except AOP & J OP motors running on D.G emergency supply, starting voltage shall
be 80%.
7.01.00 Suitable single phase space heaters shall be provided on motors rated 30KW and
above to maintain windings in dry condition when motor is standstill. Separate
terminal box for space heaters & RTDs shall be provided. However for flame proof
motors , space heater terminals inside the main terminal box may be acceptable.
7.02.00 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 and EPB 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 : Group - IIC (or Group-I, Div-II as per plant area
NEC) or ( Class-1, Group-B, Div-II as per
NEMA /IEC60034)
7.03.00 Winding and Insulation
(a) Type : Non-hygroscopic, oil resistant, flame resistant
(b) Starting duty : Two hot starts in succession, with motor
initially at normal running temperature.
(c) 11kV & 3.3 kV AC
motors
:

Thermal class 155 (F) insulation.
The winding insulation process shall be total
Vacuum Presure Impregnated i.e resin poor
method. The lightning Impulse & interturn
insulation surge withstand level shall be as
per IEC-60034 part-15
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MOTORS
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(d) 240VAC, 415V AC
& 220V DC motors
: Thermal Class( B ) or better
7.04.00 Motors rated above 1000KW shall have insulated bearings to prevent flow of shaft
currents.
7.05.00 Motors with heat exchangers shall have dial type thermometer with adjustable alarm
contacts to indicate inlet and outlet primary air temperature.
7.06.00 Noise level for all the motors shall be limited to 85dB(A) except for BFP motor for
which the maximum limit shall be 90dB(A). Vibration shall be limited within the limits
prescribed in IS:12075 / IEC 60034-14 . Motors shall withstand vibrations produced
by driven equipment. HT motor bearing housings shall have flat surfaces, in both X
and Y directions, suitable for mounting 80mmX80mm vibration pads.
7.07.00 In HT motors, at least four numbers simplex / two numbers duplex platinum
resistance type temperature detectors shall be provided in each phase stator
winding. Each bearing of HT motor shall be provided with dial type thermometer with
adjustable alarm contact and preferably 2 numbers duplex platinum resistance type
temperature detectors.
7.08.00 Motor body shall have two earthing points on opposite sides.
7.09.00 HT 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. In case cable box is offered, then Employer shall provide
termination kit. 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.
7.10.00 The spacing between gland plate & centre of terminal stud shall be as per Table-I.
7.11.00 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.
7.12.00 The motors shall be suitable for bus transfer schemes provided on the 11kV, 3.3 kV
/415V systems without any injurious effect on its life.
7.13.00 For motors rated 2000 KW & above, neutral current transformers of PS class shall
be provided on each phase in a separate neutral terminal box.
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MOTORS
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7.14.00 11kV and 3.3 kV motor Terminal Box shall be suitable for fault level of 750MVA for
0.12 sec and 250 MVA for 0.12 sec respectively. Elastimould termination kit shall be
suitable for fault level of 25 KA for 0.17 seconds.
7.15.00 The size and number of cables (for HT and LT motors) to be intimated to the
successful bidder during detailed engineering and the contractor shall provide
terminal box suitable for the same.
8.00.00 The ratio of locked rotor KVA at rated voltage to rated KW shall not exceed the
following (without any further tolerance) except for BFP motor.
(a) Below 110KW : 10.0
(b) From 110 KW & upto 200 KW : 9.0
(c) Above 200 KW & upto 1000KW : 10.0
(d) From 1001KW & upto 4000KW : 9.0
(e) Above 4000KW : 6 to 6.5
10.00.00 TYPE TEST
10.01.00 HT MOTORS
10.01.01 The contractor shall carry out the type tests as listed in this specification on the
equipment to be supplied under this contract. The bidder shall indicate the charges
for each of these type tests separately in the relevant schedule of Section - VII-
(BPS) and the same shall be considered for the evaluation of the bids. The type
tests charges shall be paid only for the test(s) actually conducted successfully under
this contract and upon certification by the employers engineer.
10.01.02 The type tests shall be carried out in presence of the employers representative, for
which minimum 15 days notice shall be given by the contractor. The contractor shall
obtain the employers approval for the type test procedure before conducting the
type test. The type test procedure shall clearly specify the test setup,
instruments to be used, procedure, acceptance norms, recording of different
parameters, interval of recording, precautions to be taken etc. for the type test(s) to
be carried out.
10.01.03 In case the contractor has conducted such specified type test(s) within last ten years
as on the date of bid opening, he may submit during detailed engineering the type
test reports to the owner for waival of conductance of such test(s). These reports
should be for the tests conducted on the equipment similar to those proposed to be
supplied under this contract and test(s) should have been either conducted at an
independent laboratory or should have been witnessed by a client. The owner
reserves the right to waive conducting of any or all the specified type test(s) under
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MOTORS
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this contract. In case type tests are waived, the type test charges shall not be
payable to the contractor.
10.01.04 Further the Contractor shall only submit the reports of the type tests as listed in
"LIST OF TESTS FOR WHICH REPORTS HAVE TO BE SUBMITTED"and carried
out within last ten years from the date of bid opening. These reports
should be for the test conducted on the equipment similar to those proposed to be
supplied under this contract and the test(s) should have been either conducted at an
independent laboratory or should have been witnessed by a client. However if the
contractor is not able to submit report of the type test(s) conducted within last ten
years from the date of bid opening, or in the case of type test report(s) are not found
to be meeting the specification requirements, the contractor shall conduct all such
tests under this contract at no additional cost to the owner either at third party lab or
in presence of client/owners representative and submit the reports for approval.
10.01.05 LIST OF TYPE TESTS TO BE CONDUCTED
The following type tests shall be conducted on each type and rating of HT
motor
(a) No load saturation and loss curves upto approximately 115% of rated voltage
(b) Measurement of noise at no load.
(c) Momentary excess torque test (subject to test bed constraint).
(d) Full load test(subject to test bed constraint)
(e) Temperature rise test at rated conditions. During heat run test, bearing
temp., winding temp.,coolant flow and its temp. 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.
(f) Lightning Impulse withstand test on the sample coil shall be as per clause
no. 4.3 IEC-60034, part-15
(g) Surge-withstand test on interturn insulation shall be as per clause no. 4.2 of
IEC 60034, part-15

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MOTORS
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The following type test reports shall be submitted for each type and rating of
HT motor
(a) Degree of protection test for the enclosure followed by IR, HV and no load
run test.
(b) Terminal box-fault level withstand test for each type of terminal box of HT
motors only.
10.02.00 LT Motors
10.02.01 LT Motors supplied shall be of type tested design. During detailed engineering, the
contractor shall submit for Owner's approval the reports of all the type tests as listed
in this specification and carried out within last ten years from the date of bid opening.
These reports should be for the test conducted on the equipment similar to those
proposed to be supplied under this contract and the test(s) should have been either
conducted at an independent laboratory or should have been witnessed by a client.
10.02.02 However if the contractor is not able to submit report of the type test(s) conducted
within last ten years from the date of bid opening, or in the case of type test report(s)
are not found to be meeting the specification requirements, the contractor shall
conduct all such tests under this contract at no additional cost to the owner either at
third party lab or in presence of client/owners representative and submit the reports
for approval.
The following type test reports shall be submitted for each type and rating of
LT motor of above 50 KW only

1. Measurement of resistance of windings of stator and wound rotor.

2. No load test at rated voltage to determine input current power and speed

3. Open circuit voltage ratio of wound rotor motors ( in case of Slip ring motors)

4. Full load test to determine efficiency power factor and slip .

5. Temperature rise test .

6. Momentary excess torque test.

7. High voltage test .

8. Test for vibration severity of motor.
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PART-B
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MOTORS
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9. Test for noise levels of motor(Shall be limited as per clause no 7.06.00 of this
section)

10. Test for degree of protection and

11. Overspeed test.

12. Type test reports for motors located in fuel oil area having flame proof
enclosures as per IS 2148 / IEC 60079-1

10.03.00 All acceptance and routine tests as per the specification and relevant standards shall
be carried out. Charges for these shall be deemed to be included in the equipment
price.

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PART-B
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MOTORS
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TABLE - I
DIMENSIONS OF TERMINAL BOXES FOR LV MOTORS
Motor MCR in KW Minimum distance between centre of
stud and gland plate in mm
UP to 3 KW As per manufacturer's practice.

Above 3 KW - upto 7 KW 85







Above 125 KW-upto 200 KW 203

For HT motors the distance between gland plate and the terminal studs shall not be
less than 500 mm.

PHASE TO PHASE/ PHASE TO EARTH AIR CLEARANCE:

NOTE: Minimum inter-phase and phase-earth air clearances for LT motors with lugs
installed shall be as follows:

Motor MCR in KW Clearance

UP to 110 KW 10mm

Above 110 KW and upto 150 KW 12.5mm

Above 150 KW 19mm

SECTION-VI
PART-B
B - 3
L.T. POWER CABLES
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PART-B
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L.T. POWER CABLES
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LT POWER CABLES
1.00.00 CODES & STANDARDS
1.01.00 All standards, specifications and codes of practice referred to herein shall be the
latest editions including all applicable official amendments and revisions. In case of
conflict between this specification and those (IS : codes, standards, etc.) referred to
herein, the former shall prevail. All the cables shall conform to the requirements of
the following standards and codes:
IS :1554 - I PVC insulated (heavy duty) electric cables for working
voltages upto and including 1100V.
IS : 3961 Recommended current ratings for cables
IS : 3975 Low carbon galvanised steel wires, formed wires and tapes
for armouring of cables.
IS : 5831 PVC insulation and sheath of electrical cables.
IS:7098 (Part -I) Cross linked polyethylene insulated PVC sheathed cables for
working voltages upto and including 1100V.
IS : 8130 Conductors for insulated electrical cables and flexible cords.
IS : 10418 Specification for drums for electric cables.
IS : 10810 Methods of tests for cables.
ASTM-D -2843 Standard test method for density of smoke from the burning
or decomposition of plastics.
IEC-754
(Part-I)
Tests on gases evolved during combustion of electric
cables.
IEC-332 Tests on electric cables under fire conditions. Part-3: Tests
on bunched wires or cables (Category-B).

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PART-B
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L.T. POWER CABLES
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2.01.00 The cables shall be suitable for laying on racks, in ducts, trenches, conduits and
under ground buried installation with chances of flooding by water.
2.02.00 Cables shall be flame retardant, low smoke (FRLS) type designed to withstand all
mechanical, electrical and thermal stresses developed under steady state and
transient operating conditions as specified elsewhere in this specification.
2.03.00 Aluminium conductor used in power cables shall have tensile strength of more than
100 N/ sq.mm. Conductors shall be stranded.
2.04.00 XLPE insulation shall be suitable for a continuous conductor temperature of 90 deg.
C and short circuit conductor temperature of 250 deg C. PVC insulation shall be
suitable for continuous conductor temperature of 70 deg C and short circuit
conductor temperature of 160 deg. C.
2.05.00 The cable cores shall be laid up with fillers between the cores wherever necessary.
It shall not stick to insulation and inner sheath. All the cables, other than single core
unarmoured cables, shall have distinct extruded PVC inner sheath of black colour as
per IS : 5831.
2.06.00 For single core armoured cables, armouring shall be of aluminium wires/ formed
wires. For multicore armoured cables, armouring shall be of galvanised steel as
follows :
Calculated nominal dia.
of cable under armour
Size and Type of armour
Upto 13 mm 1.4mm dia GS wire
Above 13 & upto 25mm 0.8 mm thick GS formed wire / 1.6 mm dia GS wire
Above 25 & upto 40 mm 0.8mm thick GS formed wire / 2.0mm dia GS wire
Above 40 & upto 55mm 1.4 mm thick GS formed wire /2.5mm dia GS wire
Above 55 & upto 70 mm 1.4mm thick GS formed wire / 3.15mm dia GS wire
Above 70mm 1.4 mm thick GS formed wire / 4.0 mm dia GS wire
2.06.01 The aluminium used for armouring shall be of H4 grade as per IS: 8130 with
maximum resistivity of 0.028264 ohm mm
2
per meter at 20 deg C. The sizes of
aluminium armouring shall be same as indicated above for galvanized steel.
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L.T. POWER CABLES
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2.06.02 The gap between armour wires / formed wires shall not exceed one armour wire /
formed wire space and there shall be no cross over / over-riding of armour wire /
formed wire. The minimum area of coverage of armouring shall be 90%. The
breaking load of armour joint shall not be less than 95% of that of armour wire /
formed wire. Zinc rich paint shall be applied on armour joint surface of G.S.wire/
formed wire.
2.07.00 Outer sheath shall be of PVC as per IS: 5831 & black in colour. In addition to
meeting all the requirements of Indian standards referred to, outer sheath of all the
cables shall have the following FRLS properties.
(a.) Oxygen index of min. 29 (as per IS 10810 Part-58).
(b.) Acid gas emission of max. 20% (as per IEC-754-I).
(c.) Smoke density rating shall not be more than 60 % (as per ASTMD-2843).
2.08.00 Cores of the cables shall be identified by colouring of insulation. Following colour
scheme shall be adopted:
1 core - Red, Black, Yellow or Blue
2 core - Red & Black
3 core - Red, Yellow & Blue
4 core - Red, Yellow, Blue and Black
2.09.00 For reduced neutral conductors, the core shall be black.
2.10.00 In addition to manufacturer's identification on cables as per IS, following marking
shall also be provided over outer sheath.
(a.) Cable size and voltage grade - To be embossed
(b.) Word 'FRLS' at every 5 metre - To be embossed
(c.) Sequential marking of length of the cable in metres at every one metre
-To be embossed / printed
The embossing shall be progressive, automatic, in line and marking shall be legible
and indelible.
2.11.00 All cables shall meet the fire resistance requirement as per Category-B of IEC 332
Part-3.
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SECTION - VI
PART-B
B - 3
L.T. POWER CABLES
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2.12.00 Allowable tolerances on the overall diameter of the cables shall be +\-2 mm
maximum, over the declared value in the technical data sheets.
2.13.00 In plant repairs to the cables shall not be accepted. Pimples, fish eye, blow holes
etc. are not acceptable.
3.00.00 Cable selection & sizing
3.01.00 LT Power cables shall be sized based on the following considerations:
(a) Rated current of the equipment
(b) The voltage drop in the cable, during motor starting condition, shall be limited
to 10% and during full load running condition, shall be limited to 3% of the
rated voltage
(c) Short circuit withstand capability
This will depend on the feeder type. For a fuse protected circuit, cable should
be sized to withstand the let out energy of the fuse.For breaker controlled
feeder, cable shall be capable of withstanding the system fault current level
for total breaker tripping time inclusive of relay pickup time.
(d) The minimum conductor size shall be 6 sqmm for aluminium conductor
cables and 2.5 sqmm for copper conductor cables. The constructional details
of copper conductor cables shall be same as indicated for copper control
cable.
302.00 Derating Factors
Derating factors for various conditions of installations including the following shall be
considered while selecting the cable sizes:
a) Variation in ambient temperature for cables laid in air
b) Grouping of cables
c) Variation in ground temperature and soil resistivity for buried cables.
3.03.00 Cable lengths shall be considered in such a way that straight through cable joints
are avoided.
3.04.00 Cables shall be armoured type if laid in switchyard area or directly buried.
3.05.00 All LT power cables of sizes more than 120 sq.mm. shall be XLPE insulated and
preferable sizes are 1Cx150, 1Cx300, 1Cx630, 3Cx150 & 3Cx240 sq.mm.
CLAUSE NO.

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SECTION - VI
PART-B
B - 3
L.T. POWER CABLES
PAGE
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4.00.00 CONSTRUCTIONAL FEATURES
(a.) 1.1 KV grade XLPE power cables shall have compacted aluminium
conductor, XLPE insulated, PVC inner sheathed (as applicable), armoured/
unarmoured, FRLS PVC outer sheathed conforming to IS:7098. (Part-I).
(b.) 1.1KV grade PVC power cables shall have aluminium conductor
(compacted type for sizes above 10 sq.mm), PVC Insulated, PVC inner
sheathed, armoured/ unarmoured, FRLS PVC outer sheathed conforming to
IS:1554 (Part-I).
5.00.00 CABLE DRUMS
(a) Cables shall be supplied in non returnable wooden or steel drums of heavy
construction. The surface of the drum and the outer most cable layer shall be
covered with water proof cover. Both the ends of the cables shall be properly
sealed with heat shrinkable PVC/ rubber caps secured by 'U' nails so as to
eliminate ingress of water during transportation, storage and erection. Wood
preservative anti-termite treatment shall be applied to the entire drum.
Wooden drums shall comply with IS: 10418.
(b) Each drum shall carry manufacturer's name, purchasers name, address and
contract number, item number and type, size and length of cable and net
gross weight stencilled on both sides of the drum. A tag containing same
information shall be attached to the leading end of the cable. An arrow and
suitable accompanying wording shall be marked on one end of the reel
indicating the direction in which it should be rolled.
(c) The standard drum length for power cables shall not be less than 500
meters. The length per drum shall be subjected to a maximum tolerance of
+/- 5% of the standard drum length. The Employer shall have the option of
rejecting cable drum with shorter lengths. For each size, the variance of total
quantity, adding all the supplied drum lengths, from the ordered quantity,
shall not exceed +/- 2%.
5.00.00 TYPE TESTS
5.01.00 General
All equipments to be supplied shall be of type tested design. During detailed
engineering, the contractor shall submit for Owners approval the reports of all the
type tests as listed in this specification and carried out within last ten years from the
date of bid opening. These reports should be for the test conducted on the
equipment similar to those proposed to be supplied under this contract and the
have been witnessed by a client.
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SECTION - VI
PART-B
B - 3
L.T. POWER CABLES
PAGE
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However if the contractor is not able to submit report of the type test(s) conducted
third party lab or in presence of client /owners representative and submit the reports
for approval.
All acceptance and routine tests as per the specification and relevant standards shall
price.
The type test reports once approved for any projects shall be treated as reference.
5.02.00 Type Tests
5.02.01 The reports for the following type tests shall be submitted for one size each of
LT XLPE and LT PVC Power cables. Size shall be decided by the employer during
detailed engineering :
S.No. Type test Remarks

For Conductor
1. Resistance test
2. Tensile test For circular non-compacted
conductors only
3. Wrapping test For circular non-compacted
only
For Armour Wires/ Formed Wires
4. Measurement of Dimensions
5. Tensile Test
6. Elongation test
7. Torsion test For round wires only

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PART-B
B - 3
L.T. POWER CABLES
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8. Wrapping test For aluminium wires /
formed wires only.
9. Resistance test
10(a) Mass of zinc coating test For GS Formed wires/wires
only
10(b) Uniformity of zinc coating For GS Formed wires /wires
only
11. Adhesion test For GS Formed wires/wires
only
For PVC/XLPE insulation & PVC Sheath
12. Test for thickness
13. Tensile strength & elongation
tests
before ageing and after ageing
14. Ageing in air oven
15. Loss of mass test For PVC insulation and sheath
only
16. Hot deformation test For PVC insulation and sheath
only
17. Heat shock test For PVC insulation and sheath
only
18. Shrinkage test
19. Thermal stability test For PVC insulation and sheath
only
20. Hot set test For XLPE insulation only
21. Water absorption test For XLPE insulation only
22. Oxygen index test For outer sheath only
23. Smoke density test For outer sheath only
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PART-B
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L.T. POWER CABLES
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24. Acid gas generation test For outer sheath only
For completed cables
25. Insulation resistance test
(Volume resistivity method)
26. High voltage test
27. Flammability test as per IEC-332 Part-3 (Category-B)
5.02.02 Acceptance Tests (as per QA table)
5.02.03 Routine Tests (as per QA table)

SECTION-VI
PART-B
B - 4
L.T. CONTROL CABLES
CLAUSE NO.

STAGE II (2X660 MW)
SECTION - VI
PART-B
B - 4
L.T. CONTROL CABLES
PAGE
1 OF 7

LT CONTROL CABLES

1.00.00 CODES & STANDARDS

conflict between this specification and those (IS : codes, standards, etc.) referred to
herein, the former shall prevail. All the cables shall conform to the requirements of
the following standards and codes :

IS :1554 - I PVC insulated (heavy duty) electric cables for working
voltages upto and including 1100V.

IS : 3961 Recommended current ratings for cables

IS : 3975 Low carbon galvanised steel wires, formed wire and
tapes for armouring of cables.

IS : 4905 Methods for random sampling.

IS : 5831 PVC insulation and sheath of electrical cables.

IS : 8130 Conductors for insulated electrical cables and flexible
cords.

IS : 10418 Specification for drums for electric cables.

IS : 10810 Methods of tests for cables.

ASTM-D -2843 Standard test method for density of smoke from the
burning or decomposition of plastics.

IEC-754 (Part-I) Test on gases evolved during combustion of electric
cables.

IEC -332 Tests on Electric cables under fire conditions
Part-3 : Tests on bunched wires or cables (category -
B)


2.01.00 The cables shall be suitable for laying on racks, in ducts, trenches, conduits and
under ground burried installation with chances of flooding by water.

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SECTION - VI
PART-B
B - 4
L.T. CONTROL CABLES
PAGE
2 OF 7

2.02.00 Cables shall be flame retardant, low smoke (FRLS) type designed to withstand all
mechanical, electrical and thermal stresses develop under steady state and transient
operating conditions as specified elsewhere in this specification.

2.03.00 Conductor of control cables shall be made of multi stranded, plain annealed copper.

2.04.00 PVC insulation shall be suitable for continuous conductor temperature of 70 deg C
and short circuit conductor temperature of 160 deg. C.

2.05.00 The cable cores shall be laid up with fillers between the cores wherever necessary.
It shall not stick to insulation and inner sheath. All the cables, other than single core
unarmoured cables, shall have distinct extruded PVC inner sheath of black colour
as per IS : 5831.

2.06.00 For multicore armoured cables, the armouring shall be of galvanised steel as
follows :-

Calculated nominal dia Size and Type of armour
of cable under armour

1) Upto 13 mm 1.4mm dia GS wire

2) Above 13 upto 25 mm 0.8 mm thick GS formed wire /
1.6 mm dia GS wire

3) Above 25 upto 40 mm 0.8mm thick GS formed wire /
2.0mm dia GS wire

4) Above 40 upto 55mm 1.4 mm thick GS formed wire/
2.5mm dia GS wire

5) Above 55 upto 70 mm 1.4mm thick GS formed wire /
3.15mm dia GS wire

6) Above 70mm 1.4 mm thick GS formed wire /
4.0 mm dia GS wire

The gap between armour wire / formed wire shall not exceed one armour wire /
formed wire space and there shall be no cross over / over-riding of armour wire /
formed wire. The minimum area of coverage of armouring shall be 90%. The
breaking load of armour joint shall not be less than 95% of that of armour wire /
formed wire. Zinc rich paint shall be applied on armour joint surface.

CLAUSE NO.

STAGE II (2X660 MW)
SECTION - VI
PART-B
B - 4
L.T. CONTROL CABLES
PAGE
3 OF 7

2.07.00 Outer sheath shall be of PVC(grade as applicable) and grey in colour . In addition to
meeting all the requirements of Indian standards referred to, outer sheath of all the
cables shall have the following FRLS properties.

(a) Oxygen index of min. 29 (As per IS:10810 (part-58))

(b) Acid gas emission of max. 20% (As per IEC-754-I).

(c) Smoke density rating shall not be more than 60% during Smoke Density Test
as per ASTMD-2843.

2.08.00 Cores of the cables of upto 5 cores shall be identified by colouring of insulation.
Following colour scheme shall be adopted.

1 core - Red, Black, Yellow or Blue

2 core - Red & Black

3 core - Red, Yellow & Blue

4 core - Red, Yellow, Blue and Black

5 core - Red, Yellow, Blue, Black and Grey

2.09.00 For cables having more than 5 cores, core identification shall be done by numbering
the insulation of cores sequentially, starting by number 1 in the inner layer (e.g. say
for 10 core cable, core numbering shall be from 1 to 10). The number shall be
printed in Hindu-Arabic numerals on the outer surfaces of the cores. All the numbers
shall be of the same colour, which shall contrast with the colour of insulation. The
colour of insulation for all the cores shall be grey only. The numerals shall be legible
and indelible. The numbers shall be repeated at regular intervals along the core,
consecutive numbers being inverted in relation to each other. When the number is a
single numeral, a dash shall be placed under neath it. If the number consists of two
numerals, these shall be disposed one below the other and a dash placed below
the lower numeral. The spacing between consecuture numbers shall not exceed 50
mm.

2.10.00 In addition to manufacturer's identification on cables as per IS, following marking
shall also be provided over outer sheath :

(a) Cable size and voltage grade - To be embossed

(b) Word 'FRLS' at every 5 metre - To be embossed

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PART-B
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L.T. CONTROL CABLES
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(c) Sequential marking of length of the cable in metres at every one metre. -
To be embossed / printed.

The embossing / printing shall be progressive, automatic, in line and marking shall
be legible and indelible.

2.11.00 All cables shall meet the fire resistance requirement as per Category-B of IEC 332
Part -3.

2.12.00 Allowable tolerances on the overall diameter of the cables shall be +\-2 mm
maximum over the declared value in the technical data sheets.

2.13.00 In plant repairs to the cables shall not be accepted. Pimples, fish eye, blow holes
etc. are not acceptable.

2.14.00 Cable selection & sizing

2.14.01 LT Control cables shall be sized based on the following considerations:

(a) Rated current of the equipment

(b) The voltage drop in the cable, during motor starting condition, shall be limited
to 10% and during full load running condition, shall be limited to 3% of the
rated voltage

(c) Short circuit withstand capability

This will depend on the feeder type. For a fuse protected circuit, cable should
be sized to withstand the let out energy of the fuse.For breaker controlled
feeder, cable shall be capable of withstanding the system fault current level
for total breaker tripping time inclusive of relay pickup time.

(d) The minimum size of conductor shall be 1.5 sqmm

2.14.02 Derating Factors

Derating factors for various conditions of installations including the following shall be
considered while selecting the cable sizes:

a) Variation in ambient temperature for cables laid in air

b) Grouping of cables

c) Variation in ground temperature and soil resistivity for buried cables.

CLAUSE NO.

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SECTION - VI
PART-B
B - 4
L.T. CONTROL CABLES
PAGE
5 OF 7

2.14.03 Cable lengths shall be considered in such a way that straight through cable joints
are avoided.

2.14.04 Cables shall be armoured type if laid in switchyard area or directly buried.


3.01.00 1.1 KV Grade Control Cables

Control Cables shall have stranded copper conductor multicore PVC insulated, PVC
inner-sheathed, armoured / unarmoured, PVC outer-sheathed conforming to
IS:1554. (Part-I).

3.02.00 Cable Drums

(a) Cables shall be supplied in non returnable wooden or steel drums of heavy
construction. The surface of the drum and the outer most cable layer shall be
covered with water proof layer. Both the ends of the cables shall be properly
sealed with heat shrinkable PVC/ rubber caps secured by 'U' nails so as to
eliminate ingress of water during transportation, storage and erection. Wood
preservative anti-termite treatment shall be applied to the entire drum.
Wooden drums shall comply with IS : 10418.

(b) Each drum shall carry manufacturer's name, purchaser's name, address and
contract number, item number and type, size and length of cable and net
gross weight stencilled on both the sides of the drum. A tag containing same
information shall be attached to the leading end of the cable. An arrow and
suitable accompanying wording shall be marked on one end of the reel
indicating the direction in which it should be rolled.

(c.) The standard drum length for control cables shall not be less than 1000
metres. The length per drum shall be subjected to a maximum tolerance
of +/- 5% of the standard drum length. The Employer shall have the option
of rejecting cable drums with shorter lengths. For each size, the variance
of total quantity, adding all the supplied drum lengths, from the ordered
quantity, shall not exceed +/- 2%.

4.00.00 TESTS

4.01.00 GENERAL

All equipments to be supplied shall be of type tested design. During detailed
engineering, the contractor shall submit for Owners approval the reports of all the
CLAUSE NO.

STAGE II (2X660 MW)
SECTION - VI
PART-B
B - 4
L.T. CONTROL CABLES
PAGE
6 OF 7


However if the contractor is not able to submit report of the type test(s) conducted
third party lab or in presence of client /owners representative and submit the reports
for approval.

All acceptance and routine tests as per the specification and relevant standards shall
price.

The type test reports once approved for any projects shall be treated as reference.

4.02.00 TYPE TESTS:

4.02.01 The Type tests reports for the following shall be submitted for one size of LT
control cable :

S. No. Type Test Remarks

a) For Conductor

1. Resistance test

b) For Armour Wires / Formed wires

2. Measurement of Dimensions

3. Tensile Test

4. Elongation test

5. Torsion test For round wire only

6. Winding test For Formed wires

7. Resistance test

8. Zinc Coating test For G.S. conductors only.

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PART-B
B - 4
L.T. CONTROL CABLES
PAGE
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c) For PVC insulation & PVC Sheath

9. Test for thickness

10. Tensile strength and
elongation test before
ageing and after ageing

11. Ageing in air oven

12. Loss of mass test For PVC insulation and sheath only

13. Hot deformation test For PVC insulation and sheath only

14. Heat shock test For PVC insulation and sheath only

15. Shrinkage test

16. Thermal stability test For PVC insulation and sheath only

17. Oxygen index test For outer sheath only

18. Smoke density test For outer sheath only

19. Acid gas generation test For outer sheath only

d) For completed cables

20. Insulation resistance test
(Volume resistivity method)

21. High voltage test

23. Flammability test as per
IEC - 332 Part-3 (Category-B)

4.02.02 Acceptance Tests (as per QA table)

4.03.00 Routine Tests (as per QA table)

SECTION-VI
PART-B
B - 5
CABLING, EARTHING & LIGHTNING
PROTECTION
CLAUSE NO.

STAGE II (2X660 MW)
SECTION - VI
PART-B
B - 5
CABLING, EARTHING &
LIGHTNING PROTECTION
PAGE
1 OF 1

CABLING, EARTHING & LIGHTNING PROTECTION

1.00.00 CODES AND STANDARDS:

conflict between this specification and those (IS codes, standards, etc.) referred to
herein, the former shall prevail. All work shall be carried out as per the following
standards/ codes as applicable.

IS:2309, IEEE:142, IEEE-80, IS:1255, IS:3043, DIN 46235.

2.00.00 REQUIREMENTS

2.01.00 The complete cable support system shall be supplied and installed for the entire
work is in the bidder's scope. The system shall enable proper laying of all power,
control, instrumentation and telephone cables, and shall provide necessary
mechanical protection, ventilation and segregation for them as per latest engineering
practices and cable manufacturers' recommendation .The cable installation shall be
carried out as per IS:1255. All hardware and anchoring arrangement shall be
included. All steel members shall be hot dip galvanized. Cable shall be terminated
using double compression type cable glands. Cable lugs for power cables shall be
tinned copper solderless crimping type conforming to DIN 46235 suitable for
aluminum compacted conductor cables.

SECTION-VI
PART-B
B - 6
ELECTRIC ACTUATORS WITH INTEGRAL
STRATERS
CLAUSE NO.

STAGE II (2X660 MW)
SECTION - VI
PART-B
B - 6
ELECTRIC ACTUATORS
WITH INTEGRAL
STARTERS
PAGE
1 OF 4

1.00.00 CODES AND STANDARDS:

2.00.00 ELECTRIC ACTUATORS WITH INTEGRAL STARTERS
2.01.00 TYPE:
2.01.01 The actuators shall have integral starters along with over load relays with built in
SPP (Single Phasing Preventer). A 415, 3 phase 3 wire power supply shall be given
to the actuator from vendor's/employer's switch board as applicable through a
switch fuse unit. Control voltage of the motor starter shall be 110 V AC / 24 V DC,
derived suitably from 415V power supply.
2.01.02 In case supplier's standard control voltage for Open/Close contactors is 110V AC,
the same is acceptable if suitable Opto Isolation circuit is provided with coupling
relays for 24 V DC command inputs.
2.02.00 INTERFACES:
2.02.01 Open/Close command termination logic with position & torque Limit Switches,
positioner circuit shall be suitably built in the PCB inside the actuator.
(a) For Binary Drive (both ON-OFF and INCHING type) :- Open/Close command
& status thereof and disturbance monitoring signal (common contact for
Overload, Thermostat, control supply failure, L/R selector switch at local &
other protections operated) shall be provided.
Interface with the control system shall be through hardware signal only. Inter
posing relays provided (with coil burden 2.5 VA) in the actuator shall be
energized to initiate opening and closing, by 24V DC signal from the external
control system.
(b) For Modulating Drive:- the command to actuator shall be in form of 4-20mA
signal. The necessary positioning circuit and motor protection shall be
provided
(c) Open/close command termination logic shall be suitably built inside actuator.
2.03.00 RATING :
(a) Supply Voltage & frequency: 415V +/- 10%, 3 Phase, 3 Wire 50HZ +/-5%.
CLAUSE NO.

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SECTION - VI
PART-B
B - 6
ELECTRIC ACTUATORS
WITH INTEGRAL
STARTERS
PAGE
2 OF 4

(b) Sizing:-
Open/Close at rated speed against designed differential pressure at 90% of
rated voltage.
For isolating service:- Three successive open-close operations or 15 mins,
whichever is higher. For regulating service 150 starts per hour or required
cycles, whichever is higher.
2.04.00 CONSTRUCTION:
(a) Enclosure:
Totally enclosed weatherproof minimum IP-55 degree of protection.
(b) Gear Train :
Metal (Fibre gears are not acceptable)) self-locking to prevent drift under
torque switch (where ever applicable) spring pressure when motor is de-
energized.
(c) Manual Wheel:
Shall disengage automatically during motor operation.
2.05.00 MOTOR :
(a) Type :
Squirrel cage induction motor suitable for Direct On Line ( DOL )starting.
(b) Enclosure:
Totally enclosed, self ventilated IP-55 degree of protection.
(c) Insulation
Class B or better. Temperature rise 70 Deg C. over 50 Deg C ambient
(d)
Bearings:

Double shielded, grease lubricated antifriction.
(e) Earth Terminals:
Two
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STAGE II (2X660 MW)
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PART-B
B - 6
ELECTRIC ACTUATORS
WITH INTEGRAL
STARTERS
PAGE
3 OF 4

(f) Protection:
Single Phasing Protection, Over heating protection through Thermostat
and wrong phase sequence protection shall be provided over and above
other protection features standard to bidder's design Suitable means shall
be provided to diagnose the type of fault locally.
2.06.00 POSITION/TORQUE SWITCHES:
2.06.01 Four nos. (2 each in open and close position) position limit switches and two nos.
(one in open and other in close direction) torque switches each having two nos. NO
and two nos. NC contacts shall be provided. A single shaft shall actuate all
contacts of limit switches at each position.

Limit switch and disturbance signals shall be available to DCS even when the power
supply to the actuators is not available.

Torque switches shall be bypassed in both the end positions with the other end
Limit switches.

Limit switches

Limit switches shall be Silver plated with high conductivity and non corrosive
type. Contact rating shall be sufficient to meet the requirement of Control System
subject to a minimum of 60 V, 6 VA rating. Protection class shall be IP-55.

2.07.00 LOCAL OPERATION:
2.07.01 It shall be possible to operate the actuator locally also. Lockable local/remote
selection shall be provided on the actuator.
2.08.00 POSITION INDICATOR :
2.08.01 To be provided for 0 to 100% travel.
2.09.00 POSITION TRANSMITTER (FOR MODULATING/INCHING TYPE) :
2.09.01 As required. Suitable for stabilized 4-20 mA signal, 2 wire inductive type, 24 volts
DC operated.

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PART-B
B - 6
ELECTRIC ACTUATORS
WITH INTEGRAL
STARTERS
PAGE
4 OF 4

2.10.00 WIRING :
2.10.01 Suitable voltage grade copper wire.
2.11.00 TERMINAL BOX :
(i) 9 pin plug and socket (1 no. per actuator to suit 4 pair 0.5 sq.mm. copper
overall shielded (16 mm OD), instrumentation cable) suitably mounted in the
starter box itself to terminate open/close command and status feedback
signals with external control systems.
(ii) Additional one number 9 pin plug and socket (to suit 4 pair 0.5 sq.mm copper
(16 mm OD) individual and overall shielded instrumentation cable) suitably
mounted in the starter box itself for actuators with 4-20 mA position
transmitters.
(iii) Necessary glands for power cables shall be provided.
2.12.00 TERMINAL BLOCK :
2.12.01 650V grade. For power cables.
2.13.00 SPACE HEATER :
2.13.01 Space heater of suitable rating. The supply shall be derived from the main power
supply available in the actuator.
2.14.00 TYPICAL WIRING DIAGRAM :
2.14.01 Refer Tender Drawing No. 0000-999-POI-A-063.

3.00.00 TRAINING

Contractor shall provide training on Integral Actuator for Employers personnel. The
duration of the training shall be as elaborated in Part-C, Section-VI of technical
specifications.

SECTION-VI
PART-B
B - 7
LIGHTING
CLAUSE NO.

STAGE II (2X660 MW)
SECTION - VI
PART-B
B - 7
LIGHTING
PAGE
1 OF 6

LIGHTING

1.00.00 GENERAL

1.01.00 This specification covers the general description of design, manufacture and
construction features, testing, supply, installation and commissioning of the Lighting
system equipment.


2.01.00 All standards and codes of practice referred to herein shall be the latest edition
including all applicable official amendments & revisions. In case of conflict between
this specification and those (IS codes, standards etc.) referred to herein, the former
shall prevail. All work shall be carried out as per the following standards & codes.

2.02.00 Lighting Fixtures and Accessories

IS:1913 General and safety requirements for luminairies.

IS:2148 Flame proof enclosures of electrical apparatus.

2.03.00 Lighting Panels, Switch-boxes, Receptacles and J unction Boxes

IS:2147 Degree of protection provided by enclosures for low-voltage
switchgear and control gear.

2.04.00 Electrical Installation Practices & Miscellaneous

IS:1944 Code of practice for lighting of public thorough fare

IS:3646 Code of practice for interior illumination.

IS:5572 Classification of Hazardous areas (other than Mines) having
flammable gases and Vapours for electrical installation

IS:6665 Code of practice for industrial lighting.

National Electrical Code

Indian Electricity Rules.

Indian Electricity Act

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STAGE II (2X660 MW)
SECTION - VI
PART-B
B - 7
LIGHTING
PAGE
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3.00.00 DESIGN PHILOSOPHY

1. A comprehensive illumination system shall be provided for the Hydrogen
plant

2. All lighting system shall be automatically controlled by synchronous timer or
photocell. Provision to bypass the timer or photocell shall be provided in the
panel.

3. In the Off site area / buildings DC lighting shall be provided by self-contained
4hours duration Emergency lighting fixtures. Each shall be provided with Ni-
cd battery, battery Charger & 2x10 W fluorescent lamps

4. The system shall include distribution boards, normal/ emergency lighting
panels, lighting fixtures, junction boxes, receptacles, switch boards, conduits,
cables and wires, etc. The system shall cover all interior and exterior lighting
such as area lighting. The constructional features of lighting distribution
boards shall be similar to AC/DC distribution boards described in chapter of
LT Switchgear. Outgoing circuits in LPs shall be provided with MCBs of
adequate ratings.

5. The illumination system shall be designed on the basis of best engineering
practice and shall ensure uniform, reliable, aesthetically pleasing and glare
free illumination. The diffusers/ louvres used in fluorescent fixtures shall be
made of impact resistant polystyrene sheet and shall have no yellowing
property over a prolonged period.

6. Apart from maintenance factor as given below, Temperature correction factor
shall be considered in the lighting design for fluorescent fixtures located in
non air conditioned area. Similarly the correction factor towards ageing of
lamps , as recommended by the lamp manufacturer shall also be considered
in the lighting design.

(a) Office area air conditioned : 0.8

(b) Office area non air conditioned and other indoor area : 0.7

(c) Dust prone and outdoor area : 0.6

7. All outdoor fixtures shall be weather proof.

8. Wires of different phase shall normally run in separate conduit.

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9. Power supply shall be fed from 415V normal AC supply, through suitable
number of conveniently located lighting panels (LP). AC lighting supply shall
be isolated from main supply by 2X100 % isolation transformers of rating
50KVA/100KVA for 10/15 nos. outgoing feeder with changeover switch
facility. The isolation transformer shall be fed from two different bus sections
of MCC. Fault level shall be restricted to 3 KA at Lighting Panels.

10. Atleast one 6/16A, 240V AC universal socket outlet with switch shall be
provided in offices, cabins, etc. 20A, 240V AC industrial receptacle with
switch shall be provided strategically in all industrial area. Suitable number of
63A,3ph., 415V AC industrial receptacles shall be provided for entire plant for
welding purposes, particularly near all major equipment and at an average
distance of 50m. Atleast one 63A,3ph.,415V AC receptacle shall be provided
in each off site building.

11. Average lux level of 150 lux shall be maintained in hydrogen plant and 20 lux
shall be maintained in outdoor areas. The type of fixtures, LP, J B, and
receptacle used in Hydrogen generation plant building shall be suitable for
group-IIC as per IS:2148 or Class-I division-II as per NEC.

3.01.00 Ballasts

(a) All HPSV and HPMV lamp fixtures shall be provided with wire-wound
ballasts. All fluorescent fixtures except for Class-I, Div-IIC fittings/ increased
safety fittings (Div-II/Hazardous Area) installed area shall be provided with
electronic ballasts.

3.02.00 All luminaires and their accessories and components shall be of type readily
replaceable by available Indian makes.

3.03.00 Fans & Regulator

Ceiling Fans, to be provided in non air conditioned office/control room area, shall be
suitable for operation on 240 V+/- 10%, 50 Hz, AC supply comprising of class E'
insulated copper wound single phase motor, 1200mm sweep, aerodynamically
designed well balanced Aluminum blades (3 Nos.), down rod, die cast aluminum
housing, capacitor, suspension hook, canopies etc. finished in stove enameled
white. Power factor of fans shall not be less than 0.9. Each fan shall cover
approximately 10sq.m. area.

3.04.00 Switch Box

Switch boxes shall be made of 1.6 mm thick, MS sheet with 3 mm. thick decorative,
perspex cover. Switchbox shall be hot dip galvanised

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3.05.00 Junction boxes

3.05.01 J unction box for lighting fixtures shall be deep drawn or fabricated type made of min.
1.6 mm thick CRCA Sheet. The box shall be hot dip galvanised.

3.06.00 Conduits, Fittings & Accessories

3.06.01 Galvanised heavy duty steel conduits for normal area and galvanised heavy duty
steel conduits with an additional epoxy coating for corrosive area shall be offered.
Alternatively glass reinforced epoxy conduits with comparable compressive and
impact strength with that of heavy duty steel conduits may be offered.

3.06.02 Rigid Steel Conduits

(a) Rigid steel conduits shall be heavy duty type, hot dip galvanised conforming
to IS : 9537 Part-I & II shall be suitable for heavy mechanical stresses,
threaded on both sides and threaded length shall be protected by zinc rich
paint. Conduits shall be smooth from inside and outside.

3.06.03 Flexible Steel Conduits

Flexible conduit shall be water proof and rust proof made of heat resistant lead
coated steel.

3.06.04 Pull-out Boxes

Pull out boxes shall be provided at approximately 4 (four) metre interval in a conduit
run .Boxes shall be suitable for mounting on Walls, Columns, Structures, etc. Pull-
out boxes shall have cover with screw and shall be provided with good quality
gasket lining. Pull out boxes used outdoor shall be weather proof type suitable for IP
:55 degree of protection and those used indoor shall be suitable for IP :52 degree of
protection. Pull out box & its cover shall be hot dip galvanised.

3.07.00 Lighting Wires

Lighting wires shall be 1100 V grade, light duty PVC insulated unsheathed, stranded
copper/aluminum wire for fixed wiring installation. colour of the PVC insulation of
wires shall be Red, Yellow, Blue and Black for R,Y,B phases & neutral, respectively
and white & grey for DC positive & DC negative circuits, respectively. Minimum size
of wire shall not be less than 1.5.sq.mm. for copper and 4 sq.mm. for aluminum.

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4.00.00 TESTS

4.01.00 All equipment to be supplied shall be of type tested design. During detail
engineering, the contractor shall submit for Owner's approval the reports of all the

4.02.00 However if the contractor is not able to submit report of the type test(s) conducted
third party lab or in presence of client/owners representative and submit the reports
for approval.

4.03.00 All acceptance and routine tests as per the specification and relevant standards shall
price.

manufacturer confirming similarity and No design change. Minor changes if any

4.05.00 Selection of samples for type test, acceptance test & routine test and acceptance
criteria for all the items shall be as per relevant I.S

4.06.00 Type test reports of the following items as per relevant standards shall be submitted
for approval.

SL NO. DESCRIPTION

i. Lighting panel of each type (Degree of Protection)

ii. J unction Box of each type

iii. Receptacles of each rating (Degree of Protection)

4.07.00 Acceptance Test and Routine Test

4.07.01 All lighting fixtures, lamps and other items shall be subjected to acceptance and
routine test, as per relevant specified standards.
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4.07.02 J unction boxes, switch boxes, receptacle enclosure etc. shall be subjected to
physical and dimensional checks.

4.08.00 Galvanizing Tests

4.08.01 The quality of galvanizing shall be smooth, continuous, free from flux stains and
shall be inspected visually.

4.08.02 In addition following tests shall be conducted as acceptance tests.

(a) Uniformity of coating - The coating of any article shall withstand four 1minute
dips in standard copper sulphate solution without the formation of an
adherent red spot of metallic copper upon the basic metal.
(b) The quality of cadmium/zinc plating on items with screw threads shall be free
from visible defects such as unplated areas, blisters and modules and shall
be inspected visually.

(c) In addition, the plating thickness shall be determine microscopically/
chemically or electronically.
SECTION-VI
PART-B
B - 8
L.T. SWITCHGEAR
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LT SWITCHGEAR
IEC: 60947, IS: 13947, IEC: 60439, IS: 8623, IEC: 61850
2.00.00 TYPE
Circuit Breakers Shall be air break, three pole, spring
charged, and horizontal drawout type,
suitable for electrical operation.
Switchgear Fully drawout type Single Front
MCC Fully drawout type Double Front.
ACDB / DCDB Fixed type Double Front

3.00.00 SYSTEM PARAMETERS
415VAC +/- 10 %(SOLIDLY GROUNDED)
50 Hz +3%/-5%
Fault Level: 45kA RMS for 1sec (105 KA PEAK)
240 V DC nominal (187V DC -242V DC) isolated type
4.00.00 TEMPERATURE RISE
The temperature rise of the horizontal and vertical busbars and main bus link
including all power draw out contacts when carrying 90% of the rated current along
the full run shall in no case exceed 55 deg. C with silver plated joints and 40 deg. C
with all other types of joints over an ambient of 50 deg C. The temperature rise of
the accessible parts / external enclosures expected to be touched in normal
operation shall not exceed 20 deg. C. The temperature rise of manual operating
means shall not exceed 10 deg. C for metallic & 15 deg. C for insulating material.
Temperature rise for the busbars shall be carried out at 90% of the rated current.
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The above temperature rise limits are applicable for busducts also without any
current derating.
5.00.00 OPERATIONAL REQUIREMENTS
5.01.00 Breakers
5.01.01 Breakers shall have anti-pumping feature.
5.01.02 The incomer and bus coupler breakers for switchgear shall be electrically operated
with Numerical communicable relays.
5.01.03 Breakers shall have inherent fault making and breaking capacities. They shall have
shunt trip coils. All breakers shall have built in interlocks for equipment and
personnel safety.
5.01.04 Paralleling of two supplies shall be avoided by interlocking except for switchgear
where auto-changeover is provided. Breaker contact multiplication, if required, shall
be through latch relay.
5.01.05 Mechanical tripping shall be through red Trip push button outside the panels for
breakers, and through control switches for other circuits.
5.01.06 Provision of mechanical closing of breaker only in Test and Withdrawn position
shall be made. Alternatively, mechanical closing facility should be normally
inaccessible, accessibility rendered only after deliberate removal of shrouds. It shall
be possible to close the door with breaker in test position.
5.01.07 Clear status indication for each circuit shall be provided through lamps, switch
positions or other mechanical means.
5.02.00 Switches, Contactors and Fuses
5.02.01 Incomers for MCCs and DBs rated below 250A shall be load break isolators.
5.02.02 Motor starter contactors shall be of air break, electromagnetic type suitable for DOL
starting of motor, and shall be of utilization category AC-3 for ordinary and AC-4 for
reversing starters. For conveyor motors, minimum rating of power contactors shall
be 200% of the full load current of the motors. For other motors minimum rating of
power contactors shall be 160% of full load current of motor. DC contactor shall be
of DC-3 utilization category.
5.02.03 Fuses shall be HRC type with operation indicator. Isolating switches shall be of AC-
23A category when used in motor circuit, and AC-22A category for other
applications. Fuse switch combination shall be provided wherever possible.

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5.02.04 The 250A & above feeders up to 630A shall have MCCB. MCCB shall be provided
with Microprocessor based inbuilt front adjustable releases (overload & short circuit)
and shall have adjustable earth fault protection unit also. MCCB shall have current
limiting feature. ON and OFF position of the operating handle of MCCB shall be
displayed and the rotary operating handle shall be mounted on the door of the
compartment housing MCCB. The compartment door shall be interlocked
mechanically with the MCCB, such that the door can not be opened unless the
MCCB is in OFF position. MCCB shall be provided with padlocking facility to enable
the operating mechanism to be padlocked.
5.03.00 Panels
5.03.01 All switchgears, MCCs, DBs, panels, modules, local starters and push buttons shall
have prominent engraved identification plates.
5.03.02 Local push button stations shall have metal enclosure of die cast aluminium or rolled
sheet steel of 1.6mm thickness & shall be of DOP IP55. The DOP shall be IP-65 in
case the same are located in dusty areas. Push buttons shall be of latch type with
mushroom knobs.
5.03.03 Where breaker / starter module front serves as compartment cover, suitable
blanking covers, one for each size of modules per switchboard shall be supplied for
use when carriage is withdrawn.
5.03.04 All non-current carrying metal work of boards / panels shall be effectively bonded to
earth bus of galvanized steel, extending throughout the switchboard / MCC / DB.
Positive earthing shall be maintained for all positions of chassis and breaker frame.
5.03.05 Suitable trolley arrangement shall be provided for breaker / starter modules. Two
trolleys per switchgear room shall be provided so that top most breaker module of all
types, sizes and rating can be withdrawn on trolley and lowered for maintenance
purpose.
5.03.06 It should be possible to carryout maintenance on a feeder with adjacent feeders
alive.
5.03.07 DC fuse board shall consist of:
-1 no.63A switch as incomer with meters, lamps and auxiliary contactors.
-8 nos. outgoing feeders with 16A HRC fuses.
5.03.08 AC fuse board shall consist of:
-1 no 63A TPN SFU as incomer with lamps and meters.
-9 nos.16A SPN SFU & 3 nos.16A TPN SFU as outgoing.
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5.04.00 Control, Protection & Metering Requirements
5.04.01 Control circuits shall operate at suitable voltage of 110V AC or 240V DC / 120V DC.
Necessary control supply transformers having primary and secondary fuses shall be
provided for each MCC, 2 x 100% per bus section. However the breakers shall
operate on 240V DC. The auxiliary bus bars for control supply shall be segregated
from main bus bars. The control supplies shall be monitored.
5.04.02 Contractor shall fully co-ordinate overload and short circuit tripping of breaker with
upstream and down stream breakers / fuses / MCCBs / motor starters. Various
equipments shall meet requirement of Type-II class of coordination as per IEC.
5.04.03 The protective relays shall be communicable numerical relays. These numerical
relays shall be of types as proven for the application and shall be subject to
Employers approval. Numerical relays shall have appropriate setting ranges,
accuracy, resetting ratio and other characteristics to provide required sensitivity. All
equipments shall have necessary protections as detailed in the standard scheme
drawings.
5.04.04 All equipments shall have necessary protections. However, following minimum
protections shall be provided:
1) Contactor controlled motor feeders (Motors below 110 kW)
a) Instantaneous short circuit protection on all phases through HRC
cartridge type fuses rated for 80 kA rms (prospective breaking
capacity at 415V).
b) Thermal overload protection
c) Single phasing protection for motors protected by fuses
2) Incomers / bus coupler / outgoing breaker feeders other than motor feeders.
a) Three phase Overcurrent protection (50)
b) Three phase earth fault protection (50N3)
c) Restricted earth fault protection for transformer incomers (64R)
3) Breaker controlled motor feeders(Motors 110KW & above)
a) Thermal Overload Protection (50I)
b) Three phase Short Circuit Protection (50)
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c) Earth Fault Protection (50N/50N2)
d) Thermal Overload Alarm (50A)
5.05.00 General requirements of Numerical Relays
5.05.01 All relays and timers shall be rated for control supply voltage as mentioned
elsewhere under parameters and shall be capable of satisfactory continuous
operation between 70-120% of the rated voltage. Making, carrying and breaking
current ratings of their contacts shall be adequate for the circuits in which they are
used. Interrogation voltage for the binary inputs shall be suitably selected to ensure
avoidance of mal-operation due to stray voltages.
5.05.02 All Numerical relays shall have communications on two ports, local front port for
communication to laptop and a second port on IEC 61850 to communicate with
owners data concentrator through LAN.
5.05.03 All Numerical Relays shall have features for electrical measurement including
voltage, current, power (active / reactive) and energy parameters.
5.05.04 All Numerical Relay shall have key pad / keys to allow relay settings from relay
front. All hand reset relays shall have reset button on the relay front. Relay to be
self or hand reset shall be software selectable. Manual resetting shall be possible
from remote.
5.05.05 The protective relays shall have at least 10 Nos. programmable potential free
contacts. Programmable Auxiliary relays shall have contacts as required.
5.05.06 For control from DDCMIS, 24V DC signal shall be provided from DDCMIS to the
numerical relays. Preferably, no separate coupling relays shall be provided.
5.05.07 Trip circuit supervision shall be provided for all feeders to monitor the circuit breaker
trip circuit both in pre trip and post trip conditions.
5.05.08 Schematics requiring auxiliary relays / timers for protection function shall be a part
of Numerical Relay. The number of auxiliary relay and timer function for protection
function shall be as required by the scheme. Auxiliary relays for interlocking
purpose shall be of self reset type.
5.05.09 The numerical processor shall be capable of measuring and storing values of a
wide range of quantities, all events, faults and disturbance recordings with a time
stamping using the internal real time clock. Battery back up for real time clock in the
event of power supply failure shall be provided.
5.05.10 Sequence of events shall have 1ms resolution at device level.
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5.05.11 Ethernet switches shall be substation hardened and shall comply to IEC61850-3
for communications and environment requirements. The Ethernet switches shall be
of managed type with four (4) numbers Single-mode Fibre Optic cable ports and
required number of Copper ports to achieve the owners LAN configuration. One
(1) no. of Ethernet switch per switch board shall be provided & these switches shall
be mounted inside the switchgear Panels.
5.05.12 In case of remote controlled breaker panels, following shall be ensured.
The circuit breaker will normally be controlled from remote control panels (employers
DDCMIS) through closing and shunt trip coils. The Local control console of the relay
flush mounted on the switchgear would normally be used only for testing of circuit
breaker in isolated position, and for tripping it in an emergency. Provision for closing
& tripping of the circuit breaker locally from laptop through serial port shall be
possible to facilitate commissioning activities. The basic control scheme of breaker
feeders shall be developed as per the schematic logics in the relay. The schematics
shall be developed in soft inside the relay. Numerical relays shall be interfaced with
employers DDCMIS through 24V DC signal for closing / opening operations.
5.05.13 Hardwired contacts from the relay shall be wired to PLC / DCS system as per
requirements. The numerical relay shall be capable of measuring and storing values
of a wide range of quantities, events, faults and disturbance recordings.
5.05.14 The alarm / status of each of protection function and trip operation shall be
communicated to PLC / DCS. The numerical relays shall have built in feature /
hardware interface to provide such inputs to PLC / DCS for analog / digital values.
5.05.15 It shall be possible to carryout open / close operation of breakers from a laptop by
interfacing through the relay front port during initial commissioning.
5.06.00 Meters / instruments
All meters / instrument shall be flush mounted on front panel, at least 96 sq.mm. size
with 90 degree linear scales and accuracy class of 2.0 or better.
5.06.01 All motors of 30kW and above upto 100kW shall have an digital Energy Meter with
analog current output. Each bus-section shall have bus VT, voltmeter with selector
switch, and other relay and timers required for protection. Adequate control and
selector switches, push buttons and indicating lamps shall be provided.
Thermostatically controlled space heaters with switches shall be provided to prevent
condensation.
5.07.00 Control from Remote
Necessary hardware shall be provided in the switchgear panel like coupling relays (if
required) of 24V DC with max. burden of 2.5VA, auxiliary relays, current / voltage
transducers (4-20mA, dual output) etc. to effect interlocks, exchange information /
status and exercise control from remote.
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L.T. SWITCHGEAR
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6.01.00 All 415V switch gear motor control centers (MCCs), AC & DC distribution boards
(DB s), etc shall have two incomers and one bus-coupler arrangement with following
features:
1) Shall be of metal enclosed, indoor, floor mounted and free standing
type.
2) All frames and load bearing members shall be fabricated using mild
steel structural sections or pressed and shaped cold rolled sheet
steel of thickness not less than 2mm.
3) Frame shall be enclosed in cold rolled sheet steel of thickness not
less than 1.6mm.Doors and covers shall also be of cold rolled sheet
steel of thickness not less than 1.6 mm. Stiffeners shall be provided
wherever necessary. Removable gland plates of thickness 3mm
(hot/cold rolled sheet steel) or 4 mm (non-magnetic material) shall
be provided for all panels.
4) All switchboards / panels shall be of dust and vermin proof. All
cutouts shall have EPDM / Neoprene gaskets.
5) All switchboards, MCCs and DB s shall have following distinct
vertical sections.
a) Completely enclosed bus bar compartment for horizontal
and vertical bus bars.
b) Completely enclosed switchgear compartments (one for
each circuit housing circuit breakers, motor starter or switch-
fuse feeder).
c) Compartment for cable alley or cable box for power and
control cables. Cable terminations located in cable alley shall
be designed to meet the Form IVb Type 7 (as per IEC
60439)l for safety purpose. The termination for each module
shall have its own integral glanding facility.
In case of cable boxes provided in distribution boards, they
shall be segregated with complete shrouding for individual
feeders at the rear for direct termination of cables.
d) For cable connection to circuit breaker, a separately
enclosed cable compartment shall also be acceptable.

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L.T. SWITCHGEAR
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e) Compartment for relays and other control devices associated
with a circuit breaker, wherever necessary.
f) The switchboards / MCC / DBs of 1600A & above rating shall
be of DOP IP42 & of IP52 for less than 1600A rating.
g) All 415V switchgears, MCCs, AC & DC distribution boards
etc. shall be painted by powder coating process. Paint shade
for complete panels excluding end covers shall be RAL9002
& RAL5012 for extreme end covers of all boards.
h) All draw out modules shall have distinct service, test and
isolated positions with provision of external pad locking
facility in each position. Power contacts shall get
disconnected in both test and isolated positions whereas the
control contacts shall get disconnected in isolated position
only.
6) Busbars shall be of high conductivity aluminium alloy or copper.
7) The cross section of the horizontal bus bars shall be uniform
through out the length of the switchboard and both horizontal as well
as vertical bus bars shall be adequately supported and braced to
withstand the stresses due to the specified short circuit currents.
Neutral bus bar short circuit strength shall be same as the main bus
bars.
8) Minimum air clearance in air between phases and phase-earth shall
be 25 mm for busbars and cable terminations. For all other
components, the Clearances shall be at least 10mm. Wherever
above is not possible except for horizontal and vertical busbars,
insulation shall be provided by anti tracking sleeving or barriers.
However for horizontal and vertical busbars, clearances specified
above shall be maintained even when busbars are insulated /
sleeved. Entire busbar system shall be insulated with PVC sleeves.
9) Busbar insulators shall be of track-resistant high strength non-
hygroscopic, non-combustible type and suitable to withstand
stresses due to over-voltages and short circuit current. Insulators
and barrier of inflammable material such as Hylam shall not be
accepted.
10) All types of relays and timer shall be subject to Employers approval.
They shall be flush mounted with connections from inside, and shall
have transparent & dust tight cover, removable from front, drawout
construction for easy replacement and testing facility. The auxiliary
relays and timer may be provided in fixed cases.
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11) Terminal Blocks
Terminal blocks shall be 650V grade, 10Amps rated, made up of
unbreakable polyamide 6.6 grade. The terminals shall be either
screw type or screw-less (spring loaded) / cage clamp type with
lugs. Marking on terminal strips shall correspond to the terminal
numbering in wiring diagrams. All metal parts shall be of non-
ferrous material. In case of screw type terminals the screw shall
be captive, preferably with screw locking design. Maxi terminal /
cage clamp type terminal blocks shall be provided for signals to
be interfaced with DDCMIS / PLC.
12) The switchgears/MCC shall be designed to offer adequate level of
safety to operating/ maintenance personnel. Means shall be
provided to prevent access to the live part to avoid accidents during
service as well as maintenance period. Bidder shall bring out the
safety means provided to achieve above. A detailed instruction plate
suitable for wall mounting shall be provided for each
switchgear/MCC room describing various safe operating
procedure/safety precautions for safe operation and maintenance of
switchgear/MCC.
13) All current and voltage transformers as required for metering &
protection specified shall be completely encapsulated cast resin
insulated type. Incomers from transformers shall have CTs for
transformer REF protection. The accuracy shall be as follows:
CTs PTs
Protection 5P20,5VA 3P
Metering 1.0 0.5
REF PS
6.02.00 Indicating lamps shall be cluster LED type. All overload relays shall have overload
reset push button.
6.03.00 Switchgear / MCC shall have bottom cable entry.
6.04.00 Contractor shall provide minimum one spare feeder for each type and rating of the
outgoing feeders on each MCC / Switchgear.

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7.00.00 TYPE TESTS
7.01.00 GENERAL
(a.) All equipments to be supplied shall be of type tested design. The Contractor
shall submit for Owners approval the reports of all the type tests as listed in
this specification and carried out within last ten years from the date of bid
opening. These reports should be for the tests conducted on the equipment
similar to those proposed to be supplied under this contract and the test(s)
should have been either conducted at an independent laboratory or should
(b.) In case the Contractor is not able to submit report of the type test(s)
conducted within last ten years from the date of bid opening, or in case the
type test report(s) are not found to be meeting the specification requirements,
the Contractor shall conduct all such tests under this contract at no additional
cost either at third party lab or in presence of client/owners representative
and submit the reports for approval.
(c.) All acceptance and routine tests as per the specification and relevant
standards shall be carried out. Charges for these shall be deemed to be
included in the equipment price.
(d.) The type test reports once approved for any projects shall be treated as
reference. For subsequent projects of NTPC, an endorsement sheet will be
furnished by the manufacturer confirming similarity and No design Change.
Minor changes if any shall be highlighted on the endorsement sheet.
7.02.00 L. T. SWITCHGEAR
The following type test certificates on each type & rating of L.T. Switchgear and
MCC panel shall be submitted.
(a.) Short time withstand test.
(b.) Temperature rise test.
(c.) Class II - Protection co-ordination test for any three ratings of MCC module
as selected by employer
(d.) Test sequence 1 & combined test sequence on each rating of circuit
breaker mounted inside the panel.
(e.) Degree of protection tests
(f.) Type test certificates for Numerical relays.
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IIIC-01
BASIC DESIGN
CRITERIA
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IIIC - 01
BASIC DESIGN CRITERIA
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BASIC DESIGN
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BASIC DESIGN CRITERIA
1.01.00 The Contractor shall provide Independent Control & Instrumentation system Distributed
Digital Control, Monitoring and Information System (DDCMIS), associated Primary and
Secondary Instruments, Panels, LIE/LIRs, Control Valves and Actuators, Process
Connection and Piping, Electric Power Supply System, associated Instrumentation and
Power Supply Cables etc. as identified in the specification.
1.02.00 The Contractor shall provide all material, equipment and services so as to make a totally
integrated Instrumentation and Control System together with all accessories, auxiliaries and
associated equipments ensuring operability, maintainability and reliability. This work shall be
consistent with modern power plant practices and shall be in compliance with all applicable
codes, standards, guides, statutory regulations and safety requirements in force.
1.03.00 Further Bidder shall also include in his proposal and shall furnish all equipment, devices and
services which may not be specifically stated in the specification but are needed for
completeness of the equipment/systems furnished by the Bidder and for meeting the intent
and requirements of the specification.
1.04.00 It is to be noted that where equipment or system for the generating units are described, it
shall be understood that the quantities described are to be provided per unit basis, i.e.,
identical sets to be furnished by the Contractor for each of the units unless specifically
indicated otherwise. Where equipment or systems for plant common facilities are described,
it will be understood that the quantities described are the total quantities required. Wherever
quantity has been specified as on as required basis, the same is to be supplied by the
contractor on as required basis by the contractor within his quoted lump sum price.
1.05.00 Bidder shall include in his bid a detailed Bill of Material (BOM) for each of the systems.
1.06.00 In addition to requirements specified under this Section-VI B, Part-B, all C&I systems/ sub-
systems/ equipment/ devices shall also meet other requirements stipulated under other Sub-
sections/ parts/ sections of specification.
2.00.00 PROVENNESS CRITERIA
2.01.00 DELETED.
2.01.01 DELETED.
3.00.00 RELIABILITY AND AVAILABILITY
3.01.00 Each component and system offered by the Bidder shall be of established reliability. The
minimum target reliability of each piece of equipment like each electronic module/card,
Power supply, Peripheral etc. shall be established by the Bidder, considering its failure
rate/mean time between failures (MTBF), meantime to repair (MTTR), such that the
availability of the complete C&I system is assured for 99.7%.
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3.02.00 When more than one device uses the same measurement or control signal, the transmitter
and other components/ module shall be fully equipped to provide all signal requirements. All
the 4-20 mA output signals from transmitters/other control system shall be able to drive
minimum 500 Ohms load resistance. The system shall be arranged so that the failure of any
monitoring device or control components or spurious intermediate grounding in the signal
path shall not open the signal loop nor cause the loss or malfunction of signal to other
devices using the same signal.
3.03.00 To ensure availability, adequate redundancy in system design shall be provided at Hardware,
software and sensor level to satisfy the availability criterion mentioned above. For the
protection system, sensing device as per Bidder standard and proven practice shall provided
to ensure adequate safety of plant equipment
4.00.00 STANDARDISATION AND UNIFORMITY OF HARDWARE
4.01.00 a) For the DDCMIS Hardware bidder shall ensure the following:-
(I) The bidder shall offer of the same make/series/family of control system
hardware so as to ensure unified HMI environment and engineering
functionalities, smooth and optimal maintenance, easy interchangeability and
efficient spare parts management.

(II) In case the offered control system hardware can-not be of the same
make/series/family based on Bidder's standard and proven practices, to be
substantiated by suitable documentary evidence as and when required by
the employer, Then the bidder must offer e UNIFIED and integrated HMIPIS
environment for the DDCMIS.

Bidder shall successfully integrate the DDCMIS with the other control system
without affecting the performance of the offered DDCMIS system in any way.

b) Bidder shall ensure that various C&I instruments /equipment that are identified in
tender P&ID and whose specifications are detailed out in the tender specifications
like 4-20mA electronic transmitters / transducers, Temperature elements and other
instruments/ local devices etc. that are being furnished by the bidder, are of the
same make, series and family of hardware so as to ensure smooth and optimal
maintenance, easy interchangeability and efficient spare parts management. For the
instruments that are proposed to be connected to Bidders Steam Turbine Generator
integral controls and other Skid Mounted instruments, Bidders standard and proven
instruments are acceptable.
5.00.00 OPERABILITY & MAINTAINABILITY
5.01.00 The design of the control systems and related equipments shall adhere to the principle of
Fail Safe Operation wherever safety of personnel / plant equipment is involved. Fail Safe
operation signifies that the loss of signal, loss of excitation or failure of any component shall
not cause a hazardous condition. However, it shall also be ensured that occurrence of false
trips are avoided / minimized.
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5.02.00 The types of failure that shall be taken into account for ensuring operability of the plant shall
include but not be limited to:
Failure of sensor or transmitter.
Failure of main and/or redundant controller/other modules.
Loss of motive power to final control element.
Loss of control power.
Loss of instrument air.
5.03.00 The choice of hardware shall also take into account sound maintainability principles and
techniques. The same shall include but shall not be limited to the following:
Standardization of parts.
Minimum use of special tools.
Grouping of functions.
Interchangeability.
Malfunction identification facility/self surveillance facility.
Easy modular replacement.
Fool proof design providing proper identification and other features to preclude
improper mounting and installation.
Appropriate de-rating of electronic components and parts.
5.04.00 The equipment shall employ latest state of the art technology to guard against obsolescence.
In any case, Bidder shall be required to ensure supply of spare parts for lifetime of the plant.
In case, the Bidder feels that certain equipment/component (barring HMI hardware &
networking components) is likely to become obsolete, the Bidder shall clearly bring out the
same in his Bid and indicate steps proposed to deal with such obsolescence. For HMI
hardware & networking components, bidder need not bring out the same in the bid, but shall
inform the employer so that employer can take appropriate action as necessary (both during
the tenure & outside the tenure of the contract).
6.00.00 UNIT CONTROL & MONITORING PHILOSOPHY
6.01.00 The Control & Monitoring philosophy envisages control from two locations
(a.) From Central Control Room (CCR)
(b.) From Local control stations for off site & ancillary plants
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6.02.00 Back-Up Instrumentation
Minimum no. of back-up instrumentation and Secondary instruments to be provided through
Station C&I package by Employer as specified in Appendix-I to Part-B of Section-VI. The
exact quantity of the back-up instrumentation shall be as finalised during detailed engineering
in consultation with the Contractor. Contractor has to supply all the required input output
modules interface of these back up instrumentation without any cost implication to the
employer.
7.00.00 ENVIRONMENTAL CONDITIONS
7.01.00 Instruments, devices and equipments for location in outdoors/indoor/air-conditioned areas
shall be designed to suit the environmental conditions indicated below and shall be suitable
for continuous operation in the operating environment of a coal fired utility station and also
during periods of air conditioning failure without any loss of function, or departure from the
specification requirements covered under this specification.
Ambient
Temperature (outside
cabinets)
Pressure Relative
humidity
Atmosphere Required
protection Class
of panels/
cabinets/ desks
to be provided by
contractor.
Outdoor Location
55 degree C max. Atmosphere 100 % Max. Air (dirty) IP 55
4 degree C min. Atmosphere 5 % min. Air (dirty) IP 55
Indoor Location
55 degree C max. Atmosphere 95 % Max. Air IP 54**
4 degree C min. Atmosphere 5 % min. Air IP 54**
Air Conditioned Areas
24 +/- 5 degree C
normal
Atmosphere 95 % Max. Air IP 22***
50 degree C max. * Atmosphere 5 %min. Air IP 22***
* During air conditioning failure for limited time.
** For non-ventilated enclosures. For ventilated enclosures, protection class shall be IP
42.
*** With a suitable canopy at the top to prevent ingress of dripping water.
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For hazardous areas the protection class shall be in accordance with the requirements of
the relevant NEC code for the location.
PCs, OWS, EWS, Servers, Network Switches, Printers, mini UPS and other peripherals,
maximum temperature limit shall be 35 Deg. C. For LVS the same shall be around 25 Deg.
C .
For the remote I/O cabinets mounted in non-AC areas the remote I/O modules should meet
the above requirements read in conjunction with 9.03.12 of sub-section- IIIC-02. If the
same is not met, panel AC shall be provided in remote IO cabinets to meet the
requirements.
8.00.00 GROUNDING SYSTEM
All panels, desks, cabinets shall be provided with a continuous bare copper ground bus. The
ground bus shall be bolted to the panel structure on bottom on both sides. The bolts shall
face inside of panels.
The system ground shall be isolated from the panel ground with suitable isolators. All internal
component grounds or common shall be connected to the system ground, which shall be
fabricated of copper flat (size 25mm x 6mm min., length as applicable).
Shield on instrumentation cables shall be grounded on panel side. When shielding
termination is required in cabinets furnished under this specification, suitable terminals shall
be furnished on copper flat forming system ground. System and shield ground shall be
connected to Employer provided earthing strip at 0.0 meter level using suitable size of cable
to be provided by the Bidder. Bidder shall refer Drawing No. 0000-110-POI-A-021.
The Contractor shall submit with the offer recommended grounding scheme required for his
system. The exact grounding scheme shall be finalised during detailed engineering.
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IIIC 02
DISTRIBUTED DIGITAL CONTROL
MONITORING & INFORMATION SYSTEM
(DDCMIS)

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DISTRIBUTED DIGITAL CONTROL, MONITORING & INFORMATION SYSTEM
1.00.00 DISTRIBUTED DIGITAL CONTROL, MONITORING AND INFORMATION SYSTEM
(DDCMIS)
1.01.01 The requirements for Distributed Digital Control Monitoring and Information System
(DDCMIS) are indicated on functional basis in this specification. Contractor shall be
responsible for engineering, selection and connection of all components and sub-systems to
form a complete system whose performance is in accordance with functional, hardware,
parametric and other requirements of this specifications. It not the intent or purpose of this
specification to specify all individual system components since the Contractor has full
responsibility for engineering and furnishing of a complete system.
1.02.00 System Configuration
1.02.01 DDCMIS shall basically consist of
1.02.02 Control System of Turbine (namely TG-C&I including its Measurement system).
1.02.03 Human-Machine Interface and Plant Information System (HMIPIS)
1.02.04 System Programming & Documentation Facility
1.02.05 DATA COMMUNICATION SYSTEM (DCS)
1.02.06 The basic configuration of DDCMIS shall be as indicated in the DDCMIS configuration
drawing No. 0000-110-POI-A-001.
1.02.07 Contract quantities of TG C&I systems shall be as per Appendix-I to Control &
Instrumentation Systems.
1.03.00 System Expandability
1.03.01 Modular System design shall be adopted to facilitate easy system expansion. The system
shall have the capability and facility for expansion through the addition of controller modules,
I/O cards, peripherals like Large Video Screen (LVS), operator workstations (OWS), printers
etc., while the existing system is fully operational. The system shall have the capability to add
any new control loops, groups/subgroups in control system, while the existing system is fully
operational.
1.04.00 On Line Maintenance
1.04.01 It shall be possible to carry out on line maintenance of the DDCMIS system as per Bidders
standard and proven practices in a such a manner so that safety of plant and personnel is
not jeopardized.

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1.05.00 Fault Diagnostics
The DDCMIS (including its HMIPIS) should facilitate on-line self-surveillance, monitoring and
diagnostic facility of various components of DDCMIS in such a manner so that a
failure/malfunction can be identified and diagnosed automatically and reported/indicated
remotely on OWS/LVS/Programmer station.
1.06.00 Fault Tolerance & Controllability
1.06.01 The DDCMIS shall provide safe operation under all plant disturbances and on component
failure so that under no condition the safety of plant, personnel or equipment is jeopardized.
Control System shall be designed to prevent abnormal swings due to loss of Control System
power supply, failure of any Control System component, open circuits/short circuits,
instrument air supply failure etc. On any of these failures the control system output shall
either remain in last position before failure or shall come to fully open/close or on/off state as
required for the safety of plant/personnel/equipment and as finalised during detailed
engineering. System shall be designed such that there will be no upset when Power is
restored.
1.06.02 NOT USED
1.06.03 The controlled variable response rate & controllability shall be limited by the characteristics of
main equipment, which is being controlled, and DDCMIS shall not impose any limitations in
the response rate or controllability. Controlled process variables shall return to normal values
in a stable manner and without control loop interactions or cycling of generation when
generation matches with load demand.
1.06.04 No single failure either of DDCMIS electronic modules or power source shall be capable of
rendering any part/system/sub-system of DDCMIS inoperative to any degree. No single
failure in HMIPIS shall lead to non-availability of more than one OWS or one LVS. In such an
event i.e., single failure leading to non-availability of any OWS/LVS, it shall be possible to
operate the entire plant in all regimes of operation including emergency conditions from each
of the other available OWS/LVS.
1.06.05 Wherever redundant equipments/systems are identified the same shall be with automatic
changeover feature.
1.07.00 DDCMIS shall meet all requirements stipulated under other Sub-sections/sections of the
specification including relevant Sub-Sections of Part-A, (including the requirement
Authorisation to shipment test ATST) Quality assurance (relevant sub-sections, Section VI of
technical specifications) & General Technical Requirements (Part C, Section VI of Technical
Specifications).
1.08.00 Signal Exchange
1.08.01 All the signal exchange between various functional groups of each control group shall be
implemented as per standard and proven practice of the bidder.
1.08.02 For interfacing with other control systems with in the scope of contractor , as a philosophy
critical signals like fire protection, as opening signals for HPBP etc shall be provided as
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hardwired. For less critical system this can also be soft wired if safety, response time and
other process criterion are met as per standard and proven practice of the bidder.
1.08.03 For all equipments/devices/drives which are under Contractor's scope of supply and are to
be controlled though Station C&I System, Contractor shall provide all required hardwired
signals on as required basis for successful implementation of Closed Loop Control System
(CLCS) and for sequence, interlock and protection functions of Open Loop Control System
(OLCS) and for implementing the Sequence of Event recorder (SOE).
1.08.04 The Contractor shall provide OPC compatible communication links through suitable interface
between HMIPIS of this package & the HMI of other system(s). These links shall be for
information purposes required from Contractor's Plant auxiliaries C&I systems for various
functions like alarms, logs, performance calculations, displays, etc.. Details shall be as
defined at clause titled Interface with Employer furnished Equipment/Systems in Sub-
section-IIC-01, scope of supply & services. Other methodology shall also be acceptable
subject to Employers approval. All these points shall be updated through the link within 1
second period. It shall be Contractor's responsibility to interact with the supplier(s) of the
other HMIs through employer to make communication links fully operational. The
hardware/software implementation of the same shall be subject to Employer's approval
during detailed engineering.
1.08.05 For interfacing with SWGR and MCC etc, Contractor control system should be able to drive
the coupling relays (typically 3 VA) under SWGR / MCC.
1.09.00 System Spare Capacity
1.09.01 Over and above the equipment and accessories required to meet the fully implemented
system as per specification requirements, DDCMIS shall have spare capacity and necessary
hardware/ equipment/ accessories to meet following requirement for future expansion at site:
1.09.02 Ten (10) percent spare channels in each of the functional groups for each type of input /
output modules fully wired up to marshalling/ field termination cabinet TBs.
1.09.03 NOT USED
1.09.04 HMIPIS shall be provided with capacity to handle at least 1 no. of each type of
peripherals/equipments, additionally, like OWS, LVS, printers, PCs etc., over and above
already specified, without any additional hardware or software. HMIPIS data base (if
applicable) shall have provision of at least 25% extra points of above mentioned signals.
1.09.05 Each controller shall have 20% spare functional capacity(after accounting for 10 % spares
Inputs/outputs as identified above) to implement additional function blocks, over and above
implemented logic/ loops and inputs/outputs.
1.09.06 NOT USED
1.09.07 Ten (10) percent spare relays of each type and rating mounted and wired in relay cabinets.
All contacts of relays shall be terminated in terminal blocks of relay cabinets. In each of the
relay cabinets 10 % spare terminal blocks shall be provided so that additional relays can be
mounted and wired.
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1.10.00 The spare capacity as specified above shall be uniformly distributed throughout all functional
groups. The system design shall ensure that above mentioned additions shall not require any
additional controller/processor/ peripheral drivers/ cabinets in the system delivered at site.
Further, these additions shall not deteriorate the system parametric requirement like
response time / duty cycle, etc. from those stipulated under this specification and shall meet
other redundancy / functional requirement.
1.11.00 DDCMIS shall meet system performance and parametric requirements as stipulated under
commissioning test under Part-B, Section-VI, of specifications. Also the Authorization to
shipment tests shall be performed in line with the relevant QA subsections of Section-VI.
2.00.00 SYSTEM DESCRIPTION
2.01.00 The DDCMIS shall include following main Systems/Sub-Systems. (Also refer DDCMIS
configuration Drg. No. 0000-110-POI-A-001). The DDCMIS shall work in full integration and
conjunction with field equipment/drives like pumps, motors, valves, actuators, dampers,
hydraulic control systems and field instruments to be provided by the Bidder. The DDCMIS
hardware (controllers, modules/cards etc.) shall be housed in cabinets located in control
equipment room (CER) except for operation interfaces located in Unit Control Desk (UCD) in
Central Control Room (CCR).
2.02.00 CONTROL SYSTEM
2.02.01 The Control system along with its measurement system shall perform functions of closed
loop control, sequence control, interlock & protection of Main Plant and auxiliaries in all
regimes of unit operation.
2.02.02 The measurement system of control system shall perform the functions of signal acquisition,
conditioning and signal distribution of various types of inputs/outputs like analog, (4-20 mA
DC- either from pressure / DP/ flow / level transmitters, analysers etc. as well as from
temperature transmitters for all temperature measurements from thermocouple, RTD to be
connected to this system), binary, pulse, digital transmission through serial port, bus
connection etc. (from remote I/O etc.), through various industry standard protocols including
MODBUS/FIELDBUS/PROFIBUS prefabs and Ethernet etc . The inputs, which are required
for only information & monitoring purposes, shall be distributed suitably in various groups
plant area-wise.
2.02.03 The control system hardware (controllers, modules/cards etc.) shall be housed in cabinets
located in respective control equipment room (CER) unitised and offsite except for the
remote I/O cubicles which shall be located in respective areas.
2.03.00 Human-Machine Interface and Plant Information System (HMIPIS)
2.03.01 The HMIPIS shall perform control, monitoring and operation of Main Plant and auxiliaries in
all regimes of unit operation, interacting with the Control System. For this, HMIPIS shall
primarily perform following functions:

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2.03.02 Operator interface for Control System
Plant Supervisory functions like displays, alarm monitoring & reporting, reports & logs,
calculations, trend recording, historical and long term data storage & retrieval, etc.
2.03.03 The Operator Workstation, LVS & printers shall be located in respective Control Rooms (CR),
unitised as well as for offsite, and all other devices/peripherals shall be located in the
Programmers Rooms. OWS/PC's & Printers shall be located in respective areas as detailed
out in relevant clauses.
2.04.00 System Programming & Documentation Facility
2.04.01 The programmer stations shall be provided for On-line configuration & tuning of Control
System and On-line program development/modifications in HMIPIS.
2.04.02 Work-station based system documentation facility/programming cum documentation facility
shall be provided to retrieve, generate & document all system documentation, logic, control
loops.
The Data Communication System shall be provided for communication between Control
System and HMIPIS, communication & signal exchange between various functional groups
as well as communication between various off site areas in the scope of the work and
offered DDCMIS system.
2.06.00 Annunciation System
The annunciation logic will be implemented as a part of DDCMIS and annunciation shall be
made available on all OWS/LVS.
2.07.00 Power supply
Power supply of control system shall be based on 24V DC. The Power supply along with its
associated circuitry is intended to provide the following functionalities.
(a) Isolation between input & output side and distribution.
(b) Multiple voltages as required by various modules as well as integration/supply
voltage to field devices.
(c) Auctioneering of dual voltages.
3.00.00 MEASUREMENT FUNCTIONS OF CONTROL SYSTEM
3.01.00 The input / output modules employed in the Control System shall be separate from the
controller hardware i.e. it shall not be an integral part of the controller module.
3.01.01 The functions listed below shall generally be performed in I/O modules; however, some of the
functions can be implemented in the controllers.
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3.02.00 Analog signal conditioning & processing
3.02.01 The conditioning and processing functions to be performed as a minimum for the analog
inputs coming for control and information purposes are:
1. : Galvanic isolation of input and output signals for which power supply source is
other than the measurement system of the control system.
2. : Transmitter power supply with per point fuse protection or current limiting and
power supply monitoring.
3.02.02 All analog signals for control purpose shall be acquired, validated, processed and their
respective Controller data base as per process requirement. For the signals required for
implementing HMIPIS functionality, the signal update rate shall be minimum 1 second. How-
ever for temperature measurement this shall be as per process requirement.
3.02.03 NOT USED.
3.03.00 Binary signal conditioning & processing
3.03.01 All binary signals for control purpose shall be acquired, validated, processed and their
respective Controller data base as per process requirement. For the signals required for
implementing HMIPIS functionality, the signal update rate shall be minimum 1 second.
3.03.02 The binary signals shall be wired either in the form of changeover type contacts (i.e. NC +
NO together) or non-changeover type contact NC or NO) depending of the requirement as
defined in Part-A of the specification.
3.03.03 NOT USED
3.04.00 Triple measurement scheme
Triple measurement scheme shall be employed for the most critical measurements as per
contractors standard and proven practice.
3.04.01 Individual transmitter signals, their status and selected value for control/ measurement and
shall be available on LVS/OWS, in the CLCS displays and pop ups.
3.05.00 Dual measurement scheme
3.05.01 Dual measurement scheme shall be employed for the most critical measurements as per
contractors standard and proven practice..
3.05.02 NOT USED
3.05.03 Individual transmitter signal, their status and selected value for control/measurement shall be
available on LVS/OWS.
3.06.00 The measurement system of control system should be capable of acquiring data from various
equipment & system in digital form through serial port, Ethernet connection using industry
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standard protocols. The control system shall include requisite modules for accepting such
signals examples of such signals will be from remote I/O signals (through extended I/O bus),
temperature transmitters, Electrical Power Supply System etc.
3.06.01 NOT USED.
3.07.00 Wiring Scheme for inputs to control system shall be as follows:
3.07.01 Each of the triple/dual redundant binary & analog inputs shall be wired in such a way that no
single failure in any component of the control system shall lead to unavailability of more than
one of dual/triple redundant input signals to control system. Similarly, no single failure in any
component of the control system shall lead to unavailability of more than one of dual/triple
redundant Output signals from the control system.
3.07.02 NOT USED.
3.08.00 The signal conditioning functions like multiple measurement schemes, square root extraction
for flow signals, pressure and temperature compensation, limit value computation can be
performed either in the controllers or in signal conditioning and processing hardware outside
controllers.
3.09.00 NOT USED
3.10.00 NOT USED
3.10.01 NOT USED
3.10.02 NOT USED
3.10.03 The control desk mounted hardwired devices and stations shall be interfaced through the I/O
modules. No signal multiplication shall be done at marshalling end input termination.
4.00.00 CONTROL SYSTEM REQUIREMENTS
4.01.00 The control system shall be broadly divided into the following control system:-
Control System of Turbine (namely TG-C&I including its Measurement system) function shall
be as defined in Section VI ,II-C-01, Part-A of the specification.
4.01.01 NOT USED
4.01.02 The numbers of Functional Groups (FGs) which have been indicated in the Section-VI PART-
A II C-01 are the minimum required. For each of the FGs, separate sets of controllers, I/O
modules, communication controllers, power packs/ modules, etc. shall be provided. Mixing of
hardware of two or more FGs shall not be acceptable. However, splitting of any functional
group in more than one FGs due to any limitation in Bidder's system (e.g. limitation in
handling number of inputs/outputs including spare capacity, limitation in implementation of
number of functional blocks including spare blocks etc.) shall be acceptable, subject to
Employer's approval. It may be noted that after splitting of the functional groups, each FG
must have its own set of controllers, I/O modules, communication controllers, power
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packs/modules etc. It shall be ensured that failure of any set(s) of hardware of any FG does
not affect other FG(s) and data communication between other FG(s) and HMIPIS. Each FG
can have one or more set of controllers, if supported by standard design of system.
4.01.03 The Contractor shall provide all hardware/software, whether or not specifically indicated in
this specification to fully meet operational/ maintenance/safety requirement as well as
statutory/international standard and proven practices.
4.01.04 The Control System shall function reliably under the environmental conditions as specified in
of Sub-Section:-Basic Design Criteria of this specification. It shall be immune from the
interference resulting from disturbances in power supply feeders, signal lines, inputs, outputs,
etc. as experienced in a coal fired power station. It shall be able to with stand power line
disturbances.
4.01.05 NOT USED
4.01.06 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 other devices
from their normal operation mode. Modifications shall not require switching off power to any
part of the system.
4.01.07 Power supply to individual functional group shall be from redundant 24V feeders with diode
auctioneering and further sub-distribution.
4.01.08 The assignment of I/O channels for Inputs/Outputs, arrangement of modules within cabinet
etc. shall be identical for all units except those inputs/outputs which are common for all units.
Further uniformity should be maintained for redundant stream of process equipment within a
unit.
4.01.09 The application programs for the functional controllers shall be software based which shall be
maintained even through power supply failure.
4.01.10 Independent and dedicated controllers (main and its 100% standby) shall be provided for
each of the functional group (FG) of Control System except for the cases where triple
redundant controllers are to be used which shall be as per bidders standard and proven
practice. All the 100% hot/redundant backup controllers shall be identical in hardware and
software implementation to their corresponding main controllers and shall be able to perform
all its tasks. The backup controller shall track its corresponding main controller. There shall
be an automatic and bump less switchover from the main controller to its corresponding
backup controller in case of main controller failure and vice versa without resulting in any
change in control status. In case of switchover from main controller to the 100% hot backup
controller, the back-up controller shall work as the main controller. Further, when only one
controller is working and other controller is inserted online (for example after repair /
replacement), there should not be any degradation in the function of the working controller
and control operation.
4.01.11 The control system hardware design shall be such that it is able to withstand power line
disturbances.
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4.01.12 The loop/logic reaction time shall be suitable to match actual process requirements, subject
to minimum requirement wherever specified.
4.01.13 NOT USED
4.02.00 Turbine Protection System (TPS)
1. Fully proven system, based on hardware/software specifically designed for Turbine
protection application meeting the provenness criteria specified in relevant
Subsection of this specification shall be provided to achieve the turbine protection
action.
2. NOT USED
3. NOT USED
4. NOT USED
5. Bidder shall provide all the required primary sensors etc. required for protection
system as per his standard and proven practices. All trip signal inputs required for
the safety of the turbine shall be generally based on 2 out of 3 logics.
6. NOT USED
4.03.00 Binary Controls/Open Loop Control System (OLCS) Functions
4.03.01 NOT USED
4.03.02 The OLCS shall include sequence control, interlock & protection for various plant
auxiliaries/valves/dampers/drives etc. The sequence control shall provide safe and automatic
startup and shutdown of plant and of plant items associated with a plant group. The interlock
and protection system shall ensure safe operation of plant/plant items at all times and shall
automatically shut down plant/plant items when unsafe conditions arise.
4.03.03 The OLCS shall be arranged in the hierarchical control structure consisting of group level,
subgroup level & drive level (as applicable).
4.03.04 NOT USED
4.03.05 NOT USED
4.03.06 NOT USED
4.03.07 NOT USED
4.03.08 NOT USED
4.03.09 NOT USED
4.03.10 NOT USED
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4.03.11 NOT USED
4.03.12 NOT USED
4.03.13 NOT USED
4.03.14 NOT USED
4.03.15 All the interlock & protection logics drive shall be implemented in redundant controllers.
4.03.16 NOT USED
4.03.17 NOT USED
4.03.18 NOT USED
4.03.19 In accordance with the scope defined under Part-A IIC-01, the Unit level and group level
sequences shall be implemented as a part of BOP C&I System in order to implement
Automatic plant start up system. Contractor shall provide and accept all necessary signals for
successful implementation of the same.
4.04.00 Modulating Controls/Closed Loop Control System (CLCS) Functions
4.04.01 NOT USED
4.04.02 The CLCS shall continuously act on valves, dampers or other mechanical modulating
devices such as hydraulic couplings etc., which alter the plant operation conditions. The
system shall be designed to give stable control action in steady state condition and for load
changes in step/ramp over the load range of 60% to 100% MCR with variation or parameters
within permissible limits as per process requirement
4.04.03 The controller capability shall, as a minimum, include (i) P, PI, PD and PID control functions
and their variations (ii) cascade control (iii) feed forward control (iv) On-Off control, (v) Ratio
and bias control, (vi) Logical operation .
4.04.04 The loop reaction time (from change of output of the transmitter/temperature element to the
corresponding control command output) shall be as per process requirement. For Turbine
Control System and HP Bypass systems, reaction time shall be as per the requirement of
Turbine Supplier.
4.04.05 NOT USED
4.04.06 NOT USED
4.04.07 Any switch over from auto to manual, manual to auto and switchover from OWS/ LVS
operation to H/A station operation and vice versa shall be bump less and without resulting in
any change in the plant regulations and the same shall be reported to the operator and
recorded automatically.
4.04.08 NOT USED
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4.04.09 NOT USED
4.04.10 The System being supplied shall be such that when permissible limits are exceeded, an
automatic switchover from an operation governed by maximum efficiency, to an operation
governed by safety and availability is affected.
4.04.11 NOT USED
4.04.12 NOT USED
4.04.13 NOT USED
4.04.14 NOT USED
4.04.15 NOT USED
4.04.16 NOT USED
4.05.00 Turbine Control System (TCS) Functions
The Turbine Control System shall consist of Turbine Governing System, Turbine Stress
Control System and BFP turbine Electro hydraulic Governing System HP/LP Bypass system
& Automatic Turbine testing (ATT) system. In addition to the specific requirements indicated
in subsequent clauses, the requirements of CLCS as specified above shall also be applicable
for TCS.
4.06.00 Turbine Governing System
Fully proven system, based on hardware/software specifically designed for Turbine
governing application meeting the provenness criteria specified in relevant Subsection of this
specification shall be provided to achieve the turbine governing action.
4.07.00 Turbine Stress Evaluation system (TSES)/Turbine stress Control System (TSCS)
Bidder as per his proven and standard practice shall provide a proven Turbine Stress
Evaluation system (TSES) or Turbine stress Control System (TSCS) which will work in
conjunction with turbine governing system and ATRS and achieve the following
functional requirements. In case it is standard and proven practice of the bidder not to
have controls of Turbine, based on TSE computation, then c) below is not applicable.
a: Continuous on-line monitoring of thermal stress levels in all critical parts of the
turbine such as per manufacturers standard practice.
b: Continuous on line computation of stress margins available for the above-
mentioned critical components of the turbine during various regimes of operation
i.e. run-up, synchronisation, loading, load maneuvering, normal operation, run
backs, unloading, shutdown etc.
c: Computation of the limits of speed and load changes allowable at any particular
instant before synchronisation and after synchronisation respectively. The system
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shall be designed to inhibit further operation like speed/steam temperature raising
or lowering wherever upper and lower temperature margins are not available
(during periods prior to synchronisation) and load/steam temperature raising or
lowering whenever upper/lower load/temperature margins are not available (after
synchronisation) within allowable limits.
d: Carry out a fatigue analysis for all affected critical components of the turbine as per
bidders standard and proven practice and also to compute the percentage service
life consumption of the turbine.
e: Display the stress margins etc. on OWS for operator guidance and storage of
necessary data such as percentage service life consumption etc. If the bidders
standard and proven practice require separate dedicated colour VDU/Printer for
realising all the function enumerated in this clause ,then the same shall also be
acceptable.
f: Store long term data & carry out Residual Life Analysis.
The system shall be complete including measuring transducers for generator load and
wall temperature, measured value processing modules, microprocessor based
controllers for stress calculations and turbine life calculations etc.,
4.08.00 HP/LP Bypass System
1 LP Bypass Control System
The LP Bypass control system shall consists of steam pressure control loop and
steam temperature control loop.
2 HP Bypass control system
The system shall consists of steam pressure control loop & steam temperature
control loop.
4.09.00 Automatic On Line Turbine Testing (ATT) System
The Bidder shall provide ATT system for on load testing of turbine protective equipment
automatically in a sequential manner without disturbing normal operation and keeping all
protective functions operative during the test. The ATT functionality shall be as per Bidders
standard and proven practice.
4.10.00 Automatic Turbine Runup System (ATRS)
ATRS shall run the turbine automatically from zero speed to synchronising speed and
then load the machine up to block loading and continuously check the operation up to
100% MCR without impairing the life of the turbine.
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The automatic turbine run up system shall be designed in general to provide for the
following functions. However exact implementation shall be as per bidders standard and
proven practice.
a Automatic start up/shut down sequence
b Stress/temperature margin controlled acceleration as per the pre selected mode
i.e. slow, normal and fast.
c Stress/temperature margin controlled loading/unloading
d Automatic synchronisation and loading up to 100% MCR.
e Unloading and shut down of the machine.
4.11.00 Turbine Supervisory System
The detailed functional requirement of main & BFP Turbine supervisory system has been
elaborated in next subsection "MAIN EQP INST SYS".
4.12.00 BFP Turbine Electro hydraulic Governing System
Electro hydraulic governor, stable and satisfactory speed control over full speed range from
0% to 100%, shall control the drive turbine speed. The exact implementation shall be as
per standard and proven practice of the bidder.
5.00.00 HUMAN-MACHINE INTERFACE AND PLANT INFORMATION SYSTEM (HMIPIS)
REQUIREMENTS
5.01.01 Human-Machine Interface system shall be designed and engineered for safe, efficient,
reliable and convenient operation. HMIPIS shall employ high-performance, non-proprietary
open system architecture to ensure fast access and response time and compatibility with
other system and portability of third party software. HMIPIS shall be used primarily for the
following functions:
(a.) As operator interface for control operation for the plant for accepting data from and
issuing commands to Control system etc.
(b.) To perform plant supervisory, monitoring and information functions
5.01.02 NOT USED.
5.02.00 Operator interface to the Control System
5.02.01 The operator interface of the HMIPIS shall consist of monitor / Mouse, Keyboards of OWS,
large video screen (LVS) (As per the scope), printers, etc.
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5.02.02 The operation shall employ powerful menu-driven window based supported input facilities for
operational ease and comfort.
5.02.03 The following functions shall be provided as a minimum:
5.02.04 All OWS/LVS of the HMIPIS shall be fully interchangeable i.e. all operator functions including
control, monitoring and operation of any plant area on drive shall be possible from any of the
OWS/LVS at any point of time without the necessity of any action like downloading of
additional files. Other OWS/LVS in the network shall be able to access all control information
related data under all operating conditions including a single processor/computer failure in
the HMIPIS. Further, simultaneous operation (availability of popup window/face plate) of at
least two drives of control system shall be possible from a single display without calling
additional displays for multiple drive operation.
5.02.05 NOT USED
5.02.06 The operator functions for each OWS/LVS shall as a minimum include Control System
operation (A/M selection, raise/lower, set point/bias change, on/off, open/close operation,
mode/device selection, bypassing criteria, sequence auto, start/stop selection, drive auto
selection, local-remote/other multi-position selection etc.); alarm acknowledge; call all kind of
displays, logs, summaries, calculation results, etc.; printing of logs & reports; retrieval of
historical data; and any other functions required for smooth operation, control & management
of information as finalised during detailed engineering.
5.02.07 The display selection process shall be optimized so that the desired display can be selected
with the minimum no. of operations. Navigation from one display to any other should be
possible efficiently through paging soft keys as well as through targets defined on the
displays.
5.02.08 The system shall have built-in safety features that will allow/disallow certain functions and
entry fields within a function to be under password control to protect against inadvertent and
unauthorized use of these functions. Assignment of allowable functions and entry fields shall
be on the basis of user profile. The system security shall contain various user levels with
specific rights and shall be as finalised by the Employer during detailed engineering.
However, no. of user levels, no. of users in a level and rights for each level shall be
changeable by the programmer (Administrator).
5.02.09 NOT USED
5.02.10 NOT USED
5.03.00 Plant Supervisory, Monitoring and Information Functions of HMIPIS
5.03.01 The HMIPIS shall be designed as an on-line system which shall process, display and store
information to provide the operator, either automatically or on demand, the relevant
information as indicated in subsequent clauses. The HMIPIS shall provide the following
information in suitable format (display or print) as per the requirement.
The following functions shall be performed by HMIPIS as a minimum:
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5.03.02 Calculations
01 Basic Calculations
Arithmetical and logical calculations related to analog points and binary points as per
process requirement
02 NOT USED
03 NOT USED
5.03.03 Alarm monitoring and reporting
The system shall display history of alarms in chronological order on any of the OWS. The
system shall have all alarm functions and related function keys like alarm acknowledge,
reset, paging, summaries etc.
Facility of audio annunciation shall be provided in LVS./OWS upon the occurrence LVS/OWS
alarms irrespective of whether alarms are displayed or not. Facility to disable the audio
annunciation per LVS/OWS shall be provided.
5.03.04 Displays
1 Various displays on the OWS/LVS shall include P&ID displays or mimic, bar chart
displays, X-Y & X-T plot (trend) displays, operator guidance message displays, group
displays, plant start-up/shutdown message displays, system status displays etc.
Number of displays and the exact functionality shall be on as required basis and
shall be as per process requirement.
2 NOT USED
3 Minimum contents & functionality of various types of displays shall be generally as
under:-
(a) Mimic displays:
These displays shall depict the process in graphical form and shall cover all
the drives operable from DDCMIS and all process areas being monitored
therein.
(b) Control Tile Display :
In this display the drives of a loop shall be displayed with related parameters
such as process value, set point, deviation, for the loop, along with facility for
any selections (like A/M selection, valve selector etc.) and the command
output, disturbance status & the position feed back signals, for each drive.

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(c) Trend Display (X-T Plots) :
These displays shall show the trend of analog points with respect to time.
These displays shall be continuous curve plot & not point plots. Time spans
of displays shall have operator selectable intervals.
(d) X-Y Plots:
There shall be X-Y plot displays freely configurable in the system as per the
process requirement. Operating curves shall be superimposed over the X-Y
plot.
(e) NOT USED.
(f) Sequence chain displays for each group & sub-group shall be used to trace
the sequence of a control chain as well as to facilitate the operator
interventions & enable mode changes/auto selection. Sequence chain
display shall present complete sequence chain, in functional blocks, steps
being carried out, criteria, sequence execution time for each step and
criteria.
(g) Drive Level Displays :
For each drive (both binary & modulating) a drive level display shall be
provided which shall indicate the drive related information including
individual drive faults & disturbance criteria. It should be possible to call
these displays as pop-up displays.
(h) CLCS Displays :
The loop schematic for each loop shall be available in a display form which
shall show the individual analog & binary values.
(i) NOT USED.
(j) Bar Graph Displays :
Horizontal & Vertical bar charts shall be provided for the display of related
points.
(k) Alarm Displays :
In order to guide the operator in case of a process fault disturbance a display
shall be provided so that the alarm sequence in time with proper description
is presented to the operator.

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(l) Point Detail Display :
From HMIPIS facility shall be provided to select any point for point detail
display displaying important point attributes like description, range, engg
units etc.
(m) Displays On large Video Screen(LVS)
The primary operation monitoring and control is intended from LVS/OWS
and hence the display shall be suitable for both LVS as well as OWS
operation.
In addition, on the top area of the LVS (around 20-25% mm), shall be
reserved for soft replica of Conventional annunciation facia which shall be
displayed (normally for permanent viewing). The exact format is as indicated
subsequently in this chapter.
(n) NOT USED
5.03.05 Logs/Summaries/Reports
The system shall generate three basic types of reports/logs i.e., Event activated, Time
activated and On-demand log & summaries. The log format and point assignment for each
logs/ report and other design features shall be as per the process requirement and shall be
as decided during detailed engineering.. The system shall have the facility for viewing of the
logs/summaries on the OWS/LVS as well as for their copying in formats compatible to be
used with MS-office or similar tools.
The system will be designed for automatic/manual printing of all the reports/logs.
a. NOT USED
b. NOT USED
c. NOT USED.
d
dd.
..
Various summaries
The system shall have a provision to get various summaries such as off scan point
summary, points in alarm summary, point quality summary, substituted values
summary. Exact details shall be as decided during detailed engineering
5.03.06 Log Generation Utility
The Contractor shall offer log/report generation utility to generate freely configurable
log/report. Exact details shall be as decided during detailed engineering.

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5.03.07 Historical storage and retrieval system (HSRS)
Complete HSRS functionality shall be implemented in redundant server/information
workstation.
5.03.08 The HSRS shall collect and store process and DDCMIS system generated data. The data
shall be saved online on hard disk and to portable storage device like MOD/DVD.
5.03.09 The data to be stored in the above system shall include alarm and event list, periodic plant
data including the data required for Residual life assessment. The strategy and
implementation of quantum and frequency of process or DDCMIS system data shall be such
that it shall not restrict/constraint any future analysis of Process or DDCMIS system
behaviour as and when it is required by the employer.
(A) Periodic Data
1. Alternate-I (Based on exception recording)
*All analog points Dead band varying from 0 - 2.5% as defined by
Employer during detailed engineering.
*All binary points On status change (with suitable protection against
excessive status change)
2. Alternate-II (without using exception recording)
* 1000 analog points 1 sec rate
* 1000 analog points 5 Sec. rate
* Balance analog
points
30 sec. rate
* Binary points On status change (with suitable protection against
excessive status change)
(B) Applicable logs & reports to be finalised during detailed engineering.
5.03.10 The system shall provide user-friendly operator functions to retrieve the data from historical
storage. It shall be possible to retrieve the selected data on OWS/LVS or printer in form of
trend/report by specifying date, time & period.
5.03.11 Quality Tag
1. The system shall identify and tag the quality of all data (scanned and calculated
points) in a way that makes all users (control, calculations, logs, displays, etc.)
aware of its quality. The same shall be as per Bidders standard practice.
2. NOT USED.
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5.03.12 Database
1. The database shall be organised in such a way that searching/querying & sorting on
any field shall be possible. The same shall be as per Bidders standard practice.
1. NOT USED
2. NOT USED.
4. All points i.e., process I/Os, generated signals, complete signals of calculations, OPC
togs shall be identified by a unique tag throughout the entire DDCMIS system. The
tagging shall be based on KKSCODE employing maximum 18 characters.
5.04.00 NOT USED
5.04.01 NOT USED
5.04.02 NOT USED
5.04.03 NOT USED
5.04.04 NOT USED.
5.04.05 NOT USED.
5.04.06 NOT USED.
5.04.07 NOT USED
5.04.08 NOT USED
5.04.09 NOT USED
5.04.10 NOT USED
5.04.11 Connection for Remote Service CENTRE:
Connection for remote access to DDCMIS for diagnostics as described at sub-Section-IIIC-02
Cl. 15.00.00 shall be through a firewall. Virtual private networks (VPN) technology shall be
used for data integrity and confidentiality. The type of VPN ( SSL, IP sec, SSL) ,no. of bits for
encryption etc shall decided during detailed engineering. Further, this access shall be strictly
under request control & record of such access shall be made available to the employers
designated personnel also. It should be ensured that the hardware at the other end of the
remote access connection (i.e. at the contractors works) shall be standalone/ isolated (i.e.
not connected to any network).

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5.04.12 SECURITY Policies/procedures and security AUDITS:
In order to enforce security in the HMI against intrusions/ vulnerabilities, security policies and
procedures, as per III-C02-J of this specification are to be followed by the Contractor during
the tenure of the Contract & by Employers site personnel thereafter.
For checking compliance to the above security policies & procedures, periodic security audit
by a certified auditor (as per CERT-IN panel) is to be arranged by the Contractor at the time
of trial operation/commissioning test of this package and every year during AMC period. This
shall include vulnerability assessment of the workstations/servers. Suitable actions based on
the findings of the security audit shall be carried out by the Contractor.
6.00.00 PROGRAMMER'S STATION (PROGRAM DEVELOPMENT/ MODIFICATION, SYSTEM
MAINTENANCE AND DOCUMENTATION FACILITY)
6.01.00 Contractor shall provide programming facilities/systems as a minimum for Control system
and HMIPIS and system documentation facility to achieve paperless documentation for
DDCMIS.
6.01.01 The programming tools shall have in-built safety features that will protect the system against
inadvertent and unauthorised use of these tools. Necessary hard key locks and software
locks, etc. shall be provided for this. During on line programming, external plant/equipment
should not be affected.
6.01.02 NOT USED.
6.01.03 The structuring/configuration/modification of Control loops/logics in Control system and
program development/modification in HMIPIS shall be possible from fully graphic displays
using familiar & conventional functional blocks.
6.01.04 Any modification done in Control System and HMIPIS shall be suitably logged so that it can
be traced to the user log-in ID and time of change.
6.02.00 Control system structuring/configuration/tuning facilities
6.02.01 Structuring/configuring and tuning facilities shall be provided for structuring/ modification,
storing/loading, testing, tuning, monitoring, etc. of all the microprocessor-based controllers of
the control system.
6.02.02 It shall be possible to configure the system with ease without any special knowledge of
programming or high level languages. The running logic should be capable of being viewed
on line with dynamic status of inputs, outputs of each logic/loop component on programmer
station. Control strategy shall be implemented using familiar and conventional automation
function blocks (software implemented). Whenever any change in configuration is done, it
shall be recorded and modified configurations shall be available for printing and
documentation and shall be stored in non-volatile memory. All the system configuration,
tuning/fixed parameters shall be documented and printed in form of function diagrams and
lists respectively.
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6.02.03 Provision to store and retrieve on immediate and long term basis the system configuration,
data base etc. on some device such as floppy disk shall be included. Facility shall be
provided to reload/down-load the system or controller module from the already stored data,
on-line.
6.02.04 Facility for modification shall be user-friendly. For example, modification of logics/loops etc.,
zooming for better display, stretching etc. should be possible.
6.03.00 HMIPIS program development/modification and system maintenance facilities
6.03.01 Online system shall be provided for programme development/modification to achieve various
functions including development, modification and testing of software of MMIPIS, generation
and modification of graphics, logs, HSRS functions in an interactive manner, MMIPIS
Database modification/creations, down loading the software with associated data base from
the console and other features necessary for system maintenance. All operator functions
shall also be available on MMIPIS programmer station. Also facility shall be provided to print
system fault as detected by the online self-diagnostic routine.
6.04.00 System Documentation Facility
6.04.01 The system shall have the facility to generate the associated documentation for both the
Control System & HMIPIS. It shall also have facility of complete DDCMIS system
documentation, complete software backups of all applications of DDCMIS from the
programmer stations including the facility to view the application.
6.05.00 NOT USED
7.01.00 The Data Communication Systems as identified under the scope of work shall be provided.
7.02.00 The design shall be such as to minimise interruption of signals. It shall ensure that a single
failure anywhere in the media shall not cause any disruption in system operation.
7.02.01 NOT USED.
7.02.02 Built-in diagnostics shall be provided for easy fault detection. Communication error detection
and correction facility (ECC) shall be provided at all levels of communication. Failure of one
bus and changeover to the standby system bus shall be automatic and completely bump less
and the same shall be suitably alarmed / logged.
7.02.03 The design and installation of the system bus shall take care of the environmental conditions
and hazardous area classification as applicable to similar services.
7.02.04 Data transmitting speed shall be sufficient to meet the responses of the system in terms of
displays, control etc.
7.02.05 Passive coaxial cables or fiber optic cables shall be employed for System Bus. Bidder may
propose other type of cables as per their standard also which shall be subject to Employers
approval. However the following buses shall be fiber-optic only.
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(a) System bus connections between CER & CCR
(b) System bus from locally mounted control system cabinets/OWS to central location
(c) I/O Bus from remote I/OS to centrally located system cabinets.
7.02.06 The redundant buses as applicable shall be physically separate and shall be routed
separately.
7.02.07 NOT USED
7.02.08 If UTP/STP cables are used, Bidder shall supply flexible conduit for their routing.
7.02.09 In case of any distance or other limitation in the Data Communication System, Bidder shall
provide special type of cables like optical fibers with repeaters as required to make the
system fully operational.
8.00.00 ANNUNCIATION FUNCTIONS (IF APPLICABLE)
8.01.01 The LVS annunciation will emulate salient features of conventional hardware annunciations
while presenting more flexibility.
8.01.02 The annunciation system shall be implemented as an in-built function of DDCMIS. The field
contacts shall be acquired through DDCMIS only. The annunciation points will be presented
on topmost area of LVS screens. The annunciation area will be divided in multiple alarm
bands. There will be 3 nos. of alarm bands in each LVS screens. The annunciation
sequence shall be as discussed and finalised during detailed engineering.
8.01.03 Bidder shall implement all the LVS annunciation functionality as described below as a
minimum.
8.01.04 There will be one alarm for each alarm window. Grouped alarms shall be provided only for
pre-defined system / field faults like non-coincidence, monitoring etc. The alarm text is to be
displayed only when that alarm is present. A tool-tip will be associated with each alarm
window, which will show tag no. of alarm point when cursor is brought over alarm window.
8.01.05 Hooters/Speakers of different frequencies shall be available for reporting new alarms and
resetting of alarms (corresponding to slow flash) etc shall be available. All flashing windows
shall flash together (synchronized) in any LVS screen. Suitable means shall be provided to
distinguish new alarms and return to normal messages.
8.01.06 Annunciation points shall be distributed on various LVS screens based on process area. That
is, each annunciation point will be assigned an LVS no. and an alarm band no.
8.01.07 No fixed space will be reserved for any alarm on any of the band. Once a particular alarm
band is full, the new alarm in that band will be reported by automatic shifting of the older
alarm(s) on left side of band one by one in FIFO fashion. A scroll bar shall be provided on
both the sides to view the alarms in a particular band after the particular band is full.
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8.01.08 The scroll button will fast flash when scrolled alarms are fast flashing, will slow flash when
alarms are slow flashing and will be steady when alarms are steady. When scrolled alarms
are of mixed type, the scroll bar will flash with highest flashing rate of scrolled alarms.
8.01.09 When operator right clicks on LVS alarm area, he will get a menu with following options (i)
acknowledge- to acknowledge all new alarm(s) on that LVS (ii) reset- to reset all alarm(s)
returning to normal in that LVS (iii) configuration utility- to view and edit alarm list, tag nos.,
etc of all points in all LVSs (iv) closing the menu. This menu can be dragged & placed
anywhere on LVS screen. The actions (i), (ii) and (iv) can be done by operator but action (iii)
will be permitted only to Programmer. The acknowledge / reset facility will be separate for
each LVS. However, with one acknowledge/ reset action, all alarm point(s) of all band(s) of
that LVS will be acknowledged/ reset.
8.01.10 The hooter sounds will be different for each of the Unit of power plant, when there is common
control room for multiple Units.
8.01.11 Bidder shall provide suitable configuration utility should be available for viewing and
modifying all alarms to be displayed on annunciation area of LVS.
8.01.12 The above LVS annunciation features will also be replicated in all OWS.
9.00.00 POWER SUPPLY, GROUNDING, CABINET/PANELS, ETC.
9.01.00 Power Supply
9.01.01 Contractor shall provide totally reliable & quality power supply for DDCMIS. The power
supply system shall meet requirements specified under Sub-Section: Electric Power Supply
of Part-B, Section-VI B.
9.01.02 Wherever hot backup or redundant equipment likes controllers, processors, I/O modules, etc.
have been specified and provided, the same shall be powered through separate power
supply feeders.
9.02.00 Grounding
All panels, desks, cabinets shall be provided with a continuous bare copper ground bus,
bolted to the panel structure on bottom on both sides. The bolts shall face inside of panels.
Bidder shall meet requirements specified under sub-section: Basic Design Criteria of Part-B,
Section-VI B.
Further, for connection of shields of the field instrumentation. Cables, a separate shield bus
independent of the ground bus shall be provided, which shall be connected to the earth risers
by means of independent cables.
9.03.00 System Cabinets/Panels
9.03.01 All DDCMIS system modules, power supply components, other control devices (except field
mounted sensors/transmitters) which are required for completeness of the system shall be
housed in cabinets furnished by the Contractor. All equipment and dedicated cabinets
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required for termination, marshalling and proper interface within Contractors system and also
with other systems shall also be provided by the Contractor.
9.03.02 The cabinet mounted equipments shall be fully assembled, installed in mounting racks, wired
and fully tested as per specification requirements and Employer approved drawings in the
manufacturing works of a qualified manufacturer prior to shipment to the project site. The
Contractor 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 provided) to system cabinets and inter-cabinet/cabinet to Control Desk.
9.03.03 The DDCMIS cabinets shall be grouped into physically separate cabinets as follows:
1. Control System Cabinets/control System cum marshalling cabinets)
2. Marshalling cabinets (if independent)
3. Relay cabinets
4. HMIPIS cabinets
However, in case Bidders system design requires the termination cabinet independent from
system cabinet, the marshalling cabinets can be combined with the termination cabinet. For
offering control system cum marshalling cabinets refer scope Part-A section II C-01 of the
specification.
The Contractor shall clearly identify in his enclosed Bill of Material, the quantity of all the
above mentioned DDCMIS cabinets along with dimensional details as included in his offer.
Contractor may make a special note that termination of field cables directly to control system
cabinet is not acceptable.
9.03.04 The Control system cabinets shall house all types of modules / hardware to achieve all
functions of Control System including signal conditioning modules, controller modules, I/O
modules, communication controller modules and all other requisite hardware for a complete
system. All system cabinets shall be totally enclosed (with front and back doors and side
panels).
9.03.05 HMIPIS hardware like server, OWS/LVS other Work Station shall be stand-alone type with
their own enclosure. The hardware along with its UPS etc. shall be mounted on a rack to be
placed behind LVS. Other hardware like network component, power supply distribution etc.
shall be suitably housed in cabinets, as approved by Employer.
9.03.06 Relay cabinets (or marshalling / termination cabinet cum relay cabinets, as the case may be)
shall house all the interfacing relays in the system.
9.03.07 Marshalling:
All the incoming / outgoing signals shall be grouped as per their origin / destination and will
be terminated in the marshalling cabinets (or marshalling cum termination cabinet as the
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case may be). The Contractor may make a special note that termination of field cables
directly to the system cabinet (whether on TBs or on the pins on I/O modules) is not at all
acceptable.
System cabinet(s) and corresponding marshalling and termination cabinet(s) shall be a single
shipping section, so that the internal wiring from field terminal to the module is done
completely at the factory itself.
9.03.08 The type of termination and terminal blocks to be used shall be as per requirements specified
under Sub-Section-Inst. cable.
9.03.09 The design of all the cabinets and layout of all equipment, terminal blocks etc. shall be based
on human Eng. Considerations, fully keeping in view the convenience of operation and
maintenance personnel and shall be subject to Employers approval during detailed
engineering.
9.03.10 Contractor shall design the cabinet internal arrangement, floor cutout and cable gland plate
such that all the cables entering or leaving the cabinet can be properly glanded in the gland
plate. In case, glanding is not possible Contractor shall indicate in his proposal his suggested
procedure for cable entry and securing the cable at place. If gland plate is not provided, then
a suitable plate of 2mm size shall be provided to close bottom entry of panels with proper
fixing through screw at number of points for giving rigid support. Contractor shall also
provide after the final installation of the cable, a suitable sealing material on the gland plates
to ensure absolute sealing of the cabinet bottom, thereby ensuring that no dust ingress takes
place from the cable entry zones.
The grouping, layout of all the above cabinets shall be as approved by the Employer during
detail engg.
9.03.11 The Contractor shall furnish with the proposal, detailed drawings and photographs giving
sufficient information to demonstrate to the Employer, the internal layouts of cabinets offered,
constructional features of cabinets, system of packaging of control modules in racks, wiring
and cabling techniques, termination method for field cables, test facilities provided, etc.
9.03.12 NOT USED
9.03.13 NOT USED
9.03.14 The cabinets shall be IP-22 protection class. The Contractor shall ensure that the packaging
density of equipment in these cabinets is not excessive and abnormal temperature rise,
above the cabinet temperature during normal operation or air-conditioning failure, is
prevented by careful design. This shall be demonstrated to the Employer during the factory
testing of the system. The Contractor shall ensure that the temperature rise is limited to 10
deg. C above ambient and is well within the safe limits for system components even under
the worst condition as specified in Sub-section-Basic Design Criteria (Part-B, Section-VIB)
and specification requirements for remote I/O cabinets. Ventilation blowers shall be furnished
as required by the equipment design and shall be sound proof to the maximum feasible
extent. If fans/blowers are required for satisfactory system operation, dual blowers/fan with
blower failure alarm shall be provided in each cabinet with proper enclosure and details shall
be furnished with proposal. Suitable louvers with wire mesh shall be provided on the cabinet.
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9.03.15 The cabinets shall be totally enclosed, free standing type and shall be constructed with
minimum 2 mm thick steel plate frame and 1.6 mm thick CRCA steel sheet or as per
supplier's standard practice for similar applications, preferred height of the cabinet is 2200
mm. The cabinets shall be equipped with full height front and rear doors. The depth of control
system cabinets shall be 800 mm. The floor mounting arrangement for other cabinets shall
be as required by the Employer and shall be furnished by the Contractor during detailed
engineering.
9.03.16 Cabinet doors shall be hinged and shall have turned back edges and additional braking
where required ensuring rigidity. Hinges shall be of concealed type. Front and rear doors
shall be provided with locking arrangements with a master key for all cabinets. If width of a
cabinet is 600 mm or above, double doors shall be provided.
9.03.17 The following clauses define the panel painting requirements. If the Bidders standard and
proven practice is different than the following stated requirement, the same shall also be
accepted subject to submission of details by the bidder and approval of employer. Two spray
coats of inhibitive epoxy primer-surface shall be applied to all exterior and interior surfaces.
A minimum of 2 spray coats of final finish color shall be applied to all surfaces. The final
finished thickness of paint film on steel shall not be less than 65-75 micron for sheet
thickness of 2 mm and 50 microns for sheet thickness of 1.6 mm. As an alternative, single
coat of anodic dip coat primer along with single textured powder coating with epoxy polyester
meeting the thickness requirement is also acceptable.
9.03.18 The Bidder shall furnish sufficient touch-up paint for one complete finish coat on all exterior
factory applied painted surface of each item of equipment. The touch up paint shall be of the
same type and color as the factory applied paint and shall be carefully packed to avoid
damage during shipment. Complete painting instructions shall be furnished.
The finish colors for exterior and interior surfaces shall conform to following shades:
Front & Rear-RAL 9002; End panel side- RAL 5012. Internal color shall be same as external
color.
Paint films which show sags, checks or other imperfections shall not be acceptable.
9.03.19.1 Cabinets shall be designed for a grounded installation on the building structure. Any Isolation
from the building ground which is required by equipment design shall be provided internal to
the cabinet.
9.03.19.2 NOT USED.
9.03.19.3 The Contractor may submit details of his standard wiring practice for similar application for
information of Employer.
9.03.20 An anti-vibration pad of minimum 15 mm thickness shall also be provided for each of the
cabinets.

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9.04.00 Relays
9.04.01 All the relays provided by Contractor shall be suitable for control supply of 24V DC. Each
relay shall have 2 4 changeover type contacts & the rating of contacts shall be 5 Amp at
240V AC & 0.2A at 220V DC. The VA burden of relays shall be suitable to match the capacity
of output modules (however, it shall not be more than 2.5 VA). Each relay shall be provided
with a freewheeling diode. All the contacts of relays shall be wired up to the cabinet terminal
blocks.
10.00.00 SYSTEM SOFTWARE REQUIREMENTS
10.01.00 The Contractor shall provide all licensed software packages required by the system for
meeting the intent, functional and parametric and performance requirements of the
specification.
10.02.00 As a customer support, the Contractor shall periodically inform and upgrade the following
softwares till completion of the warranty period.
(a) Anti Virus softwares
(b) Security software of fire wall and other network devices (as applicable)
10.03.00 All licenses shall be valid for the continuous service life of the plant.
10.04.00 (a) Following licensed software packages or suites or their combination, as applicable,
shall be provided so as to meet the complete specification requirements. Bidder shall
indicate in the bid about the specific names and details of software packages which
will implement the following listed soft wares packages.
(b) The software licenses shall be provided for the project (e.g. organization or site
license) and shall not be hardware/machine specific. That is, if any
hardware/machine is upgraded or changed, the same license shall hold good and it
shall not be necessary for Employer to seek a new license/renew license due to up
gradation/change of hardware/machine in DDCMIS at site. In case the s/w license
is dependent on no of points, then quantity to be considered is 30% above the
finally implemented points.
(i) Operating system for all OWS, PC & Servers.
(ii) System related softwares real time operating system for meeting the
functionality of DCS and HMIPIS.
(iii) System related softwares real time operating system for meeting the
functionality HMIPIS.
(iv) Backup, History management and File management software for HSRS.
(v) Programming and engineering softwares for HMIPIS functionality.

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(vi) On line diagnostics/debug software for control system.
(vii) On line diagnostics/debug software for HMIPIS.
(viii) NOT USED
(ix) NOT USED
(x) NOT USED
(xi) Software drivers and other system interfacing
(xii) Anti virus softwares for all the Machines in the station LAN.
(xiii) Client server suite for OPC connectivity.
10.05.00 NOT USED.
10.06.00 Software Upgrades
As a customer support, the Contractor shall inform the designated officer of the Employer
about the software upgrades/new releases that would be taking place after the system is
commissioned and till the currency of contract if there are any deficiencies and bugs
discovered in the offered system.
As a customer support, the Contractor shall periodically inform the designated officer of the
Employer about the software upgrades/new releases that would be taking place after the
system is commissioned so that if required, same can be procured & implemented at site.
11.00.00 SYSTEM DOCUMENTATION
The Contractor shall furnish detailed system and equipment documentation. It shall include
detailed system and components description covering the installation, operation, care and
maintenance of all system components. All final system documentation for DDCMIS
hardware and related software shall be furnished. The same shall be complete, accurate
and fully representative of the supplied system and its elements. All documentation/
catalogues etc., shall be furnished in English language. In addition to the hard copies, CD
ROM based documents shall also be provided. Over and above the Master drawing list
finalised with the Bidders during award of contract, in order to understand Bidders standard
and proven engineering practices following documents as a minimum shall be submitted by
the Bidders as and when required by the employer.

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Sl._No Document
1 Standard DDCMIS/DCS configuration schemes
2 DDCMIS System Fault Diagnostics features
3 H/W Signal exchange and Software signal exchange philosophy with-in
contractors control system
4 H/W Signal exchange and Software signal exchange philosophy with external
systems
5 Standard philosophy document for triple and dual measurement schemes
6 Standard open loop sequences schemes including ATRS
7 Standard Closed loop controls implementation schemes
8 Standard Turbine protection schemes
9 Standard Turbine Governing schemes
10 Standard ATT implementation scheme
11 HMIPIS Process Mimics implementation philosophy
12 HMIPIS OLCS and CLCS Control Display implementation philosophy
13 HMIPIS Logs/reports implementation philosophy
14 HMIPIS Trends implementation philosophy
15 HMIPIS Bars implementation philosophy
16 HMIPIS X-Y plots implementation philosophy
17 HMIPIS user authorisation and password implementation philosophy
18 HMIPIS Cyber security implementation
19 HMIPIS supported Software communication protocols for external systems
20 HMIPIS Navigation Display organisation and Philosophy
21 HMIPIS Alarm implementation Philosophy
22 HMIPIS Historical storage and retrieval system implementation philosophy.
23 DDCMIS programming and configuration tools for control system and HMIPIS
24 Quality Tag implementation Philosophy in DDCMIS for process/Calculated inputs
25 DDCMIS process point attributes philosophy
26 Specification recommendation for Server/Workstaion and other HMIPIS H/W for
DDCMIS
27 Specification recommendation for Server/Workstaion for other PC based systems
28 Remote service access and implementation philosophy
29 DDCMIS System documentation features
30 DCMIS data communication philosophy
31 DDCMIS panels standard OGA,IGA layout ,including Panel Constructional,
Painting details and internal wiring details
32 Standard Shielding and grounding philosophy of DDCMIS system
33 Standard Hook up and installation philosophy for STG integral equipment
34 Bidder's standard and optional Turbovisory instrumentation philosophy for Main
Turbine
35 Bidder's standard and optional Turbovisory instrumentation philosophy for BFP
Turbine
36 Bidder's standard Instruments Data sheets for Steam turbine and Generator
37 Bidder's standard Instruments Data sheets for Skid mounted instruments
38 Bidder's standard Control Valve Data sheets
39 Details on Turbine stress evaluation, Turbine Stress Controller and Residual Life
computation
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11.01.00 Hardware documentation
Detailed technical literature, reference manuals, users guide/manuals for the complete
hardware like control system hardware, MMIPIS hardware, I/O hardware, bulk memory units,
peripherals and their controllers, communication hardware including controllers, man-
machine interfaces programmers unit, power supply modules etc., shall be furnished by the
Bidder.
11.02.00 Operation and Maintenance manuals
The operation and maintenance manuals shall include all information required for trouble
shooting, repair and maintenance information regarding all equipments furnished for the
completeness of the system. For details refer the GTR.
11.03.00 Software Documentation And Software Listings
11.03.01 All technical manuals, reference manuals, users guide etc., in English required for
modification/editing/addition/deletion of features in the software of the DDCMIS shall be
furnished. The Bidder shall furnish a comprehensive list of all system/application software
documentation after system finalisation for Employers review and approval.
11.03.02 The project specific application implementation (softwares files) shall be handed over by the
Bidder to the employer.
12.00.00 TRAINING
12.01.00 Contractor will be responsible for providing training to Employer's personnel on offered
systems at Contractors Works/Contractors Associates Works. It shall include training
operators in the use of system, in the programming and hardware maintenance of the
equipment to the extent that the Employer's personnel can make corrections and changes to
the systems programs and maintains the system's hardware. For exact details and duration
of training, refer to Part-C, Sub-Section-VI of specification.
12.01.01 The maintenance and operator training shall include lectures and hands on experience on a
similar type of equipment/system at manufacturers works and site and/or Training Simulator.
The details of hardware and software training shall be as finalised during detailed
engineering and shall be subject to Employers approval.
13.00.00 WARRANTY
13.01.00 The Bidder shall provide an unlimited warranty on all equipment and software during the
Defect liability period. This warranty shall include repair, replacement or correction of
identified software or hardware discrepancies at no cost to Employer.
13.02.00 No repairs/replacement shall normally be carried out by the Employer when the plant is
under the supervision of Bidder's supervisory engineers. If in the event of any emergency in
the judgment of employer, delay could cause serious loss or damage, repairs may be made
by the employer or a third party chosen by the employer without advance notice to the bidder
and the cost of work shall be paid by the bidder.
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13.03.00 The Bidder shall provide warranty spares and an exhaustive list of warranty spares including
components for system hardware and instrumentation and peripherals based on (and
keeping adequate margin over) normally experienced failure rate shall be submitted by the
Bidder for Employer's review regarding adequacy of the same. The Bidder must furnish the
list before inviting Employers personnel for ATS test. The warranty spares as per the list
mentioned above will be dispatched by the Bidder along with the main equipment
consignment. The Bidder shall also provide expandable items for the warranty period. This
shall include printer ribbon, ink/toner cartridge print head etc. Excluding floppy disk, M.O.
Disk, tape cartridge and paper. Unused spare/consumable shall be contractors property and
taken back.
13.04.00 In case of any hardware failure which hampers normal operation, the Bidder during the
warranty period must provide on-site technical expertise to repair/rectify the problem within a
week and if any component is not available at site, the Bidder must arrange to supply these
components at site within additional 48 hours. If a software problem is identified, this problem
shall be corrected within two weeks.
13.05.00 After six months of DDCMIS operation the Bidder shall provide the list of parts and
expendables utilized for the period. The same information will be provided at the conclusion
of the warranty.
13.06.00 In order to discharge the warranty responsibility, the bidder shall include in his proposal lump
sum price for the provisions of a team of service personnel at Site who will be fully qualified
to perform the required duties throughout the warranty period of one year. The Bidder shall
deploy at least one engineer, one supervisor and two technicians in the team. The Employer
shall approve the exact nos. & composition of team members. In case, the team is unable to
rectify hardware or software problems, the Bidder shall depute and/or station additional
specialist to rectify the problem to ensure 99.7% availability of system. The availability of the
system shall be calculated as defined below.
(a.) To established the availabilty of the system at 99.7 % following
measurment methodology will be adopted
Down-time shall start upon loss of a system function and shall end upon full
restoration of the affected system function. A minimum of one hour's down
time shall be charged for each loss of availability in determining system availability.
The following % weigthage is assigned to each of the following
Function/Event Weight
age
Hours of
Down time
1

Total
Unit Trip attributed to offered TG
DDCMIS
1.0
Loss of generation but not unit Trip
attributed to offeered TG DDCMIS
0.5
Loss of Total HMI 0.5
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Failure of one of the paired
redundant Controllers
0.1
Failure of one of the paired
communication buses
0.1
Failure of one of the redundant HMI
Server/Historian
0.1
Note :-1) The Hours of Down time shall be as actually recorded at site till
the DDCMIS system is restored back
If availability is lost due to reasons not attributed to the Contractor /
Contractors system or due to force majeure, then downtime shall not accrue.
(b.) While establishing the availability during warranty/AMC period if there is any shortfall,
the bidder shall carry out the required modification. if shortfall and availability is till
observed despite the modifications carried out by the bidder, the issue will be further
discussed for an amicable settlement.
14.00.00 ANNUAL MAINTENANCE CONTRACT (AMC)
14.01.00 The Bidder shall provide maintenance services of complete DDCMIS System under a
comprehensive Annual Maintenance Contract (AMC) for period of Three years after Warranty
period. Employer shall have the option to not renew the AMC after end each year for first two
years after giving a notice of one month.
14.02.00 The AMC shall cover total maintenance of all hardware & software coming under the scope
of DDCMIS and shall include free repair/replacement of all cards/modules/peripherals/
cables/components etc., correction of software problems and supply of expendable items.
The Bidder shall ensure 99.7% availability of the system with the AMC. The availability of the
system shall be calculated as defined under warranty sub classes. For the AMC the Bidder
may maintain adequate no. of staff at site as per his own assessment if considered
necessary to ensure availability.
14.03.00 Further, Bidder may note that during the AMC he will be allowed to use Employer's
mandatory spares and has to replenish the same within three months time or before
completion of AMC period whichever is earlier. However, if in the opinion of the Bidder, more
spares than those included in the mandatory spare list are required to meet the availability
requirement, then Bidder shall stock the same.
14.04.00 The Bidder shall prepare detailed list of faults corrected and parts, expendables utilised
during AMC period and shall furnish the same to Employer, properly documented at the end
of AMC period. Further, during AMC period the details as required by Employer/ Project
Manager shall be made available by Bidder's personnel.

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15.00.00 REMOTE SERVICE CENTRE
Bidder shall provide the necessary hardware & software required for connecting the DDCMIS
system to Bidder's remote service centre, through which the diagnostics & fault analysis of
the DDCMIS system can be carried out. This shall include the control system and unit HMI,
however the diagnostics of bought out items like LVS. LAN switches, master & slave clock
etc are excluded. 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 plant's DDCMIS
system. The fixed charges & running cost till warranty period shall be included in the Quoted
Price. The running cost thereafter shall be included in the AMC price. How-ever employer will
obtain the initial ISDN connection and hand over the same to the Bidder as per extant laws.

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III-C-02

DISTRIBUTED DIGITAL CONTROL,
MONITORING & INFORMATON SYSTEM
(DDCMIS)

ANNEXURE III-C-02G

HMI-HARDWARE
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1.00.00 Requirements for HMI Hardware (Refer sub section- scope of supply &
services for applicability of this annexure)
1.01.00 HMIPIS Hardware
1.01.01 The HMIPIS as specified shall be based on latest state of the art Workstations and
Servers and technology suitable for industrial application & power plant environment.
Two possible alternatives for HMIPIS can be offered by the Contractor as indicated
in Drawing No. 0000-110 -POI-A-011and 0000-110-POI-A-012.
1.01.02 The actual size of the Main and Bulk Memory shall be sufficient to meet the
functional and parametric requirements as specified under ATST.
1.01.03 The Workstation/Servers employed for HMIPIS implementation shall be based on
industry standard hardware and software which will ensure easy connectivity with
other systems and portability of Employer developed and third party software.
1.01.04 NOT USED
1.01.05 NOT USED.
1.01.06 NOT USED.
1.01.07 Servers/Workstations
SI
No.
Features Servers (HMI Alt. I)/
Workstations for Information
functions (HMI Alt. II) /
Information Work Station/
Operator workstations/
Other workstations

1. Processor As recommended by OEM
as per standard design
As recommended by OEM
2. Memory As recommended by OEM
3. Hard Disk As recommended by OEM
4. Monitor (color) Min 20 TFT Flat Monitor Min 20 TFT Flat Monitor
5. RAID As recommended by OEM
as per standard design(if
applicable)

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6. Redundant hot
swappable
power-supply
applicable)
-

7. Removable
bulk storage
drive (DVD /
DAT)

8. Removable
Bulk Storage
Media for
above (with
each server/
work-station)
10 nos

9. DVD R/W As recommended by OEM
applicable)
applicable)
10. Intelligent
UPS (on line)
with remote
monitoring for
each work-
station/ server
1 no. with 30 mins. Battery
backup on machine load

11. Keyboard ASCII ASCII
12. Pointing
Device
Mouse Mouse
13 Accessories NOT APPLIBABLE NOT APPLIBABLE
14. Additional
general
purpose
software (for
using over
network by
servers/workst
ations/PCs)
Comprehensive disk
maintenance utility for disk
clean sweep/ crash
guard/antivirus, etc. (like
"Norton System Works
2007")

The mouse/keyboard/monitor shall have extra length of cable depending on the
location of CPU rack (normally placed behind LVS panel).
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1.01.08 Large Video Screen (LVS)(IF APPLICABLE)

Two no Large Video Screen (if included in the the present scope of work) for TG
C&I System complete with projectors, screens & associated accessories
1. Size (diagonal) 65 inch 70 inch
2. Type LCD Projection type with rear - screen
configuration (other type proven technology eg.
that based on digital light processing shall also be
acceptable subject to Employer approval)
3. Resolution of each
screen
1400 x 1050 pixels
4. Configuration of
LVS
Double tier with screens seamlessly combined
with provision of expansion of one screen on
each side.
5. Control Unit /
Graphical
generator

Same as operator work station without the TFT
LCD monitor. To be provided by the TG-C&I
Vendor.
Facility of projecting a particular display on a
selectable area of the screen upon activation of a
predefined event shall be provided.
6. . Interfacing with Video signals, to receive & project
pictures from any Live camera, CCTV etc.I
Signal types : PAL, NTSC or SECAM in S-
VHS/VHS,
No. of input channels : 16

Video signal
interface
Remote unit for switching between video signal &
HMI signal, selecting the video signal channel
(live camera no./location typically) shall be
provided.
7. Lamp redundancy
Redundant lamp configuration with
auto switching in case of failure of one lamp.

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8. The hardware/software of the control unit shall be
such that the command execution time of any
control command from the LVS shall be same or
better than the execution time from the OWS as
stipulated under 'Guarantee under category-III,
Sub-section-V, Part-A, Section-VI of
specifications. If during any stage of the contract,
the command response times as stated in
specifications are not achieved, the contractor
shall upgrade the hardware/software of the
control unit in order to achieve the same at no
extra cost to the Employer.
9.
The control unit shall interface with the unit LAN
of the HMIPIS. The control units shall have dual
Ethernet connection with the respective Unit
LANs and shall be located in the LVS panel.
Some of these LVS, though under the
Contractor's scope, can be interfaced with other
HMIs. The exact allocation of the LVS screens to
workstations ( of this package or other packages)
is defined in Sub-section-II Part-A ( Scope of
Supply & Services).
Suitable facility shall be provided to the operator
for transferring the screens, without any need of
changing of hardware/wiring or software.
10.
Master control unit shall be capable of projecting
HMI displays over a part of screen to multiple
screens. Any communication of windows shall be
possible. Facility for overlays shall be provided.
1.01.09 Graphical Interface Unit
Minimum specifications of Graphical Interface unit shall be as follows:-
Sl no. Features Description
1. Power supply 230 V AC
2. Display Size 10-11
3. Display Type Color,TFT screens
4. Humidity 5-95%
5. Protection class IP-65 for extremely dust prone area,
otherwise IP-55. Enclosure shall be
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provided to prevent ingress of dust.
6 Keys Function keys and numeric
keys
7 Interfacing requirements Interface with respective control
systems
8 Functional requirements Ability to operate drives locally using
function keys.
Ability to do programming.
Graphics display including alarms and
operator guidance messages.
1.01.10 Printers
Sr.
No
Features Colour Laser Printer Colour Laser Printer
1 Paper Size A3 A4
6 ppm (Color) 4 ppm (color) 2 Printing
Speed
(min.)- in
normal mode
for A4 size
paper
24 ppm (B&W) 16 ppm (B&W)
3 Type Heavy duty, at least 50000
pages/month
Heavy duty, at least 30000
pages/month
4 Resolution
(black) (min.)
600 dpi 600 dpi
=<1 min for color, =<1 min for color, 5 First page
out time (with
full graphic
display)
<45 sec for BW <45 sec for BW
6 Paper input
capacity
(min.)
500 sheets 500 sheets
7 Additional
features
Automatic Duplex Printing
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20 reams (A3) 8 Paper sheets
(1 ream =
500 sheets)
with each
printer
20 reams (A4)
20 reams (A4)
9 Additional
Cartridge/ton
er/ ribbon of
each type as
used in
printer with
each printer
1 1

1.01.11 Specification of PC/Lap TOP
The Specification of PC/LAP TOP shall be as per the specific requirement of
application and shall be as per OEM recommendation

1.01.12 NOT USED
1.01.13 NOT USED
1.01.14 Firewall :
Firewall appliance should facilitate multi-vendor, multi-application environment and
should support third-party products on open alliance. It should support Active-Active
configuration.
z 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
z The firewall must send log information to a separate log server via an
encrypted connection. Firewall logging must not impact firewall performance.
z Remote network access to the firewall should only be possible through the
administration interface.
z The firewall administration station must be capable of pushing firewall
security policies and configurations to individual or multiple firewalls through
a secure, encrypted connection to the firewall administration interfaces.
z Graphical User Interface (GUI) and a Command Line Interface (CLI) for
making changes to the firewall rules set should be provided. (Access to the
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firewalls via the GUI or the CLI must be through an secure encrypted
channel).
z Any changes or commands issued by an authenticated user should be
logged to a database configured on any of the machines in the LAN. The
administration station must allow for a hierarchical architecture for rules set
administration and viewing of firewall configurations Management.
Firewall should also meet the following requirements.
z The firewall must not support any unencrypted means of access to the
firewall.
z It should Monitors ALL network traffic-traffic at Firewalls (Internet and
external networks), in the DMZ and detect known threat through deep packet
inspection.
z Detects unknown threats via anomaly scanning.
z Detect unknown threats via behavior pattern to protect from zero day attacks.
z Keeps up-to-date on new threats and vulnerabilities.
1.01.15 NOT USED
1.01.16 NOT USED
1.01.17 Necessary KVM switches for controlling multiple operator work stations/LVS
workstations from single key board/mouse/video shall be supplied. These switches
are intended to be used only for keyboard multiplexing.
1.01.18 For extension of keyboard & mouse cables from PC rack to control desk, necessary
converters shall also be provided, if required. These shall be supplied on as
required basis within the quoted price.

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III-C-02

MONITORING & INFORMATON
SYSTEM
(DDCMIS)

ANNEXURE III-C-02J

SECURITY POLOCIES & PROCEDURES
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1.01.00 Security Policies/Procedures and Security Audits :
In order to enforce network security in the DDCMIS, security policies and procedures are to
be followed by the Contractor during the tenure of the Contract & by Employers site
personnel thereafter.

For checking compliance to the above security policies & procedures in DDCMIS, periodic
security audit by a certified auditor (as per CERT-IN panel) is to be arranged by the
Contractor at the time of trial operation and every year during AMC period. This shall
include vulnerability assessment of the workstations/servers of the DDCMIS.
These security policies/procedures envisages formation of an Information Security team
which shall comprise of vendors personnel deputed at site during tenure of the contract
and NTPC personnel thereafter. All the responsibilities of information security team have to
be discharged by vendors team during tenure of the contract and NTPC team thereafter.
Even though different roles have been identified for the individual members of the
information security team more than one role can be performed by the same person. It may
be noted that following policies/procedures are only the operation guidelines and advisory
steps to ensure maximum data security.
1.0 SECURITY POLICIES
1.1 Information Security Policy
1.1.1 Information Security Team Policy
Objecti ve
To manage information security within DDCMIS network and define the roles and
responsibilities of individuals for maintaining the security of DDCMIS information and
information processing facilities.
Information Security must be given high priority in DDCMIS network. An Information
Security Team must be established to initiate and control the implementation of
information security within DDCMIS.
Scope
This policy applies to DDCMIS network and to the users who are using this network.
Justification
The existence of an Information Security Team helps ensure clear direction and visible
management support for security initiatives taken within DDCMIS. Most of the Information
Security breaches can be traced back to non-technical, process related reasons. Such
incidents are entirely preventable; many are simple accidents or the results of ignorance
while risks are being taken. A management framework helps in increasing user awareness
on information security to achieve and constantly improve information security across
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DDCMIS. Roles and responsibilities for individuals must be defined. Without any assignment
of responsibilities, policy implementation and enforcement will often be ignored.
1.1.2 Firewall Policy
Objecti ve
To control the connections to DDCMIS from other networks and secure network access to
DDCMIS from unauthorized use.
Wherever firewall is provided, changes to firewall configuration and policies must be
controlled and authorized.
Scope
Justification
Firewall is the major defense for an organizations network Any breach at the firewall level,
compromises the information security of the DDCMIS. Firewalls can be complex and tricky to
manage and security incidents can occur. To reduce the complexity and management of the
firewall and also to provide adequate protection for the network, the deployment of the
firewall has to be done carefully and should be properly supported by a suitable policy.
1.1.3 Information Identification and Classification Policy
Objecti ve
To identify all the assets in the DDCMIS Network and to classify the information assets
based on the importance, sensitivity and criticality of the information.
An inventory of all assets of DDCMIS must be created and maintained. An owner must
be designated to all the identified assests. All information assets must be classified as
per the approved Information Classification Scheme.
Scope
Justification
To protect assets and information from threats like theft, sabotage or damage, inventory of all
IT assets needs to be created and maintained. Once the assets are identified, Accountability
for these assets is also important from the information security point of view, hence the
owner for all the assets has to be identified. All information will not have the same criticality /
sensitivity value. Information classification helps in deciding the importance of the information
and the appropriate level of protection needed by it.

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1.1.4 Security Policy Review Policy
Objecti ve
To ensure that the Information Security Policy is effective and is in line with the changes in
DDCMIS's information security needs.
Information Security Policy must be reviewed periodically to ensure its continuing
suitability, adequacy and effectiveness.
Scope
Justification
In order to ensure that any changes to the processes as well as the supporting infrastructure
of DDCMIS are reflected in the Information Security Policy, the Policy must be reviewed
periodically. This helps in identifying the gaps between the current practices and the policy
and also to ensure its continuing suitability, adequacy and effectiveness.
1.1.5 Information Labeling and Handling Policy
Objecti ve
To protect information and information processing facilities from unauthorized access or
misuse.
Procedures must be defined for information labeling and handling in accordance with
the classification scheme adopted.
Scope
Justification
Information assets need to be labelled and stored by following a standard procedure.
Confidential information, which is not labelled correctly, transported securely or destroyed
securely, could lead to disclouser of information to unauthorised people, resulting in loss /
damage of information. Inappropriate labelling and storage (physical or electronic) of
information could result in loss or disclosure of information. If a consistent information
labelling and handling procedure is not introduced, then this could result in a lack of control
and misunderstanding of access controls.
1.1.6 System Planning and Acceptance Policy
Objecti ve
To minimize the risk of system failures.
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Acceptance criteria for new information systems, upgrades and new versions shall be
established and suitable tests of the system(s) shall be carried out prior to
acceptance.
Scope
Justification
Acceptance criteria, tests to validate the criteria should be defined for all Information
systems. Advance system planning is required to ensure the availability and the operational
efficiency of the proposed system design.
1.1.7 Media Handling Policy
Objecti ve
To prevent unauthorised use of computer media, and unauthorised disclosure of classified
information.
Appropriate procedures must be established to protect media from misuse and usage
must be monitored to discourage theft and improper use.
Scope
Justification
Removable media may contain business critical and confidential information. Unauthorised
use and / or improper disposal of media may compromise confidentiality of the information.
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1.1.8 Change Control Policy
Objecti ve
To ensure that changes to information, information processes, systems and support activities
are conducted in a systematic and secure manner.
Formal change control procedures must be followed for all changes to information
systems and networking environments.
Scope
Justification
Any changes to Information systems environment can result in information security
weaknesses that could be exploited to gain unauthorised access or misuse of information
systems. If Change control procedures are not implemented, it will be very difficult to manage
changes on a priority basis. The changes in information processing facilities and systems
introduce risk. The risks associated with such changes must be identified, evaluated and
necessary measures must be taken to manage those risks.
1.1.9 Anti Virus Policy
Objecti ve
To prevent unauthorized network intrusion through malicious software / viruses and to protect
the integrity, confidentiality and availability of software and information.
Systems and application software, networks and communication systems must be
configured and safeguarded against malicious code/viruses.
Scope
Justification
Software and information processing facilities are vulnerable to the introduction of malicious
code such as computer viruses, network worms, Trojan Horses and logic bombs. Controls
are required to prevent and detect the introduction of malicious code and to safeguard the
confidentiality, integrity and availability of information.
1.1.10 System Access Policy
Objecti ve
To ensure that unauthorized access to computer resources is prevented.
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Formal procedures shall be in place to restrict access to systems to authorized users
only.
Scope
Justification
Access to information and business processes should be controlled on the basis of business
and security requirements. Lack of adequate access controls leads to abuse of information
resources resulting in critical loss or corruption of data. Similarly, the access lists for the
Networks, Operating Systems and Application Systems should be reviewed periodically to
reduce the risks.
1.1.11 Incident Handling Policy
Objecti ve
To minimize the damage from security incidents and malfunctions, and to monitor and learn
from such incidents
Formal event reporting and escalation procedures shall be established. User shall be
made aware of the reporting procedures and all security incidents must be managed
quickly and effectively.
Scope
Justification
An Information Security incident can be defined as any occurrence which by itself may not
necessarily compromise Information Security, but could result in it being compromised. An
employee may not report an Information Security incident because there are no procedures
in place to do so, resulting in a chain of events that lead to information systems being
compromised. Any breaches to Information Security should result in immediate disciplinary
action depending upon severity of the incident, loss incurred, interruption faced for its critical
business processes and disclosure of any confidential information.
1.1.12 Information Backup and Restoration Policy
Objecti ve
To maintain the integrity and availability of information processing and communication
services.
Formal procedures should be in place for identifying critical information and software
for taking, storing and testing backups. Frequency of back-ups for high-risk systems
must be set at such a value that systems can be made available within an acceptable
amount of delay.
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Scope
Justification
Information back up is important to ensure that information system restarts successfully after
a voluntary or enforced close down. Interruption to normal processing due to corruption or
loss of data / information can be rectified, if proper Information Back-up is available.
1.1.13 Network Access Policy
Objecti ve
To control access to networked services, network devices (Routers / Switches) and to ensure
the safeguarding of information in networks.
Access to and usage of networked services must be controlled and restricted unless
explicitly authorized. Controls must be implemented to achieve and maintain security
of information in networks.
Scope
Justification
The connections to the network have to be properly managed to ensure that only authorized
devices / users are connected. This is necessary to ensure that users who have access to
networks and network services do not compromise the security of these networked services.
Inadequate network security management can jeopardize the confidentiality, integrity and
availability of data / information.
1.1.14 User Access Management Policy
Objecti ve
To ensure that access rights to information assets and supporting information technology
resources are appropriately authorized, allocated and maintained.
User access to information assets and supporting Information resources must be
controlled. The normal and privilege access given to users must be recorded and
reviewed periodically.
Scope

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Justification
Inappropriate use of system privileges is often found to be a major contributory factor to the
failure of systems that have been breached. Formal procedures for User Access
Management of information systems should be implemented for tight security controls and
to identify breaches of Access Controls.
1.2 Procedures
1.2.1 Information Security Team Policy
To guide the entire information security effort, an Information Security Team is
formed at the DDCMIS Network level. The team of NTPC personnel shall comprise
of the following as members:
o Head of Department (C & I) Chairman
o Information Security Manager (ISM) - Vice Chairman
o Information Security Coordinator - Member
o System Administrator Member
o Network Administrator Member
o Database Administrator - Member
The Head of Department (C & I) will identify the appropriate persons for the
Information Security Team and get the approval from Head of the Project.
The Information Security Team will be responsible for the following:
o Own the responsibility of inculcating security within DDCMIS.
o Plan major security initiatives within DDCMIS.
o Monitor the implementation of information security controls.
o Draw up an annual Audit Plan and undertake regular audits by internal /
external auditors.
o Review the Security Audit Reports and make a plan to close all gaps
identified.
o Meet quarterly to discuss implementation of information security initiatives
and incidents within DDCMIS.
o Arrange for review of information security policy and procedures. This review
should take place as per Information Security Policy Review Policy.
o
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The detailed structure of the Information Security Team is as follows:

Coordination among the Information security Team is required for the effective
implementation of information security controls. The specific responsibilities of the
Information Security Team in this regard are as follows:
o Identifying and agreeing to the roles and responsibilities of each member in
the implementation of information security controls.
o Identifying the need for security within their areas.
o Agreeing to the major information security methodologies (Risk Assessment,
Information classification, Incident Handling, change control etc.) and
programmes (Training and Awareness) being adopted in DDCMIS.
o Implementing the policies in DDCMIS and making end-users aware of the
security initiatives taken.
The Chairman of the Information Security Team has the overall responsibility for
Information Systems Security in DDCMIS. He will be assisted by a team that is
responsible for the implementation and monitoring of Information Security activities in
DDCMIS. The responsibilities of the Chairman - Information Security Team include
the following:
o Ensure co-ordination and co-operation among the Team members.
o Monitor the implementation of information security awareness / training
programme to ensure that the employees and the related third parties are
aware of and observe their respective responsibilities for the maintenance of
information security in DDCMIS.
Chairman
Head of Department
(C&I)
Information
Security Manager
Information Security
Coordinator
System
Administrator
Network
Administrator
Database
Administrator
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o Ensure preparation of comprehensive written plans and procedures for
business continuity following disasters.
o Identify the procedures and the processes for addressing exceptions or
deviations from the information security policy document.
o Prepare and enforce internal / external audit programme to ensure
compliance with the Information Security Policy on a continuous basis and
o Ensure the review, update and upgrade of Information Security Policy in the
light of new threats and changes in IT infrastructure on a continuous basis.
The responsibilities of the Information Security Manager include the following:
o Manage the overall Information Security Programme in DDCMIS.
o Be responsible for maintaining the Information Security Policy and
procedures for use in DDCMIS. These documents will be kept up-to-date,
reflecting changes in technology, business direction and potential threats.
o Ensure that, when exceptions to the Information Security Policy are
necessitated, the risk acceptance process is completed and the exceptions
are reviewed and re-assessed periodically.
o Keep abreast of the latest threats against the information assets and the
developments in the field of information security.
o Assist in the formulation of the managements response to the audit findings
and follow-up to ensure that the security controls and procedures, as
required, are implemented within the stipulated time frame.
o Co-ordinate or assist in the investigation of security threats or other attacks
on the information assets.
o Approve all information security related operations at the administrative level
duly complying with the Information Security Policy.
o Assume responsibility or assist in the preparation and distribution of an
appropriate warning system of potentially serious and imminent threats to s
DDCMIS information assets for example outbreak of computer virus etc.
o Assist in the recovery of information and information assets from such
attacks.
o Identify individuals responsible for the protection of information and
information assets at DDCMIS.
o Define realistic business need-to-know or need-to-restrict criteria to
implement and maintain appropriate access controls and identify and obtain
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The responsibilities of the Information Security Coordinator are as follows:
o Ensure classification of information assets is as per the defined
Classification criteria, and specify the appropriate levels of security for each
class of information assets.
o Assist the users in the development of specific procedures that meet the
Information Security Policy for specific products /applications within the
DDCMIS Network.
o Review audit reports dealing with the information security issues and ensure
that they are placed before the Information Security Team.
o Understand, support and abide by DDCMIS Information Security Policy and
Procedures.
o Ensure that the employees and the related third parties working in DDCMIS
understand, support and abide by the Information Systems Security Policy
and Procedures.
o Create a positive atmosphere that encourages employees and the third
parties working in DDCMIS to report information systems security concerns
/ incidents to the Information Security Coordinator immediately.
o Escalate any information security related issues / incidents to the Information
Security Manager.
o Participate in the information systems security communication and
awareness programme.
o Consolidate the monthly status reports about the information systems
security concerns / problems received from teams under his control and
send it to the Information Security Manager.
o Ensure that information systems security reviews are undertaken, whenever
required. The circumstances that should trigger such a review illustratively
include the following:
Significant loss from a security failure
Purchase or upgrade of computer systems, either hardware or
software, or both
Discovery of a threat
The Administrators will take responsibility for the implementation of all applicable
controls at their respective areas and also their maintenance on a day-to-day basis.
o The System Administrator will be in-charge of the security of all the systems
in DDCMIS.
o The Database Administrator will be in-charge of the security of all the
databases in DDCMIS.
o The Network Administrator will be in-charge of the security of all the network
and communications in DDCMIS.
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Information Security Manager, in consultation with the Chairman of the Information
Security Team is responsible for arranging internal or external specialists advice on
information security issues. These advices should be considered as a means to:
o Improve knowledge about the best practices and staying up to date with
relevant security information
o Share and exchange information about new technologies, products, threats
or vulnerabilities
o Ensure the understanding of the information security environment is current
and complete
Information Security Manager will ensure that cooperation with all organizations
including ISPs, regulatory bodies, and law enforcement agencies required for
business purpose will be maintained.
1.2.2 Firewall Policy
Chairman in consultation with the Information Security Team will identify the
requirements of Firewalls and also will identify all the un-trusted networks to
DDCMIS.
Network Administrator will ensure that the firewall will deny all in-bound and out-
bound traffic unless specifically permitted. Only authorized traffic, as approved by
Information Security Manager, will be allowed to pass through the firewall.
Information Security Manager (ISM) will ensure that the firewall rule sets are
regularly audited and monitored to detect misuse.
Network Administrator will analyze the Firewall logs. The firewall shall be configured
to log all reports on daily, weekly and monthly basis.
The Network Administrator will ensure that each new release of the firewall software
will be evaluated to determine if an upgrade is required. All security patches
recommended by the firewall vendor will be implemented in a timely manner.
Any modification of the firewall system software will be done by the Network
Administrator in the presence of Information Security Coordinator and requires
approval of the Information Security Manager.
All changes to the firewall (including configuration, upgrades, rules) will follow the
Change Control policy.
In case of a firewall break-in, Network Administrator is responsible for reconfiguring
the firewall to address any vulnerability that was exploited. The firewall will be
restored to the state it was before the break-in so that the network is not left wide
open.
Network Administrator will ensure that the firewall rule set will block the following
types of traffic:
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o Inbound or outbound traffic from a system using a source address that falls
within the address ranges reserved for private networks.
o Inbound traffic containing IP Source Routing information.
o Inbound traffic from a non-authenticated source system containing SNMP
traffic.
Network Administrator will ensure that all permit rules should be both IP address
and TCP/UDP port (service / application) specific.
Network Administrator will ensure that all rules restrict traffic to specific IP address or
range of addresses.
Network Administrator will ensure that all traffic on the DDCMIS is typically based
only on routable IP protocols, either TCP/IP or UDP/IP. Thus any non-IP protocol
should be dropped.
1.2.3 Information Identification and Classification Policy
Information Security Manager will ensure that all the IT assets of DDCMIS are
identified, entered in the asset register and maintained.
Information Security Coordinator with the help of other Information Security Team
members will prepare an Asset Register which includes all the IT assets (data and
systems).
Information Security Coordinator will ensure that all IT assets (data and systems)
have an appointed owner who makes decisions about classification and access
rights
The Information Security Manager will be the custodian of the Asset Register and will
be responsible for maintaining and co-coordinating any changes in it. The
Information Security Coordinator will be the owner of the Asset Register.
The asset register will have a the following information:
o Asset Name
o Asset / Tag Number (only for IT Equipment Assets)
o Asset Category
o Description of the Asset
o Owner
o Location
o Classification
The Categories of the IT assets will be broadly classified as Electronic Information
Assets, Paper-based Information Assets, Software Assets, IT Equipment Assets and
Support Services Assets. Some examples are:
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o Electronic Information Assets: network diagrams, configuration files,
parameter files
o Paper based Information Assets: Printed documents, contracts
o Software Assets: Operating system software, Applications ( Office software)
o IT Equipment Assets: Monitors, CPUs, Printers
o Support Services Assets: AC, Power, UPS etc.
Information Security Manager will review every year the classification assigned to the
assets keeping in mind the change in the importance of the assets and business
priorities.
All the IT Equipment Assets and support service equipments will be uniquely
numbered as per the policies followed within NTPC.
The owners of the assets will be responsible for providing the details to the
Information Security Coordinator about any additions / deletions / changes in the
asset register.
The asset register will be updated as and when there are any movements in the
assets. Information Security Coordinator will ensure that the asset register is
updated.
Information in DDCMIS will be classified into three types as defined below as per the
sensitivity of the information content:
o CONFIDENTIAL
o INTERNAL
o PUBLIC
This standard Information classification scheme will be followed within DDCMIS.
These classifications are defined as follows:
o CONFIDENTIAL: This classification shall be applied to information and
material, the unauthorized disclosure of which could be expected to cause
serious damage. Ex: CLCS Tuning parameters
o INTERNAL: This classification shall be applied to information and material
which is essentially meant for internal official use only, and which should not
be published or communicated to any one except for official purposes. Ex:
data sent for ERP, all other information of the DDCMIS are internal
o PUBLIC: This classification shall be applied to information and material
which does not fall under any of the above two categories, and is essentially
meant for public view.
The Information asset owner will be responsible for the classification of Information
assets. The Information Security Coordinator will provide necessary assistance and
guidance to help classify the Information assets.
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Information owners will review the sensitivity classifications assigned to information
for which they are responsible. If necessary, Information owners will determine
whether sensitive information may be declassified or downgraded. This review will be
done every quarter. Information Security Coordinator will ensure that this review is
done by the Information Owners.
When Confidential information is involved, Information Security Manager will ensure
that a log is maintained reflecting the number of copies made, the location of copies,
the names of recipients, the addresses of recipients and any other information
required.
This log will be maintained as long as such information retains a Confidential
classification.
Information Security Manager will be the owner of this log and this log will also be
classified as confidential.
1.2.4 Security Policy Review Policy
Information Security Manager in consultation with Information Security Team will
plan for review of the Information Security Policy by either internal or external
consultants to check for its adequacy and effectiveness.
The Information Security Policy document will be reviewed when one or more of the
following conditions are satisfied:
o once a year, and
o when there are major changes in the business operations
1.2.5 Information Labeling and Handling Policy
Asset owners will ensure that the confidential, internal or public information either in
paper form or stored in removable media like tape, CD-ROM, floppy diskettes, DVD,
MOD will be externally labeled (marked) with the appropriate classification.
Asset owners will ensure that the labeling will be maintained until the paper /
removable media is destroyed or information is declassified.
Asset owners will ensure that in case of electronic documents, the appropriate
information classification is mentioned in the footers of the document. For PUBLIC
it is optional.
When not in use, all classified information will always be protected from unauthorized
disclosure. When left in an unattended room, such information will be stored in
locked away in appropriate containers.
Information that is classified, as Confidential will not be copied unless otherwise
required and the distribution of that information will be limited as decided by the
owner. The owner will keep track of the distribution of information by maintaining the
list of people who have been distributed a copy of that information.
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Whenever additional copies of confidential information are made, the number of
copies and recipients of these copies will be recorded in a log. Each of the recipients
will be informed that either further distribution or additional copying will take place
only after the information owner's permission has been obtained.
All waste copies of confidential information that are generated in the course of
copying, printing or otherwise handling such information will be destroyed
appropriately.
Physical media ( Hard disks, CDs, Tapes, DVD, MOD) when gone bad, should not
be sent for repair to third parties and should be properly disposed.
Whenever physical assets are disposed off, the following methods of destruction
must be used in case of removable media:
o Hard disks /Tapes degaussing / physical destruction
o Floppy Disks / CDs/DVD shredding
o Paper Documents shredding
1.2.6 System Planning and Acceptance Policy
The Information Security Manager will be responsible for the acceptance of any new
system, upgrades and new versions. Information Security Manager will ensure that
a complete system test is carried out to check for the following:
o Capacity Requirement and Performance
o Ease of use
o Agreed set of security controls are in place
Effect of the new system on the existing systems and overall
security of the DDCMIS
Check to see that installation of the new system will not adversely
affect existing systems, particularly at peak processing times.
o Training and Change Management in the operation or use of the system
o Business continuity arrangements
Acceptance criteria for new information systems, for upgrades and for new versions,
and to carry out appropriate tests prior to acceptance should be established. The key
requirement must be that the acceptance criteria for new systems should be clearly
identified, agreed and documented. The following are some of the controls:
o Computer performance and capacity requirements should be assessed and
taken into account in planning a roll-out.
o Revisions to, or establishment of new, error recovery and restart
programmes may be required.
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o Routine operating procedures will have to be (re)drafted and tested to
ensure that they are adequate.
o Appropriate new security controls will have to be put in place, consequent
upon a risk assessment, for the new software system, of all aspects of the
security arrangements upon which it impacts.
o New user manuals and documented operating instructions may be required.
o New business continuity requirements may have to be dealt with.
o The impact on other software systems and processes should be considered
and evidence sought that it will not adversely affect the running of existing
systems,
o Consideration should be given, in the risk assessment, to the possible effect
that the new system may have on the overall security of the organization.
o Users should be trained in the use of the new system and the impact that it
will have on their current working practices.
For information systems which process huge volumes of data, the Information
Security Coordinator will ensure that the processing speeds of the systems are
tested on load.
The Information Security Manager will ensure that the security requirements have
been properly addressed in the new system and will certify the system.
An information system will be moved into operational environment only after the
environment has been hardened. System Administrator will perform the Operating
System hardening (latest OS Patches, latest anti-virus, removing default
configurations, removing unnecessary services and applications) and configure the
security requirement settings as per the vendors specification.
1.2.7 Media Handling Policy
Approvals from the Information Security Manager will be taken for any management
of removable computer media, such as tapes, disks, cassettes and printed reports.
The following controls will be implemented for the management of removable
computer media:
o Computer media will be stored in safe and secure environment both offsite
and within the premises in accordance with the manufacturers
specifications.
o Data on re-usable computer media to be removed from NTPC premises will
be erased if it is not required.
o The Information Security Manager will approve removal of media from NTPC
premises.
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o When classified information is written to a removable storage media, the
media will be suitably marked with the highest relevant classification. Unless
encrypted, when not in use, this media will be stored in locked cabinets.
When the storage media such as floppy disks, CD-ROMs, Hard disks, Tapes, DVDs.
MODs etc. containing classified information become defective, they will be physically
shredded / destroyed so that they cannot be reused.
The following procedure will be followed for secure disposal of media:
o The Information Security Coordinator concerned will verify and approve the
media to be disposed.
o The Information Security Coordinator will verify the removal of data from the
media to be disposed.
o The Information Security Coordinator will maintain a record of all disposed
media to maintain an audit trail.
The following disposal processes will be used for different types of media:
o Paper documents: Shredders will be used to dispose paper documents
o Magnetic Tapes: Degaussing method will be used to erase data on
magnetic tapes. Alternatively, the magnetic tapes will be physically
destroyed.
o Removable disks and cassettes: - Degaussing method will be used to erase
data on removable disks. Alternatively, the removable disks shall be
physically destroyed.
o CD-ROMs/DVDs: - The CD-ROMs/DVDs will be shredded.
The following controls will be implemented to ensure security of system
documentation:
o The information security coordinator will ensure that the system
documentation is stored securely.
o The Network Administrator will maintain network and security devices
configuration details, network design.
o The System Administrator concerned will maintain server configuration
details and operational procedures.
o Backup of all system documentation in electronic form will be taken on
removable storage media.
Access to system documentation will be restricted and minimized, and will require
approval from the owner of the system and authorization from the Information
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1.2.8 Change Control Policy
All changes to IT infrastructure including servers, workstations, network devices and
security devices of DDCMIS will be managed and controlled.
The Information Security Team will be responsible for effectively managing the
changes to application environment, hardware and system software environment in
DDCMIS.
Before implementing any change to the systems the following shall be considered
o impact of the change will be assessed
o Changes will be done in a systematic manner so that it will not hamper the
security of the existing systems / network
o Back out plan for recovering from unsuccessful changes will be developed
o All changes shall be tested in test environment before applying the changes
on production environment.
o Proper approval process shall be in place.
Information Security Coordinator will ensure that, before applying changes to the
servers, these changes will be tested on a test server.
Where feasible, the testing of application software should take place in test
environment that is separate from development and production environments.
Changes to operational software will not be carried out directly on operational (or
live) system.
The Information Security Manager will ensure that the changes introduced are
documented in detail and proper version control procedures are followed.
The Administrator responsible for the implementation of the change will inform all the
parties / users concerned of the implemented change.
Appropriate fallback arrangement and disaster management procedures shall be
followed if the change fails. The procedures will depend on the severity of failure.
Implementation of changes will be carried out at a suitable time so as to minimize
business disruption.
The Information Security Coordinator will ensure that User procedures / manuals,
System documentation, Operational instructions shall be updated or written to reflect
the changes carried out.
The Information Security Manager will ensure that Procedures identifying
responsibilities for aborting and recovering from unsuccessful changes are in place.
The Information Security Manager will ensure that Change Request meetings are
conducted regularly. The meeting will focus on clearing pending CRs and deciding a
strategy for upcoming change requests.
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1.2.9 Anti Virus Policy
All systems within DDCMIS will be preloaded with Antivirus software.
System Administrator will ensure that Anti-Virus software is installed and
continuously updated on all systems.
Random checks will be undertaken by the Information Security Coordinator to ensure
that the virus definitions and updates are updated regularly on all systems.
System Administrator will ensure that Antivirus software will have Real-Time
Scanning option enabled on all systems.
System Administrator will monitor for the symptoms of existence of virus and notify
the Information Security Team about any symptoms of existence of virus observed /
affected. Virus prevention largely depends on virus awareness among users.
The following are some basic practices, techniques and guidelines that each user of
DDCMIS should follow to help prevent / mitigate virus attacks are:
o Scan new software for viruses
o Use only authorized and licensed software
o Do not share or copy software unauthorizedly
o Scan for viruses any removable media brought from outside
o Scan the systems for viruses regularly
o Obtain prior approval from Information Security manager before using
shareware, freeware and open-source software.
Employees will not intentionally write, generate, compile, copy, collect, propagate,
execute, or attempt to introduce any computer code designed to self-replicate,
damage, or otherwise hinder the performance of or access to DDCMISs computer,
network, or information.
1.2.10 System Access Policy
Secure terminal log on will follow procedures as given below:
o System administrators will ensure that a secure log on procedure to any
application / system will have the following:
Log on procedure will not display system / application identifiers until
the log on process is successfully completed
There will be no help messages provided during the log on
procedure
The log on information is validated only on completion of all input
data
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There will be no indication or specific error message to ensure that
the exact part of the wrong input is not disclosed. Example, Please
verify the username and password entered and not Please verify
the password entered.
Where operating system supports, date and time of last successful
log on is displayed, after the current successful log on.
Passwords are not transmitted in clear text over the network.
User Identification and Authentication plays major role in tracing any activity of the
individual user. System administrator will ensure that:
o All the activity performed by any user is traced and tracked on the basis of
user id.
o A suitable authentication mechanism is implemented to authenticate the
users access.
o Where ever possible, Administrator accounts are renamed to something less
obvious or obscure IDs.
o Guest / Anonymous accounts from all the systems are disabled.
o Proper auditing is enabled for the purpose of audit trail.
System Administrators will be responsible for the administrator accounts on the
servers and workstations.
The System Administrator will modify the settings on the servers and workstations
respectively such that after 2 minutes of inactivity the servers and workstations will
lockout automatically (This is not applicable to the operator desk PCs, OWS and
CCR LVS). The following controls will be in place:
o All inactive terminals in secure areas will get locked-out after 2 minutes of
inactivity. Screen savers will be activated for this purpose.
1.2.11 Incident Handling Policy
Information Security Team will identify a list of various security incidents. This list will
be circulated to all the users of DDCMIS to make them aware of the types of
security incidents. The common security incidents include:
o Virus Attack
o Denial of Service Attack
o Unauthorized copying / disclosure of information
o Tampering
o Unauthorized modification of information
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o Malicious alteration of operating system
o Wire-tapping
o Theft of any hardware or software resource
o Attempts to gather information
o Hacking Attempt
o Natural Disasters (Flood, earthquake etc.)
o Fire
o Electrical Outages
o Network Outages
All incidents listed above will be treated as serious security incidents. The
Information Security Manager will review the above list every quarter and update the
same with any new incidents.
Information Security Manager will ensure that all users of DDCMIS are made aware
of all the security incidents as part of their security awareness training. Sample
incidents will be used in user awareness training as examples of what could happen,
how to respond to such incidents, and how to avoid them in the future.
All users of DDCMIS will report any security incident to Information Security Team.
The incident response procedure will be as follows:
o When a user encounters a security incident, he will immediately report the
incident to Information security team.
o The incidents will be categorized. Based on the categorization the
Information Security manager will be responsible for escalating the incident
to the appropriate level.
S.No. Type of Incident To be escalated to
1 Low Risk Information Security Coordinator
2 Medium Risk Information Security Coordinator
3 High Risk Information Security Manager
If the incident is of low or medium risk, Information Security manager will direct the
Information Security Coordinator to take immediate action for the same. In case of an
emergency or a serious security breach (High Risk incidents) Information Security
Manager will take necessary decision to contain or limit the incident.
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In cases of fire, flood, power failure, break-in and theft, the concerned Department
will be informed and help from the relevant local services (eg. fire department, site
technical service, entrance control staff, security guards etc) will be taken.
Information Security manager will ensure that the incident is responded to and
appropriate preventive / corrective measures are taken to close the incident.
Information Security manager will make use of the following evidences to examine
the incident:
o Event log files
o Firewall logs
o Change of Access Control Lists (ACLs) of privileged programs
o Presence of common backdoors and sniffer programs
o Unauthorized services enabled or files installed
o Changes to password files or user account files
o Physical access logs
o Active user accounts and network connections
The following activities will be performed by the Information Security Team while
handling incidents:
o Limiting further compromise by disabling accounts or isolating the affected
system(s) from the Network.
o Backup of the compromised system to aid in a detailed analysis of the
damage and method of attack
o Analysis and identification of the cause of incident
o Collection of audit trails and similar evidence
o Communication with those affected by or involved with recovery from the
incident
o Implementing remedial measures to prevent reoccurrence of similar incident
Information Security Coordinator will investigate the whole incident and submit a
report to the Information Security Manager.
To control the risks from a security incident, the Information Security team will ensure
the following:
o Contacts with agencies like Indian Computer Emergency Response Team
(CERT-In) is established.
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o Contact list of vendors and distributors of the Information Systems is
maintained
o Contact list of vendors and distributors of security systems such as anti-virus
software, firewalls, access control systems is maintained.
o Contact list of consultants with specialist security expertise is maintained.
If the security incident is due to a security weakness, which is not already familiar,
the fact will be forwarded to appropriate parties to warn them about the security
weakness and enable them develop countermeasures. Typically, the following
parties shall be informed:
o Vendors of anti-virus software where infection by a new computer virus is
suspected but this was not detected by the virus scanner.
o Vendor of any operating system or application software within which the
security weakness was found.
The Information Security Manager will perform a post incident analysis after a
security incident has been fully handled and all systems are restored to a normal
mode of operation. He will ascertain the impact of the security incident, determine
the loss (if incident has resulted in the loss of information) and identify the
vulnerability in the system that has been exploited by the incident. He will evaluate
the existing procedures and modify them, if necessary.
Any security violation or incident committed by a user of DDCMIS will invite
disciplinary action according to NTPCs disciplinary process. In case of contractors /
third-party representatives, the action taken will depend on the terms and conditions
of the agreement / contract.
1.2.12 Information Backup and Restoration Policy
The Information Security Manager will be responsible for defining the backup
strategy. The System Administrators concerned will be responsible for implementing
the same.
The System Administrator will be responsible for scheduling regular backups of the
data.
The Information Security Coordinator will review the schedule of backups and
operator logs to ensure that the backups are proper and as per schedule.
The backup / restoration of the file system / database is done by the System
Administrator. Information Security Coordinator will be notified when a scheduled
daily / weekly backup fails.
The retention period of all the regular backups will be defined by the Information
Security Manager. System Administrator will prepare a backup planner accordingly,
keeping in mind the daily, weekly and monthly backups.
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Network Administrator will be responsible for taking the backup of configurations of
Network and Security devices. He/She will also be responsible for taking the backup
of critical logs.
Information Security Manager will ensure that all the backup media is properly
labeled and kept in a safe place under lock and key. Backup media will be tested for
correct restoration regularly (preferably once in two months) to enhance its reliability
and ensure data recovery.
Information Security Coordinator will ensure that restoration procedures are regularly
checked and tested and will be completed within the time specified in the operational
procedures for recovery. It must be ensured that safeguards are in place to protect
the integrity of data files during the recovery and restoration of data files, especially
where such files may replace more recent files.
The System Administrator will verify the backup error log after taking the backup for
any error reported. Before storing a backup tape, the System Administrator will label
it with the Date - time Server File system and other useful information like
Administrators name & signature.
1.2.13 Network Access Policy
The Information security coordinator will maintain a list of network services allowed
and shall ensure that the following controls are applied:
o Users will only be able to gain access to the services that they are
authorized to. The Network Administrator will maintain a list of users and
their access rights to various network services.
o All important network nodes will log activities. Network administrators will
analyze these logs regularly to determine security breaches. Network
administrators will send the analysis report to the Information Security
Coordinator.
o Secure Socket Layer (SSL) is enabled for data transfer over trusted or un-
trusted networks.
o Uninterrupted power supply is provided to networks to prevent loss of
service due to power fluctuations or power failures.
o Network infrastructure components are stored in secured facilities to prevent
unauthorized access.
The Information Security Manager will study the related security features before
using network services. Following are the controls for security of network services:
o Network services that are enabled but not required or not in use, are
disabled immediately to minimize possibility of unauthorized intrusion into
the network / system.
o While using network services like telnet, rlogin, rcp and rsh on the Unix
machines, The Secure Shell (SSH) technique will be used for non-secure
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network services, where possible, for securing access through these
services.
o The System Administrator responsible for Windows machines will enable
only such network services that are required for the applications running on
the O/S.
Network Administrator will ensure that Dial-back procedures and controls are in
place for connections from remote locations ( Ex. Home) to the DDCMIS network to
provide protection against unauthorized and unwanted connections. When using this
feature, it should be ensured that:
o Call forward network service is not used or disabled
o an actual disconnection on the NTPC side has occurred
Dial-back procedures and controls can be implemented by enabling the modem dial-
back facility on a remote access service. Call-back processes must only happen after
the incoming call has been disconnected, and thorough testing should be carried out
to ensure that this control actually works.
Network Administrator will ensure that Remote diagnostic ports will be closed on the
network components for usage by vendors. In the case of devices, where for
maintenance the vendor directly logs to the device, the remote diagnostic port shall
be open. In such cases, appropriate Service Level Agreements shall be maintained
and the activity will be monitored.
Information Security Coordinator will ensure that the use remote diagnostic ports
shall be controlled and all vendor provided default passwords will be changed.
In instances where the remote diagnostic port has to be opened, a formal
authorization process will be followed. The process includes:
o Request from the user to open a port.
o Recommendation from the Information Security Coordinator for opening the
port
o Approval from the Information Security Manager for opening the port
o The change control procedures will be followed for the changes taking place
in the devices.
o A log will be maintained for the same. The timestamp of the vendor log in
and log off will also be maintained.
Network Administrator will ensure that the routers, firewalls and other network and
security devices as applicable will be configured using relevant best practices (such
as Cert-In, SANS) to avoid any compromise or misuse.
The Network Administrator will keep all infrastructure diagrams up-to-date to show all
internal and external connections before allowing new connections. This will help to
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show the security, traffic and physical impact of adding a new user(s) to the LAN. All
new connections to the network will be subject to Change control Procedures.
The Network Administrator will ensure that the appropriate logon banners, warning
the users that the unauthorized access is prohibited and monitored, are displayed.
The Network Administrator will ensure that the log files are reviewed regularly for any
suspicious activity. The identified incidents are reported to the Information Security
Manager and are further investigated to diagnose the source and the reason of
attack.
The Network Administrator will prepare an Operational Procedures document and
maintain the same. The document will include:
o Network Diagram
o LAN / WAN connections
o Network Device Configurations
o Firewall Rules
o The master list of all IP Addresses in use.
1.2.14 User Access Management Policy
Information Security manager will approve for creation of a User ID for access to a
variety of services including system access, file and printer sharing etc. System
Administrator will create the user account based on the approval.
The System Administrators will make use of password management features of the
Operating Systems to the extent possible to enforce password policy.
System Administrators will ensure that the length of the password will be a minimum
of 12 characters for administrators, and a minimum of 8 characters for normal users.
Whenever a new account for a user is created, the system administrator will ensure
that the User changes his/her Password at first Log on.
Users will be responsible for maintaining the confidentiality of the password and
account, and will be fully responsible for all activities that occur under their account.
They will immediately notify the Information Security Coordinator of any unauthorized
use of their password or account or of any other breach of security.
If any user requires a privileged access, he / she will send a request to the
Information Security Manager mentioning the type of access and the period for which
the access is required. Once it is approved by the Information Security Manager, the
request goes to the System Administrator for further action.
The System Administrator will
o Give access based on the user request and approval
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o Maintain a record of all privileges allocated and the time period
o Revoke the access after completion of the time period.
The System Administrator(s) and Information Security Coordinator will review the
following points every month:
o Correctness and validity of user accounts
o access rights
o Check for the Unnecessary accounts
o Remove / block the Unnecessary accounts
Information Security Coordinator will ensure that the following activities are
performed, when a user is terminated/transferred:
o Revoking the user's authorization immediately.
o Removing all access permissions to critical/sensitive areas, such as
computer rooms, and classified areas.
o Deleting the users account and password from all systems, networks.
o Retrieving all hardware, software, and documentation which are under his
control.
1.3 Standards Referred
ISO/IEC 17799:2005 : Code of Practice for information security management
National Institute of Standards and Technology (NIST ): Guidelines on Firewalls and
Firewall Policy - SP800-41
National Infrastructure Security Co-ordination Centre (NISCC): Good Practice Guide
on Firewall Deployment for SCADA and Process Control Networks
1.4 Glossary
DMZ: De-Militarized Zone
DDCMIS: Pictorial representation of a typical DDCMIS is give in
Annexure 1
ISP: Internet Service Provider
ISM: Information Security Manager
First Party: NTPC C&I
Second Party: Network users like operations, NTPC IT, ERP
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Third Party: Any External vendor having contractual agreement with
NTPC for network and system maintenance
IDS/IPS: Intrusion Detection System / Intrusion Prevention System
Un-trusted Network: A network which is not a part of DDCMIS network is to be
considered as un-trusted network.
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III-C 03
TG RELATED CONTROL &
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1.00.00 TG RELATED CONTROL & INSTRUMENTATION SYSTEM/EQUIPMENTS
TURBINE SUPERVISORY SYSTEM (TSS)
1 The turbine supervisory equipment shall be complete including sensors, transmitters,
converters, limit value monitors, measuring and amplifier modules, power supplies
etc. with the required accessories including twisted and shielded instrumentation
cables, compensating cables, junction boxes etc.
2 Following measurements are envisaged to be provided by the Bidder for supervisory
purpose. Based on Bidders standard and proven practice, the Bidder shall clearly
identify the applicable measurements for his equipments as applicable, optional and
not-applicable-non optional in the Bid. Bidder shall include all the applicable and
optional items in his scope of work.
(a) Shaft eccentricity detection.
(b) Absolute as well as relative shaft vibration measurement, of each bearing in
both X & Y direction (both for Turbine and Generator bearing).
(c) Differential expansion of rotor and cylinder for HPT, IPT and LPT.
(d) Overall expansion of HPT and IPT.
(e) Absolute bearing vibration measurement of each bearing in both X & Y
directions (both for turbine and generator bearings).
(f) Stator winding vibration measurement in radial and tangential directions.
(g) Axial shift of the rotor, (minimum three sensors).
(h) Turbine speed (minimum three sensors).
(i) Emergency stop and control valve position.
(j) Main steam and hot reheat steam inlet temperature and pressure.
(k) Generator bearing metal temperatures.
(l) In case of vibration, shaft mounted reference detectors and required
supervisory instrument circuitry shall also be provided.
(m) Any other measurement recommended by the Turbine manufacturer as
required for the safe and reliable operation.
(n) Bearing metal and turbine casing temp.
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3 The system shall be provided with suitable hardware for necessary signal processing.
The system should be capable of signal distribution and interfacing with other Control
Systems. The system should suitably interface with HMIPIS system supplied by
Bidder.
4 For all vibration measurements indicated above, a Microprocessor/computer based
system shall also be provided to achieve the functions described under following
items a) to e). This system shall also have the feature to accept 60 nos. per unit
buffered raw input from the vibration monitors of the auxiliary drives & motors,
procured under Station C&I vibration and provide the following functionality for these
machines as well.
(a) On-line spectrum/harmonic analysis.
(b) Identification of the exact nature of failure resulting in increase in bearing
vibration and direct message on the CRT indicating the exact nature of fault
e.g. mal-alignment, shaft crack, bearing looseness etc through use of
intelligent software packages.
(c) Storage and comparative analysis of vibrations
(d) Generation / analysis of Bode Plot/ Orbit Plot and time waveform/ Nyquist plot/
shaft centre line plot/ cascade and water fall plot.
(e) All the vibration parameters as well as Turbine supervisory parameters shall
also be fed to the Turbine Control System through hardwiring or through
suitable link so that all these parameters are suitably displayed on the TG
control OWS/LVS. All required I/O cards and other processing modules etc.
shall be provided for this purpose. Further, necessary interface for hooking up
these signals to BOP C&I System hall also be provided.
(f) In addition to the vibration analysis and diagnostics systems specifcation
requirement specified, facility for adding rules for fault shall be provided.
Facility shall be provided for protecting the rules.
5 Test calibration jigs for site calibration of all sensors of TSS shall be provided.
Telephone jacks shall be incorporated in all the TSS cubicles for communication
during site calibration etc.
2.00.00 TDBFP RELATED CONTROL & INSTRUMENTATION SYSTEM/EQUIPMENTS
BFP TURBINE SUPERVISORY INSTRUMENTS
01 Following measurements are envisaged to be provided by the Bidder for supervisory
purpose. Based on Bidders standard and proven practice, the Bidder shall clearly
identify the applicable measurements for his equipments as applicable, optional and
not-applicable-non optional in the Bid. Bidder shall include all the applicable and
optional items in his scope of work.
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TG RELATED
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(i) Shaft eccentricity
(ii) Axial shift, (with three pickups)
(iii) Differential expansion.
(iv) Overall expansion.
(v) Speed (with three pickups)
(vi) Turbine casing and bearing metal temperature for all bearings.
(vii) Stop valve metal temperature
(viii) Bearing pedestal vibration (both in horizontal and vertical direction).
(ix) Absolute as well as relative shaft vibration measurement of each bearing in
both x & y direction
(x) Any other measurement recommended by the Turbine manufacturer as
required for the safe and reliable operation.
02 Duplex K-type thermocouples/duplex 100 ohm platinum RTDS shall be provided for
the metal temperature and on the thrust bearing faces.
03 Separate and independent hardware/electronics shall be employed for each of the
TDBFP.
04 Also refer item(4) of clause no 1.00.00 above
05 Test calibration jigs for site calibration of all sensors of TSS shall be provided.
Telephone jacks shall be incorporated in all the TSS cubicles for communication
during site calibration etc
3.00.00 TRAINING
3.01.00 Contractor shall provide training on Turbine Supervisory system (TSS) including vibration
analyzer, vibration monitoring system, axial shift, eccentricity measurements etc. for Main
Turbine, BFP Turbine and other systems covered under this subsection for Employers
personnel. For exact duration of training, refer to Part-C, Sub-Section-VI B of specification.

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IIIC - 04
MEASURING INSTRUMENTS
(PRIMARY & SECONDARY)

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1.00.00 MEASURING INSTRUMENTS
1.01.00 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. Refer Sub-section Basic Design
Criteria. Further, all instruments shall be of proven reliability, accuracy, and repeatability
requiring a minimum of maintenance. They shall comply with the 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 specifications,
ranges, makes/numbers as approved by the Employer during detailed engineering.
1.02.00 Every panel-mounted instrument requiring power supply shall be provided with a pair of
easily replaceable glass cartridge fuses of suitable rating. Every instrument shall be provided
with a grounding terminal and shall be suitably connected to the panel grounding bus.
1.03.00 All local gauges as well as transmitters, sensors, and switches for parameters like pressure,
temperature, level, flow etc. as required for the safe and efficient operation and maintenance
as well as for operator and management information (including all computation) of equipment
under the scope of specification shall be provided on as required basis within the quoted
lump sum price. For bidding purpose, tentative minimum instruments have been indicated on
the P&IDs. However, contractor shall supply any additional local
gauges/switches/transmitters/sensors for reasons mentioned above without any additional
cost to the Employer.
1.04.00 The necessary root valves, impulse piping, drain cocks, gauge-zeroing cocks, valve
manifolds 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 in flexible/rigid conduits, independently to suitably
located common junction boxes. The proposal shall include the necessary cables, flexible
conduits, junction boxes and accessories for the above purpose. Double root valves shall be
provided for all pressure tapping where the pressure exceeds 40 Kg./sq.cm.
1.05.00 For all instruments envisaged for sea water applications they shall be provided with wetted
parts made of Monel / Hastelloy C or any other material (if proven ness experience of the
proposed material for such applications is established by contractor:
1.06.00 All instruments shall be provided with durable epoxy coating for housings and all exposed
surfaces of the instruments.

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2.00.00 SPECIFICATION FOR ELECTRONIC TRANSMITTER FOR PRESSURE, D.P., FLOW AND
LEVEL

2.01.00 ELECTRONIC TRANSMITTERS

Sl.No. Features Essential/Minimum Requirements
1. Type of Transmitter Microprocessor based 2 wire type, Hart protocol
compatible.
2. Accuracy 0.1% of calibrated span (minimum)
3. Output signal range 4-20 mA DC (Analog) along with superimposed digital
signal (based on HART protocol)
10:1 for vacuum/very low pressure applications. 4. Turn down ratio
30:1 for other applications.
5. 0.1% of calibrated span for six months for Ranges up to
and including70 Kg/cm.

Stability
0.25% of calibrated span for six months for Ranges
more than 70 Kg/cm (g).
+/- 0.015% per deg.C at max span. 6. Zero and span drift
+/-0.11% per deg.C at min. Span.
7. Load impedance 500 ohm (min.)
8. Housing Weather proof as per IP-55 with durable corrosion
resistant epoxy coating.
9. Over Pressure 150% of max. Operating pressure
10. Connection
(Electrical)
Plug and socket type
11. Process connection 1/2 inch NPT (F)
12. Span and Zero Continuous, tamper proof, Remote as well as
adjustability manual from instrument with zero
suppression and elevation facility.
13. Accessories -Diaphragm seal, pulsation dampeners, syphon etc. as
required by service and operating condition.
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-2 valve manifold for absolute pressure transmitters (3-
valve manifold for gauge/ vacuum pressure transmitters)
and 5 valve manifold for DP/level/flow transmitters.
-For hazardous area, explosions proof enclosure as
described in NEC article 500.
14. Diagnostics Self Indicating feature
15. Power supply 24V DC 10%.
16. Adjustment/calibratio
n/maintenance
Centralised PC based system (In Station C&I Scope). In
addition total two (2) no. of hand- held type universal
calibrators per unit, compatible with HART protocol, shall
be provided.
Notes
In case it becomes necessary to use a DP transmitter for pressure measurement then a 3-
valve manifold should be used in place of 2-valve manifold.
LVDT type is not acceptable.
Where the process fluids are corrosive, viscous, solid bearing or slurry type, diaphragm
seals shall be provided. Parts below the diaphragm shall be removable for cleaning. The
entire volume above the diaphragm shall be completely filled with an inert liquid suitable
for the application.
2.02.00 GUIDED WAVE RADAR TYPE LEVEL TRANSMITTER
Guided wave radar type level transmitters shall be provided for level measurements of the
vessel under vacuum or low pressure applications.
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Type Guided wave Radar
Principle TDR (Time domain reflectometry)
Probe Type& Material Coaxial, SS316/316L. If required, probe
shall be suitable for overfill prevention.
Signal o/p 4-20mA with HART signal suitable for
overfill prevention.
Display Integral
Power supply 24 VDC
Accuracy 5mm
Electromagnetic compatibility Shall meet EN 61326-1 (1997) and
AmdtA1, class A equipment/EN 50081-2
& EN 5008 1-2 & EN 50082-2
Mounting External cage mounting

The transmitters shall be provided with IP-55 protection class with durable corrosion
resistant coating.
The transmitters shall be able to provide digital signals super imposed on 4-20 mA signal
as per HART protocol.
2.03.00 Ultrasonic Type level Transmitter

Sl.No. Features Essential/Minimum requirement
1. Type of Transmitter Non contact Microprocessor based 2
wire type, HART protocal compatible
Ultrasonic transmitter
2. Output signal Galvanically isolated 4-20mA DC
(Analog) along with superimposed
digital signal (based on HART protocol)
3. Sensor Accuracy +/- 0.5% of calibrated span.
4. Sensor Repeatibility 3mm or better
5. Power supply 24 V DC +/-10%
6. Temperature compensation To be provided within transduceer
7. Configuration Sensor unit and Electronic units are to
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be separate. It shall be possible to
mount the Electronic unit at a remote
accessible location from the
transducer. All cables and weather
proof fittings to interconnect transducer
to elecronic unit shall be provided by
Bidder.
8. Housing Weather proof as per IP-55 with
durable corrosion resistant coating.
9. Calibration Through HART Communicator.
10. Zero and Span adjustment Continuous, tamper proof, remote as
well as manual adjustabilit from
instrument. It shall be possible to
calibrate the instrument without any
level in the tank/sump etc.
11. Sensor Material Corrosion resistant material to suit
individual application requirement.
12. False signal tolerance Transmitter shall be capable of ignoring
false echoes from internal tank/sumps
obstructions such as pipes, heating
coils or agitator blades. Also transmitter
shall have adjustable damping circuitry
13. Range Range of transmiter shall be capable of
covering the complete level span of
tank taking care of blocking distance,
frequency attenuation due to surface,
obstructions, vapors etc.
14. Display Minimum 4 character LCD display with
integral keypad, access protected by
useer code
15. Diagnostics Loss of echo alarm etc.
16. Load Impedance 500 ohms minimum
17. Electrical Connection Plug and socket
18. Accessories All weather canopy for protection from
direct sunlight and direct rain.
All mounting hardware and accessories
required for erection and
commissioning mounting fittings
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material shall be Ss 316.
For hazardous areas, explosion proof
enclosure as described in NEC article
500
Note: Contractor can also provide Radar type transmitter in place of ultrasonic
transmitters subject to approval by Employer during detailed engineering.

3.00.00 TEMPERATURE ELEMENTS
3.01.00 Thermocouple
Sr.
No.
Features Essential/Minimum Requirements
1 Type of Thermocouple. : 16 AWG wire of Chromel-Alumel (Type K) or
24 AWG wire Pt-Rhodium Pt (Type R)
depending on operating temperature Range
(ungrounded type).
2 No. of element : Duplex
3 Housing/Head : IP-55/Diecast Aluminium. Plug in connectors
are to be provided for external signal cable
connection.
4 Sheathing of Thermocouple : Swaged type magnesium oxide insulation.
5 Calibration and accuracy : As per IEC-751/ANSI-C-96.1(special
class)for T/C.
6 Characteristic : Linear with respect to temp, within 1/2
percent of top range value.
7 Accessories : Thermo well (as specified below) and shall
be spring loaded for positive contacts with
the well.
8 Standard : ANSI C 96.1 for Thermocouple and ASME
PTC-19.3 for Thermo-well.

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3.02.00 Resistance Temperature Detector (RTD)
Sr.
No.
1 Type of RTD. : Four wire, Pt-100 (100 Ohms resistance at
zero degree Centigrade).
2 No. of element : Duplex
3 Housing/Head : IP-55/Diecast Aluminium. Plug in connectors
are to be provided for external signal cable
connection.
4 Sheathing of RTD : Metal sheathed, ceramic packed
5 Calibration and accuracy : As per DIN-43760 Class-A for RTD
6 Characteristic : Linear with respect to temp, within 1/2
percent of top range value.
7 Accessories : Thermo well (as specified below) and shall be
spring loaded for positive contacts with the
well.
8 Standard : DIN-43760 for RTD and ASME PTC-19.3 for
Thermo-well.
3.03.00 Metal Temperature Thermocouples
Measuring
Medium
Metal Temperature
Material of
Thermocouple.
Chromel Alumel Type K
Type of
Thermocouple
Duplex with separate hot junctions, ungrounded
Insulation Mineral Insulation Magnesium Oxide.
Thermocouple
wire gauge
16 AWG
Protective sheath SS 321
Protective sheath
dia
8 mm O.D
Characteristics of Special limits of error as in ANSI thermocouple MC
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Thermocouple 96.01.1975
Mounting
accessories
1/2" BSP SS sliding end connector, weld pad, clamps of
heat resistant steel SS310.
Cold end sealing SS pot weal with colour coded PTFE headed sleeve
Insulated flexible tails. Sealing compound- Epoxy resin.
Minimum
bending radius
30 mm
Length of T/C 30 Mtr. (minimum)
3.04.00 Thermo well (for all process temp. elements)
(a) Shall be one piece solid bored type of 315 SS of step-less tapered design. (As per
ASME PTC 19.3 1974)
(b) For Mill classifier outlet long life solid sintered tungsten carbide material of high
abrasion resistance shall be provided.
(c) For Air & Flue gas 316 SS protecting tube with welded cap. (However contractor
shall provide better material for Flue gas service if require based on the specify
boiler design parameters).
(d) For furnace zone, impervious ceramic protecting tube of suitable material along with
Incoloy supporting tubes and adjustable flanges.
4.00.00 TEMPERATURE TRANSMITTER
Following types of 2-wire temperature transmitter (directly powered from 4-20mA input
cards of DDCMIS) shall be provided. The temperature transmitter shall be fully compatible
with thermocouples and RTDs being provided by the contractor. Temperature
compensation of the thermocouples shall be performed in the temperature transmitter
itself.
a. Single Input Head mounted Temperature Transmitter
These shall be suitable for mounting in the head of temperature element itself. The
protection class of head of thermo well along with its plug-in connector shall be min.
IP65.
b. Single Input DIN-rail mounted Temperature Transmitter
These shall be suitable for mounting on DIN-rails in J Bs. The specifications of the
J Bs shall be same as indicated in Subsection INST CABLE with additional DIN-rails
and IP 65 Protection class. This temperature transmitter shall be the ones which are
especially designed for DIN-rail mounting with IP 20 protection class. These shall
have terminals for input/output provided on front side when mounted on DIN-rail.
Head mounted temperature transmitter with clamps to make it suitable for DIN-rail
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mounting shall not be acceptable under this category.
c. Dual-input Temperature Transmitter With Indicator:
These shall be suitable for mounting on pipes/ support. Both elements of the duplex
thermocouple/RTD shall be wired to a single transmitter. Indicator shall be provided
with these transmitters. These transmitters shall have bump less change over
facility to second sensor in case first sensor fails. This change-over is to be
alarmed. Protection class shall be IP65 minimum.
d. Common requirements for each of the above type of temperature
transmitters
Output : 2-wire (power supply from input card of Control
System) with 4-20mA output with superimposed HART
protocol signal.
Input : Same transmitter shall be capable to handle Pt-100
RTD , Thermocouples K&R types (input type to be
selectable at site through HART terminal)
Isolation : min. 500 V AC
EMC
compatibility
: as per EN 61326
0 to 85 deg C (without indicator) Operating
ambient
temperature
:
0 to 70 deg C (with indicator)
Power supply compatible with input module of Control System
Accessories Mounting arrangements including clamps etc.
Composite
Accuracy
(a) For head mounted and DIN-rail mounted types:
(Refer note 2 ) RTD =<0.4% of 0-250 deg C span
T/C-K type =<0.4% of 0-600 deg C span
T/C-R type =<0.4% of 0-1000 deg C span
CJ C accuracy (for thermocouples) shall be =<1 deg C
(b) For dual-input type:
RTD =<0.25% of 0-250 deg C span
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T/C-K type =<0.2% of 0-600 deg C span
CJ C accuracy (for thermocouples) shall be =<1 deg C
Notes:-
1. In case of failure (open or burn-out) of RTD/thermocouple, temp. transmitter
shall provide low temperature output.
2. Composite Accuracy is to be calculated as summation of all applicable
accuracies of temp transmitter, for converting sensor input to output in 4-20
mA (e.g., basic accuracy, digital accuracy, D/A accuracy, etc.) and
temperature effect on these accuracies at ambient temperature of 50 deg C,
based on the figure/ formula given in the standard product catalogue for span
as specified above for various types of Temperature Elements specified. All
such accuracy/ temp effect figures in catalogue shall be first converted to deg
C, and then percentage of this converted accuracy in specified span shall be
calculated to compare with the specified composite accuracy figures.
e. Field bus compatible temperature Transmitters
Temperature transmitters of this category shall be field mounting type & shall be
capable of withstanding operating ambient temperature upto 85 deg C. These
modules shall be connected to DDCMIS through field bus such as Profibus,
Foundation Field bus etc directly from the transmitter. Maximum Number of inputs
per such temperature transmitter shall be eight. These shall be mounted in cabinets
in non-AC areas.
As an alternate, these signals from temperature transmitters can be connected to
DDCMIS through standard remote I/O modules of the DCS, in which case, the
temperature transmitter signals will be acquired through 4-20mA input modules in
the remote I/O cabinet for connecting to DDCMIS through remote I/O bus.
Air conditioned panel shall be provided for remote I/O.
5.00.00 ANALYSER INSTRUMENTS:
Common Requirements
1 Output signals Analog 4-20 mA DC
Binary 2 NO +2 NC for high alarm
2. Zero & span Adjustment Available
3. Ambient temp. 50C
4. Indication Digital
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5. Enclosure Type/Material Weather & Dust proof (IP 55) Die cast Aluminium/SS
6. Type of Electronics Microprocessor based
7. Digital Signal
transmission
RS 232 Link & to suit connections protocol to
DDCMIS
8. Calibration Auto & Manual (from Remote)
9. Error Diagnostic To be provided
10. Others If analyser provides superimposed HART signal on 4-20
mA DC output, It shall also be connected to PC based
station ( In Employer's Scope).
5.01.00 Hydrogen Analyser
1. Output signals: Analog 4-20 mA DC
2. Zero & span Adjustment Available
3. Ambient temp. 50C
4. Indication Digital
5. Enclosure Type/Material Weather & Dust proof (IP 55) Die cast
Aluminum/SS
6. Type of Electronics Microprocessor based with self diagnostic facility
7. Digital Signal transmission
protocol
RS 232 Link & to suit connections to Control
System
8. Calibration Auto & Manual (from Remote)
9. Error Diagnostic To be provided
10 Repeatability 1% of calibrated span
11 Linearity 2% of calibrated span
5.02.00 PH Analyser
1. TYPE CELL - FLOW THROUGH
2. ACCURACY <1% OF SPAN
3. RANGE 0 - 14 PH, PROGRAMMABLE
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4. NO. OF STEAMS SINGLE
5. STABILITY <0.001 PH / WEEK
6. TEMP. COEFFICIENT / TEMP.
ERROR
0.001 PH / DEG. C
7. TYPE OF ELECTRONICS MICROPROCESSOR BASED WITH SELF-
DIAGNOSTIC FACILITY.
8. INDICATION DIGITAL
9. ENCLOSURE WEATHER DUST PROOF (IP55) DIE CAST
ALUMINUM.
6.00.00 SPECIFICATION FOR FLOW ELEMENTS
6.01.00 Orifice Plate
Type Concentric as per ASME PTC-19.5 (Part-II), ISA RP-
3.2, 1960 or BS-1042
Material 316 SS
Thickness 3 mm for main pipe diameter up to 300 mm and6 mm
for main pipe dia above300 mm.
Material of branch pipe Same as main pipe
Root valve type Globe
Root valve material 316 SS
Root valve size 1 inch
Impulse pipe of same material up
to root valve
Required
Tappings Flanged weld neck. 3 pairs. of tapping.
Beta Ratio 0.34 to 0.7
Beta Ratio calculation to be
submitted
Yes
Assembly drg. and flow Vs DP
Curves
Yes
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Accessories Root valves, flanges, Vent/drain hole(As required)
Contractor shall submit certified flow calculation and differential pressure vs. flow curves for
each element for Employer's approval. Sizing calculation, precise flow calculation for all the
flow elements, fabrication and assembly drawings and installation drawings shall be
submitted for Employer's approval. One Flow element of each type shall be calibrated in the
test laboratory for validation of commutated flow calculations.
6.02.00 Flow Nozzle
Type Long radius, welded type as per ASME PTC-
19.5 (Part-III) or BS-1042
Material 316 SS
Thickness Suitable for intended application.
Material of branch pipe Same as main pipe
Root valve type Globe
Root valve material 316 SS
Root valve size 1 inch
Impulse pipe of same material up to root
valve
Required
Tapping D and D/2 (3 sets of tapings points)
Beta Ratio Around 0.7
Beta Ratio calculation to be submitted Yes
Assembly drg. and flow Vs DP Curves Yes
Accessories Root valves, vent and drain hole.
Contractor shall submit certified flow calculation and differential pressure vs. flow curves for
each element for Employer's approval. Sizing calculation, precise flow calculation for all the
flow elements, fabrication and assembly drawings and installation drawings shall be
submitted for Employer's approval. One Flow element of each type shall be calibrated in the
test laboratory for validation of computed flow calculations.

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7.00.00 SPECIFICATIONS FOR PR. GAUGE, D.P. GAUGE, TEMP. GAUGE AND LEVEL GAUGE.
Sl.
No
FEATURES ESSENTIAL/MINIMUM REQUIREMENTS
Pr. Gauge/ DP
Gauge/ Draught
gauges
Temperature
Gauge
Level Gauge
1 Sensing
Element and
material
Bourdon for high
pressure,
Diaphragm/Bellow
for low pr. Of 316
SS
Mercury in steel
for below 450C
and inert gas
actuated for above
450C of SS bulb
and capillary.
Tempered * toughened
Borosilicate gauge glass
steel armoured reflex or
transparent type.
2 Body material Die-cast
aluminium
Die-cast
aluminium
Forged carbon steel/304
SS
3 Dial size 150mm 150 mm Tubular covering entire
range
4 End
connection
1/2 inch NPT (M) 3/4" NPT (M) Process connection as
per ASME PTC and
drain/vent 15 NB
5 Accuracy 1% of span 1% of span 2%
6 Scale Linear, 270 arc
graduated in
metric units
Linear, 270 arc
graduated in C
Linear vertical
7 Range
selection
Cover 125% of
max. of scale
Cover 125% of
max. of scale
Cover 125% of max. of
scale
8 Over range
test
Test pr. for the assembly shall be1.5 to the max. Design pr. at 38C.
9 Housing Weather and dust
proof as per IP-55
Weather and dust
proof as per IP-55
CS/304 SS leak proof
10 Zero/span
adjustment
Provided Provided --
11 Identification Engraved with service legend or laminated phenolic name plate
12 Accessories Blow out disc,
siphon,
snubber,
SS Thermowell Gasket for all KEL-F shield
for transparent type vent
and drain valves of
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pulsation
dampener,
chemical seal (if
required by
process) gauge
isolation valve
Steel/SS as per CS/Alloy
process Requirement.

13 Material of
Bourdon/
movement
316 SS / 304
SS
316 SS / 304 SS
Notes:-
*Bicolour type level gauges will be provided for applications involving steam and water
except for condensate and feed water services.
Length of gauge glass shall not be more than 1400 mm. If the vessel is higher, multiple
gauge glasses with 50 mm overlapping shall be provided.
entire volume above the diaphragm shall be completely filled with an inert liquid suitable for
the application.
8.00.00 ROTAMETERS
SR.
NO.
FEATURES ESSENTIAL / MINIMUM REQUIREMENTS
1. TYPE VARIABLE AREA METAL TUBE
2. FLUID MEDIA WATER/OIL
3. TUBE BODY SS316
4. MATERIAL OF
FLOAT
316 SS
5. INDICATOR LINEAR SCALE
6. ACCESSORIES FLANGE, ORIFICE IN CASE OF BYPASS ROTA METER
(FOR LINE SIZE ABOVE 100 MM)
7. HOUSING
PROTECTION
CLASS
IP-55
8. ACCURACY +2% OF MEASURED VALUE.

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9.00.00 PROCESS ACTUATED SWITCHES
FEATURES ESSENTIAL / MINIMUM REQUIREMENTS
Pressure/ Draft
Switches/ DP
Switches
Temperature
switches
Level switches
Capacitance types for oil and dirty
medium, water, condensate
application.
Float type switches for applications
as decided by Employer during
Capacitance/ Conductivity/
Ultrasonic type for acid and alkali
application.
Sensing
Element
Piston actuated
for high pressure
and diaphragm or
bellows for low
pr./ vacuum
Vapor pressure
sensing, liquid
filled bellow
type with SS
bulb and
capillary (10 m
minimum)
Radio-frequency/ Ultrasonic type
for ash hopper, ash slurry
application.
Material 316 SS Bulb 316 SS/
capillary 304 SS
316 SS
End
connection
inch NPT (F) inch NPT (F) Manufacturer standard
Over range
proof pressure
150% of max.
design pr.
- 150% of max. design pressure
Repeatability +0.5% of full range
No. of contacts 2 No.+2NC. SPDT snap action dry contact
Rating of
contacts
60 V DC, 6 VA (or more if required by DDCMIS)
Elect.
Connection
Plug in socket.
Set point/ dead
band
adjustment
Provided over full range.
Enclosure Weather and dust proof as per IP-55
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Accessories Siphon,
snubber,
chemical
seal,
pulsation
dampeners
as required
by process
Thermo well of
316 SS and
packing glands
All mounting accessories
Mounting Suitable for
enclosure/
rack
mounting or
direct
mounting
Suitable for rack
mounting or direct
mounting
-
Power Supply
(wherever
required)
24 V DC, to be arranged by Contractor except for Ash Level Switches,
where the same shall be as per Contractors Standard practice.
entire volume above the diaphragm shall be completely filled with an inert liquid suitable for
the application.
10.00.00 DEW POINT METER
Sensor
Type : Capacitance type with change in output proportional
to moisture present.
Service : Dry Air
Range : -50 to 0 Degree Centigrade Dew-Point
Sensor Accuracy : Better than +/-0.5^
Operating
Temperature
: 0 to 50 degree C.
Operating Pressure : 0-10 Kg./Cm2, suitable for process application.
Analyser
Input : Change in capacitance from dew point sensor.
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PART-B
IIIC-04
MEASURING
INSTRUMENTS

PAGE
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Display : Combined enclosure with two three-digit seven
segments LED display with decimal point after two
digits. LED height shall be 4 inches, clearly legible
from a distance of atleast 10 meters.
Range : -50 to 0 Degree Centigrade Dew-Point
Display Accuracy : Better than =/-2 Degree C.
Mounting : Table top/Flush mounting, to be finalised during
Power supply : 240V AC, 50 Hz to be arranged by the contractor.
Output : 5-20 mA DC capable of driving a load impedance of
500 ohms minimum.
4-20 mA DC Output signal is to be connected to control system in Contractors Scope
(Interconnection cables are to be provided by the Contractor).
In case the system is not suitable for Direct online mounting, then all the required sampling
system is to be provided by the contractor.
All required accessories including cables, sensor holder, desiccant chambers, mounting
fixtures etc. are to be supplied by the Contractor within his quoted lumpsum price.

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STAGE-II (2X660 MW)
SECTION-VI
PART-B
IIIC-05
ELECTRICAL POWER
SUPPLY SYSTEMS
PAGE
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IIIC - 05
ELECTRICAL POWER SUPPLY
SYSTEM

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STAGE-II (2X660 MW)
SECTION-VI
PART-B
IIIC-05
ELECTRICAL POWER
SUPPLY SYSTEMS
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ELECTRICAL POWER SUPPLY SYSTEM
1.00.00 ELECTRICAL POWER SUPPLY
1.01.00 The requirements of Electrical Power Supply system are specified herein on system basis.
The Contractor shall be responsible for engineering and furnishing a complete and
operational system fully meeting the intent and requirements of this specification including
tender drawings and Employer approved drawings during detailed engineering. All equipment
and accessories required for completeness of this system shall be furnished by the
Contractor whether these are specifically mentioned herein or not. All the equipments and
sub systems offered shall be from reputed experienced manufacturers. All system cabinets,
enclosures, & distribution boards shall be manufactured, assembled, wired and fully tested
as a complete assembly as per the requirements of this specification at the manufacturers
works.
The Contractor shall furnish all required equipment cubicles and wiring required for
conversion and/or stabilisation of the power sources provided by the Employer to all other
levels which may be necessary for meeting the individual requirement of equipment/system
furnished by him including the panel/desk mounted equipment.
1.02.00 The power supply system shall be designed to meet the electrical power requirements of
various C&I systems including DDCMIS and shall be configured as described below:
1.03.00 The DC Power Supply for various sub-systems shall consist of one or more of the following
configurations. The applicable configurations are as indicated in Appendix-1 to Part-A of
contract quantities: -
(A) DC Power Supply system shall comprise of two sets. Each set shall consist of 2 x
100% microprocessor controlled, intelligent, modular rectifier banks, Controller one
for each rectifier bank, 1 x 100% Nickel - Cadmium batteries for one (1) hour duty, 1
x 100% DC distribution board.
1x100% Microprocessor controlled Battery Health Monitoring System (BHMS)
common for both the sets.
(B) DC power supply system shall comprise of two sets, each set shall consist of 1 x
100% microprocessor controlled, intelligent, modular rectifier banks, Controller one
for each rectifier bank, 1 x 100% Nickel - Cadmium batteries for one (1) hour duty, 1
X 100% DC distribution board.
(C) DC power supply system shall comprise of 2 x100% power supply unit along with
1x100% sealed maintenance free lead Acid batteries for 30 Min back up and DC
Distribution Board. DC power supply unit along with batteries shall be housed in a
single panel. The power supply unit shall be capable of charging the batteries and
feeding the load simultaneously. The DC distribution board shall have redundant
feeders for critical loads.
(D) DC power supply system shall consist of one set of 24 VDC redundant power supply
system with 30 Min battery back up as per manufacturers standard practice.
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(E) DC power system shall consist of one set of 24V DC redundant power supply
system with 12 hours battery back up as per manufacturers standard practice.
(F) Power supply system as per manufacturers standard practice.
Bidder shall clearly bring out in the proposal the redundancy features along with configuration
diagram, single line diagram & data sheets etc. and this shall be finalized and subject to
Employer's approval during detailed engineering. For configuration of 24 V DC power supply,
refer tender drawing nos 0000-405-POI-A-019 SH-1 & 2.
For systems/ instruments such as HMIPIS portion of DDCMIS including peripherals like
Monitors LVSs, OWSs, printers, disks, Control Desk (draw out portion) mounted
instruments, Flue gas & SWAS analyzers, Vibration monitoring Systems, PA System &
CCTV System etc. requiring stabilized power, the power supply shall be derived from either
the 24V DC or UPS as per specific requirement of the equipment supplier and as approved
by Employer during detailed engineering.
1.04.0 Contractor shall also provide local power supply distribution boxes on as required basis for
sub-distribution of all 230V AC and 24V DC utility feeders for various field mounted
instruments/devices (e.g. Analysers etc.) supplied by the Bidder, Remote I/O Cabinets and
also for the instruments/devices provided by the Employer. The power supply distribution box
shall include necessary change over circuitry (as applicable), switch fuse units, MCB,
terminal blocks etc suitable for the application. The sub distribution of feeders in a local
power D.B. shall be finalised during detailed engineering. Contractor to note that the
minimum fuse rating in local power D.B. shall be 6 Amp.
1.05.0 The Power supply systems in the above-mentioned configurations at Cl.No.1.03.00 (A) and
(B) above shall meet the following specification requirements at Cl.No.2.01.00 to 2.04.00 as
a minimum. Bidder to ensure that offered rectifier modules, controller and batteries for
configurations (A) and (B) are of same make. The power supply systems in the above-
mentioned configurations at 1.03.00 (C) shall meet the following specification requirements
at Cl.No.2.05.00.The Power supply configurations at 1.03.00(D),(E) and (F) shall be as per
manufacturers standard.
2.00.00 DC POWER SUPPLY SYSTEM (24 V),
2.01.00 Microprocessor based, Intelligent, Modular Power Supply
2.01.01 Microprocessor based, Intelligent, Modular Power Supply shall be sized for continuous duty
to meet 100% load requirements and keep the connected battery fully charged in float mode.
A provision of 10% design margin shall be kept over and above the load requirement. Either
of the bank of rectifier modules shall be able to re-charge the fully discharged battery within 8
hours. It shall also be possible to discharge batteries periodically manually. Each rectifier
bank shall be provided with N+1 rectifier modules and the maximum numbers of rectifier
modules shall not be more than 25 Nos. the exact sizing of the rectifiers in one bank shall be
subject to Employer approval during detailed engineering. It shall be ensured that all rectifier
modules in one rectifier bank shall be of same rating and not more than three ratings of
rectifier modules shall be used in various rectifier banks. Provision for manual boost charging
with isolation of loads shall be provided. While selecting the components and finalizing the
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SECTION-VI
PART-B
IIIC-05
ELECTRICAL POWER
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cooling arrangements. Bidder to note that these rectifier modules are required to operate at
30-40% of the rated load for most of the time. While sizing, the temperature derating factor
as applicable, is to be considered for arriving at the rating of the modules as per Bidders
manufacturing standard if the modules are rated for lower than the 50 deg. C ambient. For
the rectifier bank, matching controller along with applicable software shall be provided to
meet system requirements under all modes of operation.
2.01.02 The rectifier module shall be microprocessor controlled, IGBT/ Power MOSFET based, high
frequency with active load sharing, designed for single and parallel operation with battery and
shall have automatic voltage regulators for a close voltage stability even when AC supply
voltage and DC load fluctuates, effective current limiting features, front access design,
programmable temperature compensation feature for battery charging and filters on both
input and output to minimise harmonics. The rectifier module output regulation shall be 1%
or better from no load to full load with an input power supply variation of 10% in voltage and
5% in frequency. In addition to indications/display on rectifier panel, alarms like O/P voltage
high & low, battery isolated, multiple rectifier modules failed, AC Input supply out of specified
range, communication fault, Battery Fuse Blown, Surge Protection Failure, Controller faulty,
System Overload etc. along with relevant analog measurements shall also be provided by
employing RS 485 Port Modbus Protocol / Ethernet TCP/IP protocol for use in DDCMIS.
Further isolated 4-20 mA signals shall be provided for important parameters like rectifier
module voltage, rectifier bank current, battery voltage etc. The list of alarm output & 4-20 mA
signals shall be as approved by Employer during detailed engineering. Necessary provision
shall be done in DDCMIS end also.
2.01.03 "Float/Boost" charge functions shall be provided with alarm/indications.
2.01.04 Each rectifier bank shall be rated for 100% load requirement and keep the connected battery
full charged and at least one spare rectifier module.
2.01.05 The rectifier module circuitry shall be of fail-safe design and failure of any component should
not result in any rectifier bank output voltage to increase beyond acceptable limits of the C&I
system being fed from it.
2.01.06 The rectifier module shall be current limited for circuit protection and protection of battery
from overcharge. The current limit shall be continuously programmable.
2.01.07 The rectifier module 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 energised.
2.01.08 The rectifier module shall be fed from 415V AC, 50 HZ, 3 phase, 3 wire system.
2.01.09 The full load efficiency of rectifier module at nominal input and output shall be 90%. The
ripple content shall be limited to +/- 0.5 % of output voltage.
2.01.10 Contractor shall furnish the equipment complete in all respects along with rectifier module
rating & voltage drop calculations, supporting curves/data etc.

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2.01.11 The Controller shall be microprocessor controlled for monitoring & control of rectifier modules
with features viz. Auto/Manual battery discharge test, battery reserve time prediction, energy
management, remote control, float/boost mode control etc.
2.01.12 All Software as required for smooth operation and monitoring of rectifier modules in
conjunction with Controller & BHMS shall be provided by the Contractor.
2.02.00 Batteries,
2.02.01 The batteries shall be heavy duty Nickel-cadmium type and shall be sized for one hour of full
load operation during non-availability of AC supply / chargers. The Ni-Cd batteries shall
conform to IS: 10918. For sizing calculation, an aging factor of 0.8 and a temperature
correction factor as per manufacturers standard at 4 deg. C electrolyte temperature (Based
on temperature characteristics curve to be submitted by the Contractor at a temperature of 4
deg. C). Capacity factor shall be taken into consideration, if applicable and ambient
temperature shall be considered as the electrolytic temperature. The sizing of the battery
shall be as approved by Employer during detailed engineering. However, Contractor shall
consider a suitable voltage drop from battery room to DCDB and DCDB to load, while sizing
the battery. The system shall also be suitably designed to overcome any over voltage that
may arise during low-load operation of the rectifier modules.
2.03.00 DC Distribution Board (DCDB)
Redundant DC feeders (one from each DCDB) shall supply each of the connected loads. The
exact design, rating & number of feeders of the each redundant DCDB shall be as finalised
during detailed engineering and as approved by Employer. However, 25% spare feeders
(min. 1 no.) with MCB and fuses for each rating shall be provided in each DCDB.
2.04.00 Battery Health Monitoring System (BHMS)
BHMS, wherever applicable, shall include microprocessor based hardware and software to
monitor the condition of each battery cell of 24 V DC systems & UPS battery banks on-line.
With BHMS it shall be possible to measure & analyse the minimum and maximum voltage
values of each battery-cell so that any damage to battery shall be prevented by pro-active
maintenance. BHMS shall communicate with the DDCMIS and provide alarms as finalized by
Employer during detailed engineering. BHMS shall be offered if all the features/functions
listed herein are not a part of Controller.
2.05.00 Power Supply shall be sized to meet connected load requirements and keep the connected
battery full charged in Float/ Boost mode. The rectifier module output regulation shall be
1% or better from no load to full load with an input power supply variation of 10% in voltage
and 5% in frequency. In addition to indications/display on the panel, potential free contacts
for alarms like O/P voltage high & low, AC Input supply out of specified range, battery feeding
the load etc shall also be provided for use in respective control system i.e., PLC/Remote IO
etc . Further isolated 4-20 mA signals shall be provided for important parameters like rectifier
signals shall be as approved by Employer during detailed engineering. The exact design,
rating & number of feeders of the DCDB shall be as finalised during detailed engineering and
as approved by Employer. However, 25% spare feeder (min. 1 no.) with fuses for each rating
shall be provided in each DCDB.
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3.00.00 UNINTERRUPTIBLE POWER SUPPLY (UPS) SYSTEM (IF APPLICABLE)
Each UPS system shall have 2x100% parallel redundant chargers and inverters, 1x100%
battery bank for one (1) hour duty, bypass line transformers and voltage stabiliser, static
switch, manual bypass switch, 1x100% Microprocessor controlled Battery Health
Monitoring System (BHMS) (unless specified otherwise), 2x100% AC distribution boards,
other necessary protective devices and accessories and shall meet the following
requirements as a minimum.
The KVA rating of UPS shall be as required by expected loads and include 10% spare
capacity guaranteed at 50 deg. C ambient and load power factor of 0.8 lagging. However,
for bidding purpose, a minimum capacity as indicated in Appendix-I to Part-A shall be
considered. If UPS KVA rating is applicable at a lower ambient temperature than specified
50 deg.C, the Bidder shall consider a derating factor of at least 1.5%/deg.C for arriving at
the specified UPS capacity at 50 deg.C ambient. The UPS shall have an overload capacity
of 125 % rated capacity for 10 minutes and 150 % rated capacity for 10 seconds. The
inverter shall have sufficient capability to clear fault in the maximum rated branch circuit,
limited to 12 percent of finally selected UPS Capacity. The sizing of UPS shall be based on
the power factor of the loads being fed subject to a maximum of 0.8.The batteries for UPS
shall also confirm to requirements specified at cl.No.2.02.00 above. The UPS system shall
be supplied with Input isolation transformer.
3.01.00 Chargers
3.01.01 The chargers shall be self regulating, solid state silicon controlled, full-wave rectifier type
designed for single and parallel operation with battery and shall have automatic voltage
regulators for close voltage stability even when AC supply voltage fluctuates, effective
current limiting features and filters to minimise harmonics. The charger should be capable to
fully charge the required batteries as well as supply the full rated load through inverter.
Furthermore the charger should be able to re-charge the fully discharged battery within 8
hours. The charger output regulation shall be 1% from no load to full load with an input
power supply variation of 10% in voltage and 5% in frequency. In addition to
indications/display on charger panel, alarms like charger O/P voltage high, battery isolated,
charger failed etc. along with relevant analog measurements shall also be provided by
employing RS 485 Port Modbus Protocol / Ethernet TCP/IP protocol for use in DDCMIS.
Further isolated 4-20 mA signals shall be provided for important parameters like rectifier
signals shall be as approved by Employer during detailed engineering.
3.01.02 The charger shall be current limited for charger circuit protection and protection of battery
from overcharge shall also be provided. The current limit shall be continuously adjustable.
The chargers 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 energised.
3.01.03 The chargers shall be fed from 415V AC, 50 HZ, 3 phase, 3 wire system. Charger design
shall ensure that there is no component failure due to fluctuations of input supply or loss of
supply and restoration.
3.01.04 The minimum full load efficiency at nominal input and output shall be 90%. The ripple content
shall be limited to +/- 2 % of Charger output voltage.
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ELECTRICAL POWER
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3.01.05 The UPS battery shall have sufficient amp-hour capacity to supply 100% full load current of
UPS for 60 minutes. For this, the UPS capacity to be considered as the finally selected UPS
rating, irrespective of the actual load on UPS. A drop of 4V from battery room to the inverter
input will be considered for design. The battery shall meet other specification requirements
as specified above.
3.01.06 The UPS system shall be capable of operating without D.C. battery in circuit under all
conditions of load and the performance of various components of UPS like inverter, charger,
static switch etc. shall be guaranteed without the battery in circuit.
3.01.07 The UPS system design shall ensure that in case of failure of mains input power supply to
one of the chargers, the other charger whose mains input power supply is healthy, shall feed
to one or both the inverters as the case may be as per manufacturer's standard practice &
continue to charge the D.C. battery at all load conditions. The Bidder should note that this
situation should not in any way lead to the discharge of the D.C. Battery.
3.02.00 Static Inverters
The static inverter shall be of continuous duty, solid state type using proven Pulse Width
Modulation (PWM)/Quasi square wave/step wave technique. Ferro-resonant types Inverters
are not acceptable. The nominal voltage output shall be 230 Volts.single phase ,50 Hz. The
inverter equipment shall include all necessary circuitry and devices to conform to
requirements like voltage regulation, current limiting, wave shaping, transient recovery,
automatic synchronization etc. The steady state voltage regulation shall be +/-2% and
transient voltage regulation (on application/removal of 100% load) shall be +/-20%. Time to
recover from transient to normal voltage shall not be more than 50 milli Sec. Frequency
regulation for all conditions of input supplies, loads and temperature occurring simultaneously
or in any combination shall be better than 0.5% (automatically controlled). The total
harmonic content shall be 5% maximum and content of any single harmonic shall be 3%
maximum. The inverter efficiency shall be at least 85% on full load and 80% on 50% load.
The synchronisation limit for maintenance of synchronisation between the inverter and stand
by AC source shall be 48-52Hz, field adjustable in steps of 1 Hz..
3.03.00 Static Switch and Manual Bypass Switch
The static switch shall be provided to perform the function of transferring UPS loads
automatically without any break from (i) faulty inverter to healthy inverter in case of failure
of one of the two inverters and (ii) from faulty inverter to standby AC source in case of
failure of both the inverters. The transfer time shall be cycle maximum.
Manual bypass switch shall be employed for isolating the UPS during maintenance.
Continuous and overload capacity of the switches shall be equal to 100% of the
continuous and overload rating of each inverter. Peak Capacity shall be 1000% of
continuous rating for 5 cycles.
3.04.00 Step Down Transformer and Voltage Stabiliser
One 415V three phase to 230V, single phase transformer along with associated voltage
stablizer shall be furnished with each UPS system. The transformer and stablizer
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combination shall convert Employer furnished 415V 10% three phase plant auxiliary AC
supply to 230 V 2%, single phase standby AC Power Supply source.
The transformer shall be of low impedance air-cooled type and its KVA rating and
percentage impedance should be selected so that extremely fast fault clearance is
achieved.
The overload capacity of the transformer and voltage stabilizer shall not be less than 300%
for 200 millisecond duration. The voltage stabilizer shall employ servo-controlled circuitry
and shall maintain the specified output voltage for 0-100% load with maximum input
voltage variations as indicated above. The efficiency of the stabiliser shall be 95% or
better.
The make, type and other details shall be subject to Employers approval.
3.05.00 AC Distribution Board (ACDB)
The details of the AC distribution board, i.e. exact design, rating and number of feeders etc.
of the 2x100% ACDB shall be as finalised during detailed engineering and as approved by
Employer. ACDB shall be designed to cater to the requirements of both Employers System
and Contractors systems. Further, 25% spare feeders (min. 1 no.) with MCB and fuses for
each rating shall be provided in each ACDB.
4.00.00 AUXILIARY EQUIPMENTS
4.01.00 All required auxiliary equipment/materials as finalised during detailed engineering shall be
furnished with each rectifier bank, UPS & battery bank and shall include as a minimum
various meters (AC/DC voltage/current, kVA, power factor, frequency meters etc), circuit
breakers, selector switches, push buttons indicating lights, ground detector system, battery
accessories like (inter cell connectors, inter step connectors, battery racks etc.) isolated 4-20
mA signals for important parameters and potential free contacts for important alarms shall be
provided for use in DDCMIS.
4.02.00 Manual Discharge Resistance bank of adequate capacity for UPS & 24 V DC Power Supply
System batteries as indicated in Appendix-1 to Part-A of contract quantities shall be
provided by the Contractor.
4.03.00 Following accessories and devices required for maintenance and testing of batteries shall be
supplied for each set of the batteries:
a Hydrometer 2 Nos.
b Set of hydrometer syringes suitable for the vent holes in different
cells
2 Nos.
c Thermometer for measuring electrolyte temperature 2 Nos.
d Specific gravity correction chart 2 Nos.
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e Wall mounting type holder made of teak wood for hydrometer &
thermometer
2 Nos.
f Cell testing voltmeter (3-0-3 V) 3 Nos.
g Alkali mixing jar 2 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) 2 Nos.
m Instruction card 5 Nos.
n Temperature indicator 1 No. per room
o Cell lifting facility 1 Set per room
5.00.00 BATTERY RACKS
Two tier battery racks of mild steel construction in accordance with applicable codes and
standard shall be provided. AISC specification shall apply in the absence of another design
specification.
6.00.00 DRAWINGS/DOCUMENTS REQUIREMENTS
Bidder shall furnish the power supply distribution scheme, single line diagram, all calculations
such as Rectifier Modules / UPS Charger / Inverter rating calculations, battery sizing
calculation etc. for DC system as well as for UPS during detailed engineering for Employers
review and approval.
7.00.00 LOAD END POWER SUPPLY DISTRIBUTION
Bidder shall provide power supply distribution panels/cabinets/ boxes for sub-distribution of
main UPS/ DC/ Utility feeder(s) on as required basis. These shall include necessary auto-
change over circuitry, switch-fuse units, MCB, terminal blocks etc. suitable for the application.
The design of these distribution panels/cabinets/boxes shall be as approved by Employer
during detailed engineering stage. Each of the control cabinets, however, shall be provided
with redundant DC/ UPS feeders.
8.00.00 CABINETS / ENCLOSURES
The Construction details for Power Supply System Cabinets/ Enclosure/Racks shall conform
to the requirements of the following paragraphs.
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PART-B
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(1) Equipment enclosures shall match and line up in assemblies of freestanding floor
mounted cabinets designed for indoor service.
(2) Individual enclosure shall be ventilated switchboard type fabricated from not less
than 1.6-mm thick sheet steel. Enclosures shall be furnished with concealed hinges.
Front and rear doors shall be designed to permit easy access to all components for
maintenance or replacement. The enclosures shall be reinforced with formed steel
members as required to form a rigid self-supporting structure. Doors shall have three
point latches.
(3) Each assembly may be shipped in sections for ease of handling and field assembly.
Terminal blocks shall be furnished as required adjacent to each shipping split to
facilitate field assembly. Cable bundles cut to the required length and furnished with
terminal lugs tagged for identification shall be provided for the wiring between
shipping sections.
(4) Adequate ventilating louvers and enclosure top panels shall be included. All vent
openings shall be covered with corrosion resistant fine screen coverings.
(5) The temperature rise inside all the cabinets/enclosures shall not exceed 10 deg.C
above ambient temperature. The cabinets shall be IP-22 protection class .Contractor
shall furnish calculation to establish this during detailed engineering stage.
(6) The Colour shade of Panels exterior/interior shall be as per RAL 9002, end panel
Colour shall be as per RAL 5012.
9.00.00 COOLING SYSTEM
If the equipment supplied requires forced air cooling, the cooling system furnished shall meet
the following requirements:
(1) Reserve cooling equipment shall be furnished for each assembly. Reserve fan
capacity shall be equal to 100 percent of cooling fan requirements for full load
operation with only one bank of rectifier/inverter in service at the specified maximum
ambient temperature.
(2) Completely independent duplicable wiring and control systems shall be provided for
the normal cooling fan system and the reserve cooling fan system.
(3) Each cooling fan shall normally run continuously and shall be powered from the
output of the inverter whose enclosure it serves (for cubicles housing inverters). For
other cubicles, fan power supply shall be as finalised during detailed engineering.
Each cooling fan supply circuit shall be separately fused.
(4) Each cooling fan shall be equipped with a switch having an alarm contact that closes
upon failure of airflow or rise of temperature.
10.00.00 SITE TESTS
The Contractor shall also carry out the site tests on equipments/systems as specified below.
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However, these shall not be limited to this specification only and in case any other site test is
required to be conducted as a standard practice of the Contractor or deemed necessary by
the Employer and mutually agreed between the Contractor and the Employer, the same shall
also be carried out.
10.01.00 Uninterruptible Power Supply System
10.01.01 Functional Test
On completion of installation and commissioning of the equipment the following tests/checks
shall be carried out with the max. available load, which does not exceed the rated continuous
load. These tests/checks shall include but not limited to the tests as indicated below.
The details of the tests are as indicated below:
1. Light Load Test
This test is carried out to verify that the UPS is correctly connected and all functions
operate properly. The load applied is limited to some percent of rated value. The
following points should be checked:
(a) Output voltage, frequency and the correct operation of meters;
(b) Operation of all control switches and other means to put units into
operation.
(c) Functioning of protective and warning devices.
(d) Operation of remote signaling and remote control devices.
2. Checking of Auxiliary Devices
The functioning of auxiliary devices, such as lighting, cooling, pumps, fans,
annunciation, etc., should be checked, if convenient, in conjunction with the
preliminary light load test.
3. Synchronisation Test
If possible, frequency variation limits should be tested by use of a variable frequency
generator, otherwise, by simulation of control circuit conditions. If applicable the rate
of change of frequency during synchronization shall be measured.
4. A. C. Input Failure Test
The test is performed with a fully charged battery and is carried out by tripping input
circuit breakers or may be simulated by switching off all UPS rectifiers and bypass
feeder as at the same time. Output voltage variations are to be checked for specified
limits with an oscilloscope or equivalent. Frequency variation is defined as the steady
state frequency of the UPS with and without AC input. The rate of change of
frequency is measured by the time it takes to reach steady-state values.

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5. A. C Input Return Test
AC input return test is performed by closing AC input circuit breakers, or is simulated
by energizing rectifiers and bypass feeders.
Proper operation of rectifier starting and voltage and frequency variations are to be
observed.
Note: This test is normally performed with a fully of partially charged battery.
6. Simulation of Parallel Redundant UPS Fault
This test is applicable for UPS with parallel redundant connections. Faults of rectifier
or inverter units may be carried out by simulation. Output transients are to be
observed.
7. Transfer Test
This test is applicable for UPS with bypass, particularly in the case of an electronic
bypass switch. Transients shall be measured during load transfer to bypass caused
by a simulated fault and load retransfer after clearing of the fault.
8. Full load test
Load tests are performed by connecting the actual load to the UPS output.
Large UPS in parallel connection may be load tested by testing the individual UPS
units separately. Load tests are necessary for testing output voltage and frequency,
rated stored energy, recharge time, ventilation, temperature rise and determination of
efficiency. Load tests are performed to prove transient voltage deviations specified
under step load conditions.
9. Efficiency
Efficiency should be determined by the measurement of the active power at input
and output.
10. Actual Load Test
Conditions under actual load may differ from those with a dummy load. Steady-state
generation of current and voltage harmonics and transients at load switching
conditions should be observed
11. Current Division in Parallel
Load sharing between the Modular DC power supply rectifier banks & UPS units
shall be measured with actual load under conditions of parallel operation.

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STAGE-II (2X660 MW)
SECTION-VI
PART-B
IIIC-05
ELECTRICAL POWER
SUPPLY SYSTEMS
PAGE
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12. Rated Stored Energy Time (Battery Test)
This test is a load test to prove the actual possible time of battery operation.
If rated load is not available in the case of large UPS, it is possible to apply a partial
load to check the actual battery discharge characteristics and compare these with
characteristics specified by the battery manufacturer. Discharge time with rated load
shall then be calculated. The test shall be performed with a fully charged battery and
also may be done under other battery conditions to be specified, if so agreed. Active
power output of the UPS and the battery voltage shall be recorded during the test.
Since new batteries often do not provide full capacity during a starting up period, the
discharge test may be repeated after a reasonable recharge time if the original test
has failed.
13. Rated Restored Energy Time
Restored energy depends on the charging capacity of the rectifiers and the battery
characteristics. If a certain recharging rate is specified, it shall be provided by
repeating the discharge test after the specified charging period.
14. Battery Ripple Current
If battery ripple currents are specified, then the ripple current which depends on UPS
operation shall be checked under normal operating conditions. Rough measuring
methods are sufficient.
15. On site Ventilation Test
The test is performed with the actual load. Temperature conditions of all Modular DC
power supply rectifiers & UPS cubicles are to be observed.
16. Overload Capability Test
Overload capability test is a load test. Specified values of short time overload or
starting up sequences of actual load are to be applied for the time interval specified.
Specified values of voltage and current are to be recorded.
17. Short Circuit Current Capability
If short-circuit current capability is specified, it may be tested by applicable of a short
circuit to UPS output if necessary, via a suitable fuse, Short-circuit current is to be
recorded.
18. Short Circuit Fuse Test
Fuse tripping capability of a UPS shall be tested, by short-circuiting the UPS output
via a fuse of specified type.
The test shall be repeated to ensure against fuse non-uniformity and switching time
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SECTION-VI
PART-B
IIIC-05
ELECTRICAL POWER
SUPPLY SYSTEMS
PAGE
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during the cycle. The test is carried out at an appropriate UPS load, under normal
operation, if not otherwise specified by Employer.
19. Restart
Automatic or other restart means are to be tested after a completed shut-down as
specified.
20. Output Over voltage
Output over voltage protection is to be checked.
21. Periodic output voltage modulation
When this test is specified, it may be checked by voltage recording at different loads
and operating conditions.
22. Harmonic Components
Harmonic components of output voltage shall be checked with the actual load.
Methods of specification and checking shall be subject to Employers approval.
23. Earth Fault Test
If the DC Power Supply/ UPS output is isolated from earth, then an earth fault can be
applied to any output terminal. DC Power Supply/ UPS output transients (if any) shall
be measured.
If the battery is isolated from earth, then an earth fault can be applied to any output
terminals. DC Power Supply/ UPS output transient (if any) shall be measured.
10.02.00 24V DC Power Supply System
The functional tests to be carried out for 24V DC Power Supply system shall be the same as
specified under clause no. 10.01.01 above excepting the Sl. Nos. 2,3,6,7,17,18 and 22.
11.00.00 CONTRACT QUANTITIES
Refer Appendix-I to part A, Section VI of technical specifications.
12.00.00 TRAINING
Contractor shall provide training on UPS & 24V DC Power Supply system for Employer's
personnel. The duration of the training shall be as elaborated in Part-C, Section-VI of
technical specifications.

CLAUSE NO.

STAGE-II (2X660 MW)
SECTION-VI
PART-B
IIIC-06
PCP

PAGE
1 OF 9

IIIC - 06
PROCESS CONNECTION AND
PIPING

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STAGE-II (2X660 MW)
SECTION-VI
PART-B
IIIC-06
PCP

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PROCESS CONNECTION AND PIPING
1.00.00 PROCESS CONNECTION PIPING
1.01.00 The Contractor shall provide, install and test all required material for completeness of
Impulse Piping System and Air Piping System as per the requirements of this Sub-section,
enclosed installation drawings and source connection drawings on as required basis for the
connection of instruments and control equipment (provided by the Contractor) to the process
/ Employers main equipment / systems. The installation & source connection of various
items shall generally as per installation drawings (drawing no. 0000- 110 -POI-A-022 to 033,
0000- 110 -POI-A-034) and instrument source connection drawings (drawing nos. 0000-110 -
POI-A -035), however, the Contractor shall furnish during detailed engineering. Installation
drawings, GA and fabrication drawings of LIES / LIRs, other relevant drawings, material and
tech data sheets of various items service wise for Employer's approval / information.
1.01.01 All materials, furnished under this sub-section and the installation thereof shall conform to the
latest editions of American National Standard Code for Pressure Piping, Power Piping, ANSI
B 31.1, ANSI B16.11, ASME Boiler and Pressure Vessel Codes, IBR and other applicable
ASME, ANSI and state standards.
1.01.02 All materials supplied under this Sub-section shall be suitable for intended service, process;
operating conditions and type of instruments used and shall fully conform to the requirements
of this specification. The bidder is responsible for the performance of equipment furnished
under this specification on system basis. The Bidder may offer suggestions for improvement
based on his experience, during detailed engineering, which shall be subjected to the
Employer's approval.
1.01.03 Contractor to note that any reducers, nipple etc. for proper connection of the impulse piping
system to Employers root valves / isolation valves / stubs etc. shall be in Contractors scope
only, unless otherwise clearly excluded.
1.02.00 IMPULSE PIPING, TUBING, FITTINGS, VALVES AND VALVE MANIFOLDS
1.02.01 All impulse pipe shall be of seamless type conforming to ANSI B36.10 for schedule numbers,
sizes and dimensions etc. The material of the impulse pipe shall be same as that of main
process pipe. For various applications specification of impulse pipe materials and associated
fittings and valves shall be as given in Table PCP. For protection against sea environment,
all impulse pipes, fittings etc shall be provided with durable epoxy coating with poly urethane
finish.
1.02.02 Stainless steel tube shall be provided inside enclosures & racks from tee connection to valve
manifold and then to instrument. For high pressure/temperature applications (piping class
A,B,C & D of the table no. PCP) the material shall be ASTM A 213 TP 316H it and for other
applications material shall be ASTM A 213 TP 316L. The wall thickness of the tube shall be
in accordance with the ANSI B31.1 standard. The bending radius of the tube shall be greater
than 6D.
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1.02.03 All fittings shall be forged steel and shall conform to ANSI B16.11. The material of forged
tube fittings for shaped application (e.g. Tee, elbow etc.) shall be ASTMA 182 Gr. 316 H for
high pressure/ temperature applications (as defined above) and ASTMA 182 Gr. 316L for
other applications. The material for bar stock tube fitting (for straight application) shall be
316 SS. Metal thickness in the fittings shall be adequate to provide actual bursting strength
equal to or greater than those of the impulse pipe or SS tube, with which they are to be used.
1.02.04 The source shut-off (primary process root valve) and blow down valve shall be of 1/2 inch
size globe valve type for all applications except for air and flue gas service wherein no source
shut-off valves are to be provided. For various applications the valve body material, stem
material and pressure class shall be as given in Table PCP. The end connections of valves
shall be of socket welded type unless otherwise specified in the instrument installation
diagrams The disc and seat ring materials of carbon steel and alloy steel valves be ASTM A-
105 and ASTM A-182, Gr. F22, hard faced with stellite (minimum hardness - 350 BHN.) The
surface finish of 16 RMS or greater is required in the area of stem packing. The valve design
shall be such that the seats can be reconditioned and stem and disc may be replaced without
removing the valve body from the line.
1.02.05 The valve manifolds shall be of 316 stainless steel with pressure rating suitable for intended
application. 2-valve manifold and 3-valve manifold shall be used for pressure measurements
using pressure transmitters/ pressure switches and differential pressure transmitter/ switches
respectively. 5-valve manifold shall be used for remaining applications like DP, flow and level
measurements.
1.02.06 For Pr./D.P gauges in fluid application two-way globe valve on each impulse line to the
instrument and in Air / Flue gas application two-way gate valve on each impulse line to the
instrument shall be provided near the instrument. These shall be in addition to the three ways
gauge cock provided alongwith the pr./D.P gauges.
2.00.00 AIR SUPPLY PIPING
2.01.00 All pneumatic piping, fittings, valves, air filter cum regulator, purge Rotameter and other
accessories required for instrument air for the various pneumatic devices/ instruments shall
be provided. This will include as a minimum air supply to pneumatically operated control
valves, actuators, instruments, continuous and intermittent purging requirements etc.
2.02.00 Instrument air supply shall be provided for continuous purging requirements of local
instrument enclosures (LIEs) and any other instrument supplied by the Contractor which
requires instrument air. Also for intermittent purging requirements of local instrument
enclosures (LIEs) all pipings, fittings valves etc. shall be provided for service air supply to
LIEs housing air and flue gas transmitters. Service air supply shall also be provided for any
other instrument supplied by the contractor requiring service air. The contractor shall also
provide and connect pneumatic tubing to E/P convertors and then to control valves supplied
by the Employer but controlled by the C&I Contractor.
2.03.00 For individual supply line and control signal line to control valve, 1/4-inch size light drawn
tempered copper tubing conforming to ASTM B75 shall be used. The thickness of cu-tubing
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SECTION-VI
PART-B
IIIC-06
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shall not be less than 0.065 inch and shall be PVC coated. The fittings to be used with
copper tubes shall be of cast brass, screwed type.
2.04.00 All other air supply lines of 1/2 inch to 2 inch shall be of mild steel hot dipped galvanized
inside and outside as per IS-1239, heavy duty with threaded ends. The threads shall be as
per ASA B.2.1. Fittings material shall be of forged carbon steel A234 Gr. WPB galvanized
inside and outside, screwed as per ASA B2.1. Dimensions of fittings shall be as per ASA
B16.11 of rating 3000 lbs.
2.05.00 The Employer shall provide instrument air at two points for the boiler area and one point for
the turbine area at a convenient point for each unit. Similarly the Employer shall provide
service air also at two points for the boiler area and one point for the turbine area at a
convenient point for each unit. For air supply to various devices mentioned above, the
contractor shall provide 2 inch size GI pipe header with isolation valve from the instrument air
and service air terminal points. In the boiler area the 2 inch head shall be provided upto top
most elevation of boiler floor and from this 2 inch header, 1 inch sub-header shall be
branched off at each floor with isolation valve. From this 1 inch sub-header, branch line of 1/2
inch, with isolation valve shall be provided upto various devices. In the Turbine area the 2
inch head shall be provided upto top most elevation of Turbine floor and from this 2 inch
header, 1 inch sub-header shall be branched off at each floor with isolation valve. From this 1
inch sub-header, branch line of 1/2 inch, with isolation valve shall be provided upto various
devices. Similar system is to be followed for service air required for intermittent purging in the
Local Instrument Enclosures (LIEs) etc.
2.06.00 All instrument air filters cum regulator set with mounting accessories shall be provided for
each pneumatic device requiring air supply. The filter regulators shall be suitable for 10-kg/
sq.cm max. Inlet pressure. The filter shall be of size 5 microns and of material sintered
bronze. The air set shall have 2-inch size pressure gauge and built in filter housing blow
down valve. The end connection shall be 1/4 inch / 1/2 inch / 3/4 inch NPT as per the
requirement to be finalised during detailed engineering.
2.07.00 All the isolation valves in the air supply line shall be gate valves as per ASTM B62 inside
screw rising stem, screwed female ends as per ASA B2.1. Valve bonnet shall be union type
& trim material shall be stainless steel, body rating 150 pounds ASA. The valve sizes shall be
inch to 2 inch.
2.08.00 Purge Air Connection for Air and Flue gas Applications
The continuous purging with instrument air shall be done, for all air and flue gas
measurements, at the process source connection end. Necessary arrangements required
for continuous purging shall be provided inside all instrument enclosures and instrument
racks for Air and Flue gas applications as per enclosed drawing no. 0000-999-POI-A-034.
For intermittent purging with service air, necessary arrangements inside all the air and
Flue gas enclosures shall be provided as per drawing no. 0000-110-POI-A-034. The SS
four ways valve provided in the SS tubing shall be used for isolating the transmitter &
connecting the service air quick disconnect line.
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STAGE-II (2X660 MW)
SECTION-VI
PART-B
IIIC-06
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Purging arrangement is not required for Instrument air and service air measurement
applications.
Purge air lines shall be of mild steel hot dipped galvanised inside and outside as per IS1239,
heavy duty with threaded ends.
3.00.00 INSTALLATION AND ROUTING
3.01.00 All instrument piping, tubing and its accessories shall be supported in a safe manner to
prevent excessive vibrations and anchored sufficiently to prevent undue strain on connected
equipment. Instrument piping & tubing shall not be routed across equipment removal areas,
above or below monorails, cranes, removable gratings, cable trays.
3.02.00 Instrument Piping System
3.02.01 For steam and liquid measurements, the impulse pipe should preferably slope downward
from source connection to instrument and instrument shall be installed below the source
point. If due to any reason instrument is installed above the source point, the impulse pipe
should slope upwards continuously and a 'pigtail' should be provided at the instrument to
assure water seal for temperature protection. For vacuum measurements instrument shall be
installed above source point and impulse pipe should slope upwards.
3.02.02 Impulse piping for air and flue gas shall slope upwards and instrument shall be installed
above source point. If this requirement cannot be met special venting or drain provision shall
be provided with vent & drain lines alongwith isolation valves and other accessories including
drainpipes. This drain is to be connected to plant drain through open funnel also. Horizontal
runs must have a slope of not less than 40 mm per meter and must be adequately supported
to maintain a constant slope and to prevent sag in piping.
3.02.03 All impulse piping shall be installed to permit free movement due to thermal expansion.
Wherever required expansion loops shall be provided.
3.02.04 Special accessories such as condensing pots/ reservoirs shall be provided and installed
wherever required. In any case condensing pots shall be provided for all level measurements
in steam and water services, all flow measurement in steam services and flow
measurements water services above 120 Deg. C. For drum level measurement required
balancing chamber shall be provided and installed.
3.02.05 Colour coding of all impulse pipes shall be done by the Contractor in line with the colour
coding being followed for the parent pipes.
3.03.00 Instrument Air & Service Air Piping/ Tubing System
3.03.01 The air supply headers, sub-headers and branch pipes shall be supported properly by
clamps or supports to be provided and fabricated by the Contractor. Air supply piping shall be
installed with a slope of over 1/100 to prevent accumulation of condensed water within the
pipe. Signal/control air tubing shall run with the minimum number of changes in direction.
Suitable identification tags shall be provided for easy link up and checking of proper
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STAGE-II (2X660 MW)
SECTION-VI
PART-B
IIIC-06
PCP

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connections. Single and multi tubes shall run with the minimum number of changes in
direction. Suitable identification tags shall be provided for easy checkup and for connections.
4.00.00 PIPING/TUBING SUPPORT
Impulse piping and sample piping shall be supported at an interval not exceeding 1.5 meters.
Each pipe shall be supported individually using slotted angle mounted clamps with necessary
fixtures. Tubing shall run in proper perforated trays with proper cover. Tubing shall be
supported inside the trays by aluminium supports. Hangers and other fixtures required for
support of piping and trays shall be provided, either by welding or by bolting on walls, ceilings
and structures. Hanger clamps and other fastening hardware shall be of corrosion resistant
metals and hot-dip galvanized.
5.00.00 SHOP AND SITE TESTS
5.01.01 The equipment and work performed as per this Sub-section shall be subject to shop and site
test as per requirements of Sub-section-IIIE-04 (Quality Assurance & Inspection) other
applicable clauses of this Sub-section and Employer approved quality assurance plan.
5.01.02 Hydrostatic and pneumatic tests shall be performed on all pipes, tubing and systems and
shall conform to ANSI B31.1.
5.02.00 Hydrostatic Testing
All instrument piping/ tubing shall be hydrostatically tested upon completion of erection. The
test pressure shall be 1.5 times the maximum process pressure. The test shall be performed
either with the testing of associated process piping or without the associated process piping
(by closing the root valve). In both the cases the instrument shall be isolated by closing the
shut-off valve.
5.02.00 Air Testing
All air headers & branch pipes shall be air tested by pressure decay method as per ANSI
B31.1. Flexible hoses and short signal tubing shall be tested at normal pressure for leakage.
Long signal tubing shall be tested by charging each tube with air at 2 kg/ sq. cm. through a
bubbler sight glass. The boiler draft and vacuum piping shall be air tested by the same
method as long signal tubing.
6.00.00 LOCAL INSTRUMENT ENCLOSURE AND RACKS
The internal layout shall be such that the impulse piping/ blow down lines are accessible
from back side of the enclosure / rack and the transmitters etc. are accessible from front
side for easy maintenance. Bulkheads, especially designed to provide isolation from
process line vibration shall be installed on instrument enclosures/racks to meet the process
sensing line connection requirement.
Vibration dampeners shall be installed for each enclosure / rack.
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The enclosures shall be constructed of 1.6 mm sheet plate and shall be of modular
construction with one or more modules and two end assemblies bolted together to form an
enclosure. Channel and frame shall be 3 mm thick. Double inter locking doors shall be
provided. The doors shall be the three-point locking type constructed of not less than 1.6
mm thick steel. Doors shall have concealed quick removal type pinned hinges and locking
handles. Door locks shall accept the same key.
Gaskets shall be used between all mating sections to achieve protection class of IP-55.
The instrument racks shall be free standing type constructed of suitable 3 mm thick channel
frame of steel and shall be provided with a canopy to protect the equipment mounted in
racks from falling objects, water etc. The canopy shall not be less than 3 mm thick steel,
and extended beyond the ends of the rack. Bulk heads, especially designed to provide
isolation from process line vibration shall be provided. Exact fabrication details shall be as
finalised during detailed engineering stage. The junction box for racks also shall conform to
IP 55 protection class.
Enclosures/racks shall be reinforced as required to ensure true surface and to provide
adequate support for instruments and equipment mounted therein. Centre posts or any
member which would reduce access shall not be provided.
Each transmitter enclosure housing instruments requiring purge air for continuous air
purging, shall be provided with common purge air header, redundant air filter regulators of
sufficient capacity, required pressure gauges, valves, fittings, SS tubings and individual
purge meters for each purge line etc. as required and indicated in Instrument Installation
drawings enclosed herewith.
A 15 mm NB service air header shall be furnished in each instrument enclosure housing
air & flue gas and coal mill instruments. The header shall be furnished complete with a
pressure regulating valve, pressure gauge, and quick disconnect connections. A hose for
connecting each header to the draft instrument line four-way valves shall be furnished. The
hose shall be self-storing nylon tubing having a burst pressure of 15 kg/sq.cm. The size of
the hose shall be 1/2" minimum. The service air header shall originate at a bulkhead
penetration or fitting located on one of the bulkhead plates.
The contractor shall prepare the piping drawings and the general arrangement layout
drawings for each of the enclosures and racks. Special attention shall be given in the piping
layout to avoid air traps in liquid filled piping or water pockets in piping intended to be dry.
Drawings shall indicate the arrangement of all equipment, piping, valves and fittings within,
the enclosure/racks and shall be subject to Employer's approval.
All liquid filled blow down lines, except those measuring vacuum shall be connected to a
two inch header which is extended through one end of the enclosure and turned downward
for directing the blow down into a drain. The material of the blow down header shall be
carbon steel as per ASTM A 106 Gr C.
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The Contractor shall submit to the Employer with his proposal a copy of his welding
procedure specification together with proof of his compliance with the latest applicable
welding ANSI code. Prior to any welding being performed, the Contractor shall submit the
qualifications of the craftsmen who will perform the work.

STAGE-II (2X660 MW)
SECTION-VI
PART-B
IIIC-06
PCP

PAGE
9 OF 9

7.00.0 TABLE PCP
System/Line Description Piping
Class
Impulse Pipe
Material
Schedule (Size) Materials for
Fitting/Valve Body
Valve Stem Material Rating of
Piping/ Fittings
Pr. Class
of Valve
Main Steam/ Upstream of HP bypass and Auxiliary
Steam Pressure reducing valve, Drum Level
A ASTM-A335 Gr.P-
91/22 (Note-2)
XXS (1/2 inch) (Note-3) (Note-3) 9000 lb 3000 SPL
BFP disch, superheater attemperator, spray to
PRDS, Phosphate dozing pp disch, BCW pump
B ASTM-A106 Gr. C 160 (1/2 inch) ASTM-A105 ASTM-A-182 Gr.F6a 6000 lb 2500
Reheater attemperator C ASTM-A106 Gr. C 160 (1/2 inch) ASTM-A105 -do- 6000 lb 1500
Hot Reheat/ down stream of Aux. Steam press.
Reducing valve upto desuper heater/ Flash tank
drain manifold, HP heater level.
D ASTM-A335 Gr. P-
91/22 (Note-2)
160 (1/2 inch) ASTM-A182 Gr.F-22 (Note-3) 3000 lb 900
Cold reheat upto Tee-off for HP Bypass / Extraction
steam to HPH
E ASTM-A335 Gr.P-
22
80 (1/2 inch) ASTM-A182 Gr.F-22 ASTM-A-182 Gr.F6a 3000 lb 800
Cold reheat down steam of Tee-off (HP Bypass) F ASTM-A106 Gr. C 80 (1/2 inch) ASTM-A105 -do- 3000 lb 800
BFP suction, Condensate System/ Extraction to
LPH/ Ext-4 to BFPT, Deaerator/ auxiliary steam,
service air, inst air, ECW pump, ACW pump and
other low pr water services
G ASTM-A106 Gr. B 80 (1/2 inch) ASTM-A105 -do- 3000 lb 800
Air/ Flue gas outside furnace M ASTM-A106 Gr.
B/C
80 (3/4 inch) ASTM-A105 -do- 3000 lb 800
Air/ Flue gas inside furnace N ASTM-A335 Gr.P22 80 (3/4 inch) ASTM-A182 Gr. F-22 -do- 3000 lb 800
NOTE:
1 Rating of piping/fittings/valves etc. is subjected to the final design pressure & temperature during the detailed engineering.
2 In case temperature is more than 540 deg C, the material shall be P-91 only.
3 Material shall be compatible with that of the impulse pipe material and design parameter.
4 Separator related impulse piping material shall be as per main process pipe/tank material
CLAUSE NO.

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IIIC-07
INSTRUMENTATION
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IIIC - 07
INSTRUMENTATION AND
POWER SUPPLY CABLES

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INSTRUMENTATION AND POWER SUPPLY CABLE
1.00.00 INSTRUMENTATION CABLE, POWER SUPPLY CABLE, INTERNAL WIRING AND
ELECTRICAL FIELD CONSTRUCTION MATERIAL
1.01.01 All cables including special cables, internal wiring and electrical field construction material
shall conform to this specification, Employer approved detail engineering drawings &
documents and the latest edition of the relevant standards & guidelines. The Bidder shall
furnish all material and services required for the completeness of the work identified in his
scope as per this specification.
1.01.02 The Contractor shall supply, erect, terminate and test all instrumentation cables for control
and instrumentation equipment/devices/systems included under Contractor's scope as
illustrated in the enclosed Drg. No. 0000-110-POI-A-021 and ensuring completeness of the
control system.
1.01.03 Any other application where it is felt that instrumentation cables are required due to
system/operating condition requirements, are also to be provided by Contractor.
1.01.04 Other type of cables like fiber optic/co-axial cables for system bus, cables for connection of
peripherals etc. (under Contractor's scope) are also to be furnished by the Contractor.
1.01.05 Contractor shall supply all cable erection and laying hardware from the main trunk routes like
branch cable trays/sub-trays, supports, flexible conduits, cable glands, lugs, pull boxes etc.
on as required basis for all the systems covered under this specification.
1.01.06 Wherever the quantity has been defined as on as required basis, the same are to be
furnished by contractor on as required basis within his quoted lump sump price without any
further cost implication to the Employer.
2.00.00 Specification of Instrumentation cable
2.01.00 Common Requirements
S.
No.
Property Requirement
1 Voltage grade 225 V (peak value)
2. Codes and standard All instrumentation cables shall comply with
VDE 0815, VDE 0207, Part 4, Part 5, Part
6, VDE 0816, VDE 0472, SEN 4241475,
ANSI MC 96.1, IS-8784, IS-10810 (latest
editions) and their amendments read along
with this specification.

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S.
No.
Property Requirement
3. Continuous operation suitability At 70 deg. C for all types of cables, while
205 Deg C for Type-C cables.
4. Progressive automatic on-line
sequential marking of length in meters
To be provided at every one meter on outer
sheath.
5. Marking to read FRLS To be provided at every 5 meters on outer
sheath except for Type-C cable.
6. Allowable Tolerance on overall
diameter
+/- 2 mm (maximum) over the declared
value in data sheet
7. Variation in diameter Not more than 1.0 mm throughout the
length of cable.
8 Ovality at any cross-section Not more than 1.0 mm
9 Others a) Durable marking at intervals not
exceeding 625 mm shall include
manufacturers name, insulation
material, conductors size, number of
pairs, voltage rating, type of cable,
year of manufacturer to be provided.
b) Cables shall be suitable for laying in
conduits, ducts, trenches, racks and
underground-buried installation
c) Repaired cables shall not be
acceptable.
2.02.00 Specific Requirements
Specification
Requirements
Type-A cable Type-B
cable
Type F & G
cable
Type-C cable
A. Conductors
Cross section area 0.5 sq. mm
Conductor material ANSI type KX ANSI type
SX
High conductivity
Annealed bare
copper
ANSI type KX
Colour code Yellow-Red Black-Red As per VDE-815 Yellow-Red
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Conductor Grade As per ANSI MC 96.1 Electrolytic As per ANSI MC
96.1
No & dia of strands 7x0.3 mm (nom)
No. of Pairs 2 2 4,8,12,16,24,48 2
Max. conductor
resistance per Km
(in ohm) at 20 deg.
C
As per ANSI MC 96.1 73.4 (loop) As per ANSI MC
96.1
Reference
Standard
As per ANSI MC 96.1 VDE 0815 As per ANSI MC
96.1
B. Insulation
Material PVC type YI 3 Teflon (i.e.
extruded FEP)
Thickness in mm
(Min/Nom/Max)
0.25/0.3/0.35 0.4/0.50
Volume Resistivity
(Min) in ohm-cm
1 x 10
14
at 20 deg. C & 1x10
11
at 70 deg. C. ---
Voltage Rating 225 V peak operating voltage
Reference
Standard
VDE 0207 Part 4 VDE 0207 Part 6
& ASTMD 2116.
Core diameter
above insulation
Suitable for cage clamp connector
C. Pairing & Twisting
Max. lay of pairs
(mm)
50
Single layer of
Polyester tape on
each pair provided
Numbered tape Yes N.A.
Unit formation of
four pairs with
printing of no. of
Unit provided
N.A.

Yes N.A.
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Conductor /pair
identification as per
VDE0815
N.A.

To be provided
(color coding
attached).
N.A.
D. Shielding
Type of shielding Al-Mylar tape
Individual pair
shielding
No To be provided
for F-type cable
No
Minimum thickness
of Individual pair
shielding
No 28 micron No
Overall cable
assembly shielding
To be provided
Minimum thickness
of Overall cable
assembly shielding
55 micron
Shielding coverage 100% with at least 20% overlap
Drain wire provided
for individual shield
N.A.

Yes (for F-type)
7-strand 20
AWG (0.51 mm
2
)
annealed Tin
coated copper
N.A.
Drain wire provided
for overall shield
Yes. 7-strand 20 AWG (0.51 mm
2
) annealed Tin coated copper
E. FILLERS
Non-hygroscopic,
flame retardant
To be provided
F. Outer Sheath
Material Extruded PVC compound YM1 with FRLS
properties
Teflon (i.e.
extruded FRP)
Minimum Thickness
at any point
1.8 mm 0.4 mm
Nominal Thickness
at any point
>1.8 mm 0.5 mm
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Color Blue
Resistant to water,
fungus, termite &
rodent attack
Required
Oxygen index as
per ASTMD-2863
not less than 29% N.A.
Temperature index
as per ASTMD-
2863
not less than 250 deg.C N.A.
acid gas generation
by weight as per
IEC-60754-1
Maximum 20% N.A.
Smoke Density
Rating as per
ASTMD-2843
Maximum 60%
(defined as the average area under the curve
when the results of smoke density test plotted
on a curve indicating light absorption vs. time as
per ASTMD-2843)
N.A.
Reference standard VDE207 Part 5 VDE207 Part 6 &
ASTM D2116
G. Electrical
Parameters

MUTUAL
CAPACITANCE
BETWEEN
CONDUCTORS
AT 0.8 KHZ
(MAX.)
200 nF/km 120 nF/km for F
type
100 nF/km for G-
type
200 nF/km
INSULATION
RESISTANCE
(MIN)
100 M Ohm/Km
CROSS TALK
FIGURE (MIN.) AT
0.8 KHZ
60 Db 60 dB N.A.
CHARACTERISTIC
IMPEDANCE
N.A. 320 ohm for F-
type
N.A.
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(MAX) AT 1 KHZ
340 ohm for G-
type
ATTENUATION
FIGURE AT 1 KHZ
(MAX)
N.A. 1.2 db/km N.A.
H. Complete Cable
Complete Cable
assembly
Shall pass Swedish Chimney test as per SEN-
SS 4241475 class F3.
N.A.
Flammability Shall pass flammability as per IEEE-383 read in
conjunction to this specification
N.A.
I. Accessories
Cable accessories
of flame retardant
quality.
Yes. (Accessories such as harnessing components, markers,
bedding, cable jointer, binding tape etc.)
J. Tests
Routine &
Acceptance tests
Refer sub-section IIIE
Type tests Refer sub-section-CNI TYPE TEST
K Cable Drum
Type Non-returnable wooden drum (wooden drum to be constructed from
seasoned wood free from defects with wood preservative applied to
the entire drum) or steel drum.
Outermost layer
covered with
waterproof paper
Yes
Painting Entire surface to be painted
Length 1000 m +5% for up to & including 12 pairs
500 m +5% for above12 pairs
3.00.00 SPECIFICATION OF OPTICAL FIBER CABLES (OFC)
3.01.00 Optic Fiber cable shall be 4/8/12 core, galvanised corrugated steel taped armoured, fully
water blocked with dielectric central member for outdoor/indoor application so as to prevent
any physical damage. The cable shall have multiple single-mode or multi mode fibers on as
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required basis so as to avoid the usage of any repeaters. The core and cladding diameter
shall be 9 +/- 1 micrometer and 125 +/- 1 micrometer respectively. The outer sheath shall
have Flame Retardant, UV resistant properties and are to be identified with the
manufacturers name, year of manufacturer, progressive automatic sequential on-line
marking of length in meters at every meter on outer sheath.
3.02.00 The cable core shall have suitable characteristics and strengthening for prevention of
damage during pulling viz. Steel central member, Loose buffer tube design, 4 fibers per
buffer tube (minimum), Interstices and buffer tubes duly filled with Thixotropic jelly etc. The
cable shall be suitable for a maximum tensile force of 2000 N during installation, and once
installed, a tensile force of 1000 N minimum. The compressive strength of cable shall be
3000 N minimum& crush resistance 4000 N minimum. The operating temperature shall be
20 deg. C to 70 deg.C
3.03.00 All testing of the fiber optic cable being supplied shall be as per the relevant IEC, EIA and
other international standards.
3.04.00 Bidder to ensure that minimum 100% cores are kept as spares in all types of optical fibre
cables.
3.05.00 Cables shall be suitable for laying in conduits, ducts, trenches, racks and under ground
buried installation.
3.06.00 Spliced / Repaired cables are not acceptable.
3.07.00 Penetration of water resistance and impact resistance shall be as per IEC standard.
4.00.00 SPCIFICATION OF POWER SUPPLY CABLES
Refer relevant subsections of this specification.
5.00.00 INSTRUMENTATION CABLE INTERCONNECTION AND TERMINATION PHILOSOPHY
The cable interconnection philosophy to be adopted shall be such that extensive grouping of
signals by large scale use of field mounted Group J unction Boxes (J Bs) at strategic locations
(where large concentration of signals are available, e.g. valves limit & torque switches,
switchgear) is done and consequently cable with higher number of pairs are extensively
used. The details of termination to be followed are mentioned in the given Table A.

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TABLE A: CABLE TERMINATION TO BE FOLLOWED
Application Type Of Termination Type Of
Cable
FROM (A) TO (B) END A END B
Valves/dampers
drives (Integral
J unction box)
Marshalling cubicle/
Marshalling cum
termination
Cubicle/local group
J B
Plug in
connector
Posts mount
cage clamp
type.
G
Transmitters,
Process Actuated
switches mounted
in LIE/LIR
Integral J unction box
of LIE/LIR
Plug in
connector
Cage clamp
(Rail mount)
type.
F,G
RTD heads Local junction box Plug in
connector
Cage clamp
(Rail mount)
type.
F
Thermocouple CJ C Box (if
applicable)
Plug in
connector
Cage clamp
(Rail mount)
type.
A,B,C*
Other Field
Mounted
Instrument
Local J B/Group J B Plug in
connector
Screwed, Cage
clamp (Rail
mount) type
F,G
RTD Temperature
transmitter
Plug in
connector
Screwed, Cage
clamp type
F
Thermocouple Temperature
transmitter
Plug in
connector
Screwed, Cage
clamp type
A,B,C*
Local J unction
box, Temperature
Transmitter, Int.
J unction box of
LIE/ LIR/Group
J B/ MCC/SWGR
Group J B Cage clamp
(Rail mount)
type.
Cage clamp
(Rail mount)
type.
F,G
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Local J unction
box, Temperature
Transmitter, Int.
J unction box of
LIE/ LIR/Group
J B/ MCC/SWGR
Marshalling Cubicle/
Marshalling cum
Termination Cabinet
Cage clamp
(Rail mount)
type.
Posts mount
cage clamp
type.
F,G
Marshalling
cubicle/
Termination
Cabinet
Electronic system
cabinet
Cage clamp
Post
mounted
type.
Plug in
connector/Othe
r System as per
manufacturers
Standard
Internal
wiring
Marshalling/
Termination
System Cabinets
UCD mounted
equipments

Post mount
cage clamp
type.
Plug in
connector/Cage
clamp type (rail
mounted).
F,G (with
plug-in
connector
at one end)
DDCMIS/PLC
cabinets
PC, Printers etc. Plug in
connector
Plug in
connector
Mfr.s
Standard
Notes 1. Normally 10% spare cores shall be provided when the numbers
of pairs of cables are more than four pairs except for pre-
fabricated cables which shall be as per manufacturers standard.
2. For analog signals, individual pair shielding & overall shielding &
for Binary signals, only overall shielding of instrumentation
cables shall be provided.
3. Also refer Drg. 0000-110-POI-A-021.
4. *For high temperature applications only.
5. Instrument Cabling for instruments/equipments covered under
subsection MAIN EQP INST SYS shall be as per manufacturers
standard .
6.00.00 TERMINAL BLOCKS
6.01.00 All terminal blocks shall be rail mounted/post mounted, cage clamp type with high quality
non-flammable insulating material of melamine suitable for working temperature of 105 deg.
C. The terminal blocks in field mounted junction boxes, temperature transmitters, instrument
enclosures/racks, etc., shall be suitable for cage clamp connections. The terminal blocks in
Control Equipment Room logic/termination/marshalling cubicles shall be suitable for post
mounted cage clamp connection at the field input end. The terminal blocks for DDCMIS
input/output connections from/to SWGR/MCC, Actuators with Integral Starter (for coupling
relays and check back signals of 11 kV and 3.3 kV auxiliaries, LT drives/valves &
dampers/solenoids, CT & VT, etc.) shall be provided with built in test and disconnect facilities
complete with plug, slide clamp, test socket etc. The exact type of terminal blocks to be
provided by the Bidder and the technical details of the same including width etc. shall be
subject to Employer's approval.
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6.02.00 All the terminal blocks shall be provided complete with all required accessories including
assembly rail, locking pin and section, end brackets, partitions, small partitions, test plug
bolts and test plug (as specified above for SWGR connections) transparent covers, support
brackets, distance sleeves, warning label, marking, etc.
6.03.00 The marking on terminal strips shall correspond to the terminal numbering on wiring
diagrams. For terminals catering to Employers supplied system requirement at least 20%
spare unused terminals shall be provided everywhere including local junction boxes,
instrument racks/enclosures etc.

For terminals catering to contractors supplied system requirement at least 10% spare used
terminals shall be provided everywhere including local junction boxes, instrument
racks/enclosures termination/marshalling cabinets.

All terminal blocks shall be numbered for identification and grouped according to the function.
Engraved labels shall be provided on the terminal blocks
6.04.00 For terminating each process actuated switches, drive actuators, control valves,
Thermocouple, RTD, etc. in Local J unction Boxes, etc, refer Drg no. 0000-999-POI-A-065.
6.05.00 The terminal blocks shall be arranged with at least 100 mm clearance between two sets of
terminal blocks and between terminal blocks and junction box walls.
6.06.00 For ensuring proper connections, Bidder shall provide suitable accessories, along with
insulation sleeves. The exact connecting accessory shall be finalised as per application
during detail engineering stage subject to Employer's approval without any cost
repercussions.
6.07.00 Internal wiring in factory pre-wired electronic equipment cabinets may be installed according
to the Bidder's standard as to wire size and method of termination or internal equipment.
Terminal blocks for connection of external circuits into factory prewired electronic equipment
cabinets shall meet all the requirements as specified above.

7.00.00 INTERNAL PANELS/ SYSTEM CABINETS WIRING
7.01.00 Internal panel/cabinet wiring shall be of multi-stranded copper conductor with FRLS PVC
insulation without shield and outer sheath meeting the requirements of VDE 0815.
7.02.00 Wiring to door mounted devices shall be done by 19 strand copper wire provided with
adequate loop lengths of hinge wire so that multiple door opening shall not cause fatigue
breaking of the conductor.
7.03.00 All internal wires shall be provided with tag and identification nos. etched on tightly fitted
ferules at both ends in Employer's approved format. All wires directly connected to trip
devices shall be distinguished by one additional red colour ferrule.
7.04.00 All external connection shall be made with one wire per termination point. Wires shall not be
tapped or spliced between terminal points.
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7.05.00 All floor slots of desk/panels/cabinets used for cable entrance shall be provided with
removable gasketed gland plates and sealing material. Split type grommets shall be used for
prefabricated cables.
7.06.00 All the special tools as may be required for solder less connections shall be provided by
Bidder.
7.07.00 Wire sizes to be utilised for internal wiring.
(i) Current (4-20 mA), low voltage signals
(48V); Ammeter/Voltmeter circuit, control
switches etc. for electrical system.
0.5 Sq.mm.

(ii) Power supply and internal illumination. 2.5Sq.mm.
minimum (shall be
as per load
requirement.)
8.00.00 INSTRUMENTATION CABLE INSTALLATION AND ROUTING
8.01.00 All cables assigned to a particular duct/conduit shall be grouped and pulled in simultaneously
using cable grips and suitable lubricants. Cables removed from one duct/conduit shall not be
reused without approval of Employer.
8.02.00 Cables shall be segregated as per IEEE Std.-422. In vertically stacked trays, the higher
voltage cable shall be in higher position and instrumentation cable shall be in bottom tier of
the tray stack. The distance between instrumentation cables and those of other system shall
be as follows:
From 11 kV/6.6 kV/3.3 kV tray system - 914 mm
From 415V tray system - 610 mm
From control cable tray system - 305 mm
8.03.00 Cables shall terminate in the enclosure through cable glands. All cable glands shall be
properly gasketed. Fire proof sealing (to prevent ingress of dust entry and propagation of fire)
shall be provided for all floor slots used for cable entrance. Compression cable glands
(double for armoured and single for other cables) shall be provided.
8.04.00 All cables shall be identified by tag. Nos. provided in Employer's approved format at both the
ends as well as at an interval of 5 meters.
8.05.00 Line voltage drop due to high resistance splices, terminal contacts, insulation resistance at
terminal block, very long transmission line etc. shall be reduced as far as practicable.
8.06.00 The cables emanating from redundant equipment/devices shall be routed through different
paths. The above segregation of cables & wiring for redundant equipments/devices shall be
in accordance with IEEE-Std-422.
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9.00.00 CABLE LAYING AND ACCESSORIES
9.01.00 CABLE LAYING
1 CABLES SHALL BE LAID STRICTLY IN LINE WITH CABLE SCHEDULE.
2 IDENTIFICATION TAGS FOR CABLES.
INDELIBLE TAGS TO BE PROVIDED AT ALL TERMINATIONS, ON BOTH
SIDES OF WALL OR FLOOR CROSSING, ON EACH CONDUIT/DUCT/PIPE
ENTRY/EXIT, AND AT EVERY 20 M IN CABLE TRENCH/TRAY.
3 CABLE TRAY NUMBERING AND MARKING.
TO BE PROVIDED AT EVERY 10M AND AT EACH END OF CABLE WAY &
BRANCH CONNECTION.
4 J OINTS FOR LESS THAN 250 METERS RUN OF CABLE SHALL NOT BE
PERMITTED.
5 BURIED CABLE PROTECTION
WITH CONCRETE SLABS; ROUTE MARKERS AT EVERY 20 METERS ALONG
THE ROUTE & AT EVERY BEND.
6 ROAD CROSSINGS
CABLES TO PASS THROUGH BURIED HIGH DENSITY PE PIPES ENCASED IN
PCC. AT LEAST 300 MM CLEARANCE SHALL BE PROVIDED BETWEEN
- HT POWER & LT POWER CABLES,
- LT POWER & LT CONTROL CABLES
- LT CONTROL & INSTRUMENTATION CABLES,
SPACING BETWEEN CABLES OF SAME VOLTAGE GRADE SHALL BE IN
ACCORDANCE WITH THE DERATING CRITERIA ADOPTED FOR CABLE
SIZING.
7 SEGREGATION (PHYSICAL ISOLATION TO PREVENT FIRE J UMPING)
A ALL CABLE ASSOCIATED WITH THE UNIT SHALL BE SEGREGATED
FROM CABLES OF OTHER UNITS.
B INTERPLANT CABLES OF STATION AUXILIARIES AND UNIT CRITICAL
DRIVES SHALL BE SEGREGATED IN SUCH A WAY THAT NOT MORE
THAN HALF OF THE DRIVES ARE LOST IN CASE OF SINGLE INCIDENT
OF FIRE.
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8 CABLE CLAMPING
ALL CABLES LAID ON TRAYS SHALL BE NEATLY DRESSED UP & SUITABLY
CLAMPED/TIED TO THE TRAY. FOR CABLES IN TREFOIL FORMATION,
TREFOIL CLAMPS SHALL BE PROVIDED.
9 Optical fiber cables inside conduit shall be laid on cable trays wherever
available and feasible. In areas where the same are required to be buried, the
same shall be buried in separate trench approx.1.6 meter depth, to be laid in
2 GI/rodent proof HDPE conduits covered with sand, brick and soil along
the pipe line route;
While crossing roads - to be laid in GI/rodent proof HDPE conduits with sand
filling at bottom and sand, soil filling at top with cement concrete;
While crossing canals/river- to be laid in GI/rodent proof HDPE conduits
within hume pipe.
9.02.00 Bidder shall supply and install all cable accessories and fittings like Light Interface Units,
Surge suppressors, Opto isolators, Interface Converters, Fibre Optic Card Cage, Fibre Optic
Line Driver, Repeater / Modem (for Optical Fibre Cables), cable glands, grommets, lugs,
termination kits etc. on as required basis.
9.03.00 Bidder shall furnish two completely new sets of cable termination kits like Crimping tools,
etc., which are required for maintenance of the system as per the type of termination used.
9.04.00 Cables, which terminate in cabinets of draw out sections shall have sufficient cable coiled in
the bottom of the cabinet to permit full withdrawal of draw out sections without disconnecting
the cables. When prefabricated cables with factory connectors on both ends are longer than
required, the excess cable shall be coiled in the bottom of one or both termination cabinets.
9.05.00 No splices shall be made in conductors for instrument and control circuits except where
required at connections to devices equipped with factory installed pigtails. Such splices shall
be made only in approved splicing boxes of fitting with removable cover. The splices shall be
made with sufficient slack left in the wires to permit withdrawal of the splice from the splicing
box for ease of future disconnection of the splices. All exposed conductor or connector
surfaces shall be covered with a minimum of three half-lapped layers of all weather vinyl
plastic electrical tape. Taping shall extend a minimum of two cable diameters over the cable
jacket and a similar distance over the other insulation or connections requiring insulation.
9.06.00 The Bidder shall be responsible for proper grounding of all equipment under C&I package.
Further, proper termination of cable shields shall be verified and the grounding of the same
shall be coordinated so as to achieve grounding of all instrumentation cable shields at same
potential. This shall be completed prior to system tests. All the cables etc. required for
grounding of all equipments supplied under this package are to be supplied by the Bidder.
9.07.00 The Contractor shall take full care while laying / installing cables as recommended by cable
manufacturers regarding pulling tensions and cable bends. Cables damaged in any way
during installation shall be replaced at the expense of the Contractor.
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10.00.00 FIELD MOUNTED LOCAL JUNCTION BOXES
(i) No. of ways 12/24/36/48/64/72/96/128 with 20% spares terminals.
(ii) Material and
Thickness
4mm thick Fiberglass Reinforced Polyester (FRP).
(iii) Type Door gasket shall be of synthetic rubber.
(iv) Mounting clamps
and accessories
Suitable for mounting on walls, columns, structures etc. The
brackets, bolts, nuts, screws, glands and lugs required for
erection shall be of brass, included in Bidders scope of supply.
Raceways shall be provided inside J Bs for proper termination
of cables.
(v) Type of terminal
blocks
Rail mounted cage-clamp type suitable for conductor size upto
2.5 mm
2
. A M6 earthing stud shall be provided.
(vi) Protection Class IP: 55 minimum for indoor & IP-65 minimum for outdoor
applications.
(vii) Grounding To be provided.
(viii) Color To be decided during detailed engineering & subject to
Employers approval.
11.00.00 CONDUITS
11.01.00 Conduits shall be generally used for interconnecting cables from field instruments to Local
J Bs. All rigid conduits, couplings and elbows shall be hot dipped galvanised rigid mild steel
in accordance with IS: 9537 Part-I (1980) and Part-II (1981). The conduit interior and exterior
surfaces shall have continuous zinc coating with an overcoat of transparent enamel lacker or
zinc chromate. Flexible conduit shall be heat resistant lead coated steel, water leak, fire and
rust proof. The temperature rating of flexible conduit shall be suitable for the following areas.
(i) Mills
(ii) Drum
(iii) Main steam, RH steam
(iv) Air heater
(v) Furnace, BFP DTs
And for remaining applications, water leak, fire & rust proof flexible G.I conduits shall
be provided.
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11.02.00 The Bidder shall install conduits according to the general routing as approved by Employer
and shall coordinate conduit locations with other works.
11.03.00 All grounding bushings within all enclosures shall be wired together and connected internally
to the enclosure grounding lug or grounding bus with 8 AWG bare copper conductor. Conduit
runs to individually mounted equipment shall be grounded to the Employer's cable tray
grounding conductor with 12 AEG bare copper conductor. All grounding bushings, clamps
and connectors shall be subject to approval of the Employer.
11.04.00 All rigid conduit fittings shall conform to the requirements of IS: 2667, 1976. Galvanized steel
fitting shall be used with steel conduit. All flexible conduit fittings shall be liquid tight,
galvanized steel. The end fittings shall be compatible with the flexible conduit supplied.
11.05.00 All individually mounted equipment and devices shall be connected to the supply conduit,
using not more than one meter of flexible conduit adjacent to the equipment or device.
Flexible conduit shall be installed in all conduit runs, which are supported by both building
steel and structures subject to vibration or thermal expansion. This shall include locations
where conduit supported by building steel enters or becomes supported by the turbine
generator foundation and where conduit supported by building steel or foundation becomes
supported by steam generator framing.
11.06.00 Special areas, such as control rooms in which external noise is to be minimized, shall have
flexible conduit in conduit runs where the runs cross from the main building framing to the
control room framing.
11.07.00 Conduit supports shall be furnished and installed in accordance with these specifications.
Support material shall comply with the following requirements.
i) Hanger rods shall be 12 mm diameter galvanized threaded steel rods.
ii) Single conduit supports shall be one-hole cast metal straps and clamp backs unless
other types are acceptable to the Employer. Multiple conduit bank supports shall be
constructed of special galvanized support channels with associated conduit clips.
11.08.00 Conduit sealing, explosion proof, dust proof and other types of special fittings shall be
provided as required by these specifications and shall be consistent with the area and
equipment with which they are installed. Fittings installed outdoors and in damp locations
shall be sealed and gasketed. Hazardous area fittings and conduits sealing shall conform to
NEC requirements for the area classification.
11.09.00 Contractor shall provide double locknuts on all conduit terminations not provided with
threaded hubs and couplings. Water tight conduit unions and rain tight conduit hubs shall be
utilised for all the application which shall be exposed to weather. Moisture pockets shall be
eliminated from conduits.
11.10.00 Conduits shall be securely fastened to all boxes and cabinets.
12.00.00 CABLE SUB-TRAY & SUPPORT
12.01.00 The cable sub-trays and the supporting system, to be generally used between Local/Group
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J Bs and the main cable trays and the same shall be furnished and installed by the
Contractor. It is the assembly of sections and associated fittings forming a rigid structural
system used to support the cable from the equipment or instrument enclosure upto the main
cable trays (trunk route).
12.02.00 The covers on the cable sub-trays shall be used for protection of cables in areas where
damage may occur from falling objects, welding spark, corrosive environment, etc. & shall be
electrically continuous and solidly grounded. The cable trays shall not have sharp edges,
burrs or projections injurious to the insulation or outer sheath of the cables.
12.03.00 The supporting arrangement of cable tray system shall be able to withstand the weight of the
cable and cable tray system. The supporting interval shall not be more than the
recommended span for the above loading for the type of cable tray selected. The tray shall
not overhang by more than one meter from the support at the dead end. As far as practicable
the cable sub-tray system shall be supported from one side only, in order to facilitate
installation and maintenance of cables.
12.04.00 The Bidder shall furnish and install the estimated quantities and sizes of sub trays/troughs
including all required fittings and adaptors on as required basis.

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IIIC-8
CONTROL VALVES ,
ACTUATORS AND
ACCESSORIES
PAGE
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IIIC - 08
CONTROL VALVES, ACTUATORS
AND ACCESSORIES
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CONTROL VALVES ,
ACTUATORS AND
ACCESSORIES
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CONTROL VALVES AND ACTUATORS
1.00.00 CONTROL VALVES, ACTUATORS & ACCESSORIES
1.01.01 The control valves and accessories equipment furnished by the Bidder shall be designed, con-
structed and tested in accordance with the latest applicable requirements of code for pressure
piping ANSI B 31.1, the ASME Boiler & pressure vessel code, Indian Boiler Regulation (IBR),
ISA, and other standards specified elsewhere as well as in accordance with all applicable
requirements of the Federal Occupational Safety and Health Standards, USA or acceptable
equal standards. All the Control Valves, their actuators and accessories to be furnished under
this Sub-section will be fully suitable and compatible with the modulating loops covered under
the Specification.
1.01.02 All the control valves and accessories offered by the Bidder shall be from reputed,
experienced manufacturers of specified type and range of valves.
1.01.03 This specification does not cover special type of control valves such as combined pressure
and temperature control valve for Aux PRDS applications, Separator Drain Control Valves etc.
1.02.00 CONTROL VALVE SIZING & CONSTRUCTION
1.02.01 The design of all valve bodies shall meet the specification requirements and shall conform to
the requirements of ANSI (USA) for dimensions, material thickness and material specification
for their respective pressure classes.
1.02.02 The valve sizing shall be suitable for obtaining maximum flow conditions with valve opening at
approximately 80% of total valve stem travel and minimum flow conditions with valve stem
travel not less than 10% of total valve stem travel. All the valves shall be capable of handling
at least 120% of the required maximum flow. Further, the valve stem travel range from
minimum flow condition to maximum flow condition shall not be less than 50% of the total
valve stem travel. The sizing shall be in accordance with the latest edition of ISA handbook on
control valves. While deciding the size of valves, Bidder shall ensure that valves trim exit outlet
velocity as defined in ISA handbook does not exceed 8 m/sec for liquid services, 150 m/sec.
for steam services and 50% of sonic velocity for flashing services. Bidder shall furnish the
sizing calculations clearly indicating the outlet velocity achieved with the valve size selected by
him as well as noise calculations, which will be subject to Employers approval during detailed
engineering.
1.02.03 Control valves for steam and water applications shall be designed to prevent cavitation, wire
drawing, flashing on the downstream side of valve and down stream piping. Thus for
cavitation/flashing service, only valve with anti cavitation trim shall be provided. Detailed
calculations to establish whether cavitation will occur or not for any given application shall be
furnished.
1.02.04 Control valves for application such as HP/LP heater Emergency level control, Emergency
Make-up to Condenser hotwell, GSC minimum flow, Deaerator Drain to condenser hotwell,
condensate spill to condensate reserve tank, condenser normal make-up and valve gland
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CONTROL VALVES ,
ACTUATORS AND
ACCESSORIES
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sealing supplying pressure control, CEPS minimum flow control, BFP recirculation control
valve shall have permissible leakage rate as per leakage Class V. All other control valve shall
have leakage rate as per leakage Class-IV.
1.02.05 The control valve induced noise shall be limited to 85 dBA at 1 meter from the valve surface
under actual operating conditions. The noise abatement shall be achieved by valve body and
trim design and not by use of silencers.
2.00.00 VALVE CONSTRUCTION
2.01.00 All valves shall be of globe body design & straightaway pattern with single or double port,
unless other wise specified or recommended by the manufacturer to be of angle body type.
Rotary valve may alternatively be offered when pressure and pressure drops permit.
2.02.00 Valves with high lift cage guided plugs & quick-change trims shall be supplied.
2.03.00 Cast Iron valves are not acceptable.
2.04.00 Bonnet joints for all control valves shall be of the flanged and bolted type or other construction
acceptable to the Employer. Bonnet joints of the internal threaded or union type will not be
acceptable.
2.05.00 Plug shall be of one-piece construction cast, forged or machined from solid bar stock. Plug
shall be screwed and pinned to valve stems or shall be integral with the valve stems.
2.06.00 All valves connected to vacuum on down stream side shall be provided with packing suitable
for vacuum applications (e.g. double vee type chevron packing)
2.07.00 Valve characteristic shall match with the process characteristics.
2.08.00 Extension bonnets shall be provided when the maximum temperature of flowing fluid is greater
than 280 deg. C.
2.09.00 Flanged valves shall be rated at no less then ANSI press class of 300 lbs.
3.00.00 VALVE MATERIALS
Sr.
No.
Service Body material Trim Material
Carbon steel ASTM-A216 Gr.
WCB for fluid temperature below
275 Deg. C
1 Non-corrosive,
non-flashing
and non-
cavitation
service except
DM service
Alloy steel ASTM-A217Gr. WC9
for fluid temperature above 275
Deg. C
316SS stellited with stellited
facedguide posts and
bushings.
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2. Severe
flashing/cavitati
on services
Alloy steel ASTM-A217 Gr. WC9 440 C
3. Low
flashing/cavitati
on service
Alloy steel ASTM-A217 Gr. WC6 17-4 PH SS
4. DM water
service
316 SS 316 SS
NOTE Valve body rating shall meet the process pressure and temperature
requirement as per ANSI B16.34.
However, Bidder may offer valves with body and trim materials better than specified materials
and in such cases Bidder shall furnish the comparison of properties including cavitation
resistance, hardness, tensile strength, strain energy, corrosion resistance and erosion
resistance etc. of the offered material vis-a-vis the specified material for Employers
consideration and approval.
4.00.00 END PREPARATION
Valve body ends shall be either butt welded/socket welded, flanged (Rubber lined for
condensate service) or screwed as finalised during detailed engineering and as per
Employers approval. The welded ends wherever required shall be butt welded type as per
ANSI B 16.25 for control valves of sizes 65 mm and above. For valves size 50 mm and below
welded ends shall be socket welded as per ANSI B 16.11. Flanged ends wherever required
shall be of ANSI pressure-temperature class equal to or greater than that of the control valve
body.
5.00.00 VALVE ACTUATORS
All control valves shall be furnished with pneumatic actuators. The Bidder shall be responsible
for proper selection and sizing of valve actuators in accordance with the pressure drop and
maximum shut off pressure and leakage class requirements. The valve actuators shall be
capable of operating at 60 deg.C continuously.
Valve actuators and stems shall be adequate to handle the unbalanced forces occurring under
the specified flow conditions or the maximum differential pressure specified. An adequate
allowance for stem force, at least 0.15 Kg/sq.cm. per linear millimeter of seating surface, shall
be provided in the selection of the actuator to ensure tight seating unless otherwise specified.
The travel time of the pneumatic actuators shall not exceed 10 seconds.
6.00.00 CONTROL VALVE ACCESSORY DEVICES
6.01.00 All pneumatic actuated control valve accessories such as air locks, hand wheels/hand-jacks,
limit switches, microprocessor based electronic Positioner, diffusers, external volume
chambers, position transmitters (capacitance or resistance type only), reversible pilot for
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Positioner, tubing and air sets, solenoid valves and junction boxes etc. shall be provided as
per the requirements.
7.00.00 SPECIFICATIONS FOR MICROPROCESSOR BASED ELECTRONIC POSITIONER
Input Signal 4-20 mA
Power Supply Loop Powered from the output card of Control
System.
Hart Protocol Compatibility For Remote Calibration &
Diagnostics (Super-Imposed HART signal on
Input Signal 4-20 mA)
Electrical

Valve Position
Sensing
Position Sensing (Non Contact-Type), 4-20 mA
O/P Signal For Control System to be provided
Operating Temp (-)30 To 80 Deg. C
Humidity 0-95 %
Environment

Protection Class IP-65 Minimum
Remote
Configuration and
Diagnostics

a. The following functions shall be provided in the positioner:
Remote Configuration, Calibration and Testing of the Actuator and
advanced Diagnostic Features Like Stroke Counter or Travel Counter,
Leakage In Actuators, On Line Partial Closure Test, Valve Signature
Analysis, Step Response Test, Valve Friction/ J amming Detection etc.
(See Note* below)
b. Factory Valve Signature Tests Reports (Pr Vs Valve Travel And
Travel Vs I/P Signal) are to be provided.
Tests Certificates Test certificates as per Manufacturer Standard/Relevant Standard are
to be submitted
Configuration/ Remote Calibration, Auto & Manual Calibration Shall Be Possible
Operating Operating Range Full Range & Split Range Signal Range
Modes Valve Action Direct & Reverse. Valve Action
Flow
Characterisation
Possible To Fit Valve Characteristic Curve Linear
& Equal Percentage
Fail Safe/Fail
Freeze
Fail Safe/Fail Freeze Feature is to Be Provided.
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Air Capacity Sufficient To Handle The Valves
Selected/Boosters To Be Supplied If
required.
Air Supply Pressure To Suit The Air Supply Pressure/Quality
Available.
Pneumatic

Process Connection 1/4 Inch NPT
Characteristic
Deviation
<=0.5 % Of Span Performance

Ambient Temp Effect <=0.01 %/Deg C Or Better
EMC & CE
Compliance
Required To
International Standard
Like EN/IEC.
En50081-2 & En50082 Or Equivalent
In Built Operator Panel Display With Push Buttons For
Configuration And Display On The Positioner
Itself (Password Protected/Hardware Lock)
Hand Held Hart
Calibrator
Universal Hart Calibrator To Be Provided,
One Per Unit
Press Gauge Block For Supply & Output Pr., Filter Regulator
Other Accessories Shall Be Provided As On
Required Basis For Making System
Complete.
Electrical Cable Entry 1/2-Npt,Side Or Bottom Entry To Avoid
Water Ingress
Accessories

Valves Mounting
Assembly
For Sliding Stem/Rotary/Single
Acting/Double Acting On Required Basis
* Note:
Employer is providing a centralized HART management system including the HART
multiplexing/interfacing system. The HART signals shall be picked up from marshalling
terminals of DDCMIS (SG/TG DDCMIS as well as BOP DDCMIS), as applicable. The details
of the above mentioned employers HART management system are as below:

The following functionalities are provided through software of the HART management system:
1. For electronic transmitters, temperature transmitters and analysers:
a. Constant scanning to monitor faults or changes to instrument configuration.
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b. Employer-defined and standard calibration and configuration procedures for all
transmitters.
c. Constant signal data collection facilities to maintain continuously updated records.
d. Automatic tracking of configuration changes made in the field, such as may be
introduced by hand-held communicator. All configuration function associated with
hand-held communicators shall be available in the system.
e. Event and log reports on screen as well as on printer.
f. Any addition/deletion of transmitter will be reported on printer and logged in hard disk.
Above functionalities are achieved by the Employers HART management system by providing
industry standard softwares.

Further, the positioners shall be monitored from the above described HART management
system. To achieve this, Bidder shall provide the necessary software to achieve the
functionalities described above under Remote Configuration and Diagnostics, and this
software shall be loaded in the Employers HART management system.

Bidder has to list out in his bid the softwares that are compatible with his electronic
positioners.
8.00.00 TEST AND EXAMINATION
All valves shall be tested in accordance with the quality assurance programme agreed
between the Employer and Contractor, which shall meet the requirements of IBR and other
applicable codes mentioned elsewhere in the specifications. The tests shall include but not be
limited to the following:
8.01.00 Non Destructive Test as per ANSI B-16.34.
8.02.00 Hydrostatic shell test in accordance with ANSI B 16.34 prior to seat leakage test.
8.03.00 Valve closure test and seat leakage test in accordance with ANSI-B 16.34 and as per the
leakage class indicated above.
8.04.00 Functional Test: The fully assembled valves including actuators control devices and accesso-
ries shall be functionally tested to demonstrate times from open to close position.
CV Test: Please refer Sub-section-IV:I10. (Type test requirements).
8.05.00 CONTROL VALVE QUANTITIES
Bidder shall furnish all the control valves under this main plant package as finalised
during detailed engineering stage without any price repercussions whatsoever
depending on the process requirements. All the control valves provided by the Bidder
for this project shall meet the specifications requirements specified herein.
Specification for control valves in this Sub-section has to be read in conjunction with
other relevant Sub-sections of this specification.
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IIIC-09
PLANT AUXILIARY
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PAGE
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IIIC - 09
PLANT AUXILLIARY SYSTEMS
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PLANT AUXILIARY
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PLANT AUXILIARY SYSTEM
1.00.00 CONTROL AND INSTRUMENTATION FOR HYDROGEN GENERATION PLANT
1.01.00 Contractor shall provide complete Control and Instrumentation system with all accessories,
auxiliaries and associated equipments and cables for the safe, efficient and reliable operation
of the plant auxiliary systems as indicated under scope part at IIC, Part-A, Section VI.
1.02.00 The quantity of instruments for each plant 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 instruments and devices, which are needed for
the completeness of the plant auxiliary system/equipment, supplied by the Contractor, even if
the same is not specifically appearing in the P&ID.
1.03.00 All electrical devices like switches/ transmitters/ controller/ analyzer/ solenoid valves which
are located in the hydrogen generation plant shall be made intrinsically safe by providing
suitable type of transformer isolated barrier/ Zenner barrier of standard make. Otherwise
such instruments shall be provided with explosion proof enclosure suitable for hazardous
areas described in National Electric Code (USA), Article 500, Class-I, Division-I or EN60079-
14or shall comply with the essential requirements of ATEX directives. All fittings, cable
glands etc. shall be strictly as per NEC recommendation article, 500 to 503.
1.04.00 Contractor shall provide PLC control systems for safe, efficient and reliable operation of each
of the plant auxiliary systems. The type of control system shall be as indicated under scope
part at IIC, Part-A, Section VI.
1.05.00 Control, interlock/ protection, indication of incomers and bus-coupler (even if they are not in
the scope of the contractor) are also to be performed from Contractor's Control System for
each of the plant auxiliary system as applicable.
1.06.00 It shall be possible to remove/replace online various modules (like any I/O module, interface
module, etc.) from its slot for maintenance purpose without switching off power supply to the
corresponding rack. System design shall ensure that while doing so, undefined signaling and
releases do not occur and controller operation in any way is not affected (including controller
trip to manual, etc) except that information related to removed module is not available to
controller. Further, it shall also be possible to remove/replace of controller module without
switching off the power to the corresponding rack and this will not result in system
disturbance or loss of any controller functions for the other controller. The on-line
removal/insertion of controller, I/O modules shall in no way jeopardize safety of plant and
personnel.
1.07.00 The control system shall provide safe operation under all plant disturbances and on
component failure so that under no condition the safety of plant, personnel or equipment is
jeopardized. Control system shall be designed to prevent abnormal swings due to loss of
Control System power supply, failure of any Control System component, open circuit/short
circuit etc.
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1.08.00 The Control system shall include on-line self-surveillance, monitoring and diagnostic facility
giving the details of the fault on the Human Machine Interface System (HMIS). The faults to
be reported shall include fault in main & standby power supplies, sensor fault, Input/ Output
card failure, Memory Status, Controller fault, failure of Communication/ Network links to
PLCs, LAN etc. These faults shall be reported as colour change on system status display
and as messages on HMIS as well as through local indication on the faulty module and on
respective rack/ cubicle. The diagnostic system shall ensure that the faults are detected
before any significant change in any controller output has taken place.
1.09.00 The Control system shall operate in non-air conditioned area and shall meet the minimum
requirements as specified below.
2.00.00 PROGRAMMABLE LOGIC BASED CONTROL SYSTEM
2.01.00 PLC PROCESSOR
The processor unit shall be capable of executing the following functions:-
a Receiving binary and analog signals from the field and providing command output to
MCC/SWGR/Drive etc. through Input / Output modules and operator initiated
commands from HMIS / control panel.
b Implementing all logic functions for control, protection and annunciation of the
equipment and systems.
c Implementing modulating control function for certain application as specified
elsewhere in the specification.
d Providing supervisory information for alarm, various types of displays, status
information, trending, historical storage of data etc.
e Performing self-monitoring and diagnostic functions.
2.02.00 The memory shall be field expandable. The memory capacity shall be sufficient for the
complete system operation and have a capability for at least 20% expansion in future.
Programmed operating sequences and criteria shall be stored in non volatile semi conductor
memories like EPROM. All dynamic memories shall be provided with buffer battery back up
which shall be for at least 360 hours. The batteries shall be lithium or Ni-Cd type.
2.03.00 Priority of different commands shall be as follows:
2.03.01 Manual intervention shall be possible at any stage of operation. Protection commands shall
have priority over manual commands and manual commands shall prevail over auto
commands.
2.03.02 A forcing facility shall be provided for changing the states of inputs and outputs, timers and
flags to facilitate fault finding and other testing requirements. It shall be possible to display
the signal flow during operation of the program.

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2.04.00 HUMAN MACHINE INTERFACE SYSTEM ( HMIS )
2.04.01 Operator work station (OWS) shall perform control, monitoring and operation of all auxiliaries/
drives interacting with PLC based control system. It shall be possible to use the same as
programming station of the PLC and the Human Machine Interface System. It shall basically
perform the following functions. In case the PC based OWS can not be used as programming
station of the PLC and the Human Machine Interface System, then separate PC based
programming station shall be provided.
2.04.02 Operator shall be able to access all control/information related data under all operating condi-
tions including a single processor/computer failure in the HMIS.
2.04.03 All frequently called important functions including major displays shall be assigned to
dedicated function keys on a soft keyboard for the convenience of the operator for quick
access to displays & other operator functions.
2.04.04 The operator functions for each OWS shall as a minimum include Control System operation
(A/M selection, raise/lower, set point/bias change, on/off, open/close operation, mode/device
selection, bypassing criteria, sequence auto, start/stop selection, drive auto selection, local-
remote/other multi-position selection etc.); alarm acknowledge; call all kind of displays, logs,
summaries, calculation results, etc.; printing of logs & reports; retrieval of historical data; and
any other functions required for smooth operation, control & management of information as
finalized during detailed engineering.
2.04.05 The display selection process shall be optimized so that the desired display can be selected
with the minimum no. of operations. Navigation from one display to any other should be
possible efficiently through paging soft keys as well as through targets defined on the
displays. There should be no limitation on number of such targets.
2.04.06 The system shall have built-in safety features that will allow/disallow certain functions and
entry fields within a function to be under password control to protect against inadvertent and
unauthorised use of these functions. Assignment of allowable functions and entry fields shall
be on the basis of user profile. The system security shall contain various user levels with
specific rights as finalised by the Employer during detailed engineering. However, no. of user
levels, no. of users in a level and rights for each level shall be changeable by the
programmer (Administrator).
2.05.00 When any drive or sequence is being controlled from one OWS, the system shall inhibit
control access of the same drive or sequence from other OWS or Local Control Panel.
2.06.00 PROGRAMMING FUNCTIONALITIES
Programming of the PLC Processor / controller as well as programming of HMIS shall be
user friendly with graphical user interface and shall not require knowledge of any
specialized language. For example, the programming of PLC shall use either of the
following:-
- Flow-chart or block logic representing the instructions graphically.
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- Ladder diagrams.
The programming of HMIS (like development and modification of data base, mimics, logs /
reports, HSR functionalities etc.) shall also be possible through user-friendly menus etc
All programming functionalities shall be password protected to avoid unauthorized
modification.
2.07.00 SOFTWARE REQUIREMENT
2.07.01 All necessary software required for implementation of control logic, operator station displays /
logs, storage & retrieval and other functional requirement shall be provided. The programs
shall include high level languages as far as possible. The contractor shall provide sufficient
documentation and program listing so that it is possible for the Employer to carry out
modification at a later date.
2.07.02 The Contractor shall provide all software required by the system for meeting the intent and
functional/parametric requirements of the specification.
2.07.03 Industry standard operating system like UNIX/WINDOWS (latest version) etc. to ensure
openness and connectivity with other system in industry standard protocols (TCP-IP/ OPC
etc.) shall be provided. The system shall have user friendly programming language &
graphic user interface.
2.07.04 All system related software including Real Time Operating System, File management
software, screen editor, database management software. On line diagnostics/debug
software, peripheral drivers software and latest versions of standard PC-based software and
latest WINDOWS based packages etc. and any other standard language offered shall be
furnished as a minimum.
2.07.05 All application software for PLC system functioning like input scanning, acquisition,
conditioning processing, control and communication and software for operator interface of
monitors, displays, trends, curves, bar charts etc. Historical storage and retrieval utility, and
alarm functions shall be provided.
2.07.06 The Contractor shall provide software locks and passwords to Employers engineers at site
for all operating & application software so that Employers engineers can take backup of
these software and are able to do modifications at site.
2.08.00 PARAMETRIC REQUIREMENTS
The control system shall be designed such that under worst case loading conditions the
response time shall not be worst than the following:-
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On/Off Command - The response time for screen update after the
execution of the control command from the time
the command is issued (for example command to
start a motor to the time the screen is updated)
shall be two seconds (excluding the drive actuation
time).
Adjustment Command - 0.5 to 1 second.
On screen Updating - 1 second.
All Control related displays - 1 second.
Bar Chart displays - 2 to 3 seconds.
Plant Mimic displays - 2 to 3 seconds.
Group review displays - 2 to 3 seconds.
X-T Plot Displays - 1 to 2 seconds.
Plant Summary Displays - 1 to 2 seconds.
Even under worst case loading condition of HMIS and system Bus, each HMIS processor
shall have 50 % spare time when measured over any one minute period and the system
bus shall have at least 50 % spare duty cycle.
3.00.00 INPUT/OUTPUT MODULES
3.01.00 The PLC system should be designed according to the location of the input/output cabinets as
specified.
3.02.00 Input Output modules, as required in the Control System for all type of field input signals (4-
20 mA, RTD, Thermocouple, non change over/change over type of contact inputs etc.) and
outputs from the control system (non change over/change over type of contact, 24/48 VDC
output signals for energizing interface relays,4-20 mA output etc.) are to be provided by the
Contractor. Contractor to refer drawing nos. 0000-999-POI-A-065 for interface/termination
requirements of Field Instruments/Drives.
3.03.00 Electrical isolation of 1.5KV with optical couplers between the plant input/output and
controller shall be provided on the I/O cards. The isolation shall ensure that any inadvertent
voltage or voltage spikes (as may be encountered in a plant of this nature) shall not damage
or mal-operate the internal processing equipment.
3.04.00 The Input/output system shall facilitate modular expansion in fixed stages. The individual
input/output cards shall incorporate indications on the module front panels for displaying
individual signal status.
3.05.00 Individually fused output circuits with the blower fuse indicator shall be provided. All
input/output points shall be provided with status indicator. Input circuits shall be provided
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with fuses preferably for each input, alternatively suitable combination of inputs shall be done
and provided with fuses such that for any fault, fuse failure shall affect the particular drive
system only without affecting other systems.
3.06.00 All input/output cards shall have quick disconnect terminations allowing for card replacement
without disconnection of external wiring and without switching of power supply.
3.07.00 The Contractor shall provide the following monitoring features:
a Power supply monitoring.
b Contact bounce filtering.
c Optical isolation between input and output signals with the internal circuits
d In case of power supply failure or hardware fault, the critical outputs shall be
automatically switched to the fail-safe mode. The fail-safe mode shall be
intimated to the successful Contractor during detailed engineering.
3.08.00 Binary Output modules shall be rated to switch ON/OFF coupling relays of approx. 3 VA at
24 VDC. Analog output modules shall be able to drive an load impedance of 500 Ohms
minimum.
3.09.00 Output module shall be capable of switching ON/OFF inductive loads like solenoid valves,
auxiliary relays etc. without any extra hardware.
3.10.00 Only one changeover contact shall be provided in MCC for control and interlock requirement.
Further multiplication, if required, shall be done by the contractor in PLC system.
3.11.00 All input field interrogation voltage shall be 24V DC or 48 V DC.
3.12.00 In case of loss of I/O communication link with the main processing unit, the I/O shall be able
to go to predetermined fail safe mode (to be decided during detailed engineering) with proper
annunciation.
3.13.00 Wiring Scheme for inputs to control system shall be as follows:
3.13.01 Each of the triple redundant binary & analog inputs shall be wired to separate input modules.
Similarly each of the dual redundant binary & analog inputs shall be wired to separate input
modules. These redundant modules shall be placed in different racks, which will have
separately fused power supply distribution. Implementation of multiple measurement
schemes of these inputs will be performed in the redundant hardware. Loss of one input
module shall not affect the signal to other modules. Other channels of these modules can be
used by other inputs of the same functional group.
3.13.02 The single (i.e. non-redundant) binary & analog signal required for control purposes shall be
wired as follows:
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3.13.03 All single analog & binary inputs including the limit switches of valves/dampers MCC/SWGR
check-backs of all drives & information related signals shall be wired to single (i.e. non-
redundant) input modules.
3.13.04 The on-off status of HT drives etc, however, be wired to two input modules in parallel.
3.14.00 Inputs and Outputs related to each of the redundant drives / equipments (eg. each of the
3x50 % drives, each of the storage vessel/sump/tank storing same fluid, each of the streams
and its related drives etc.) shall be wired to separate input and output modules.
3.15.00 The signal conditioning functions like multiple measurement schemes, square root extraction
for flow signals, pressure and temperature compensation, limit value computation can be
performed either in the controllers or in signal conditioning and processing hardware outside
controllers.
The maximum number of inputs/outputs to be connected to each type of module shall be as
follows:
1. Analog input module 16
2. Analog output module 16
3. Binary input module 32
4. Binary output module 32
5. Analog input & output (combined) 16
6. Binary input and output (combined) 32
3.16.00 Any single sensor/transducer/transmitter failure alarm shall be provided on programmer
station screens for all sensors/transducers/transmitters. Similarly sensor break alarm for
thermocouples etc. shall also be displayed on the screens.
3.17.00 Contractor shall provide remote Input/Output modules Housed in free-standing
cabinets/racks (with suitable redundant data link to the central PLC system) as specified.
These Input/Output modules shall meet the technical requirements as mentioned in the
above clauses. Further these Input/Output modules shall be designed to continuously work
under the environment expected to be encountered in assigned areas without any air-
conditioning support. Wherever the cable route distance of these I/O cabinets/racks exceeds
a distance of 300 meters from the Central PLC, fiber optic data link has to be provided.
4.00.00 SYSTEM SPARE CAPACITY
4.01.00 Over and above the equipment and accessories required to meet the fully implemented
system as per specification requirements, Control System shall have spare capacity and
necessary hardware/ equipment/ accessories to meet following requirement for future
expansion at site:
4.02.00 10% spare channels in input/output modules fully wired up to cabinets TB.
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4.03.00 Wired-in "usable" space for 20% modules in each of the system cabinets for mounting
electronic modules wired up to corresponding spare terminals in system cabinets. Empty
slots between individual modules/group of modules, kept for ease in maintenance or for heat
dissipation requirement as per standard practice of Contractor shall not be considered as
wired-in "usable" space for I/O modules. Terminal assemblies (if any in the offered system),
corresponding to the I/O modules shall be provided for above mentioned 20 % blank space.
4.04.00 Each processor / controller shall have 30% spare functional capacity to implement additional
function blocks, over and above implemented logic/ loops. Further, each processor /
controller shall have spare capacity to handle minimum 30% additional inputs/ outputs of
each type including above specified spare requirements, over and above implemented
capacity. Each of the corresponding communication controllers shall also have same spare
capacity as that of processor/controller.
4.05.00 The Data communication system shall have the capacity to handle the additions mentioned
above.
4.06.00 Twenty (20) percent spare relays of each type and rating mounted and wired in cabinets TB.
All contacts of relays shall be terminated in terminal blocks of cabinets.
4.07.00 The spare capacity as specified above shall be uniformly distributed throughout all cubicles.
The system design shall ensure that above mentioned additions shall not require any
additional controller/processor/ peripheral drivers in the system delivered at site. Further,
these additions shall not deteriorate the system response time / duty cycle, etc. from those
stipulated under this specification.
5.01.00 The Communication System shall include a Main System Bus and Other applicable bus
systems like cubicle bus, local bus, I/O bus etc.
The DCS shall have the following minimum features :
a Communication controllers shall be provided to handle the communication between
I/O Modules (including remote I/O) and PLCs and between PLCs and operator work
station/HMI device.
b The design shall be such as to minimise interruption of signals. It shall ensure that a
single failure anywhere in the media shall cause no more than a single message to
be disrupted and that message shall automatically be retransmitted. Any failure or
physical removal of any station/module connected to the system bus shall not result
in loss of any communication function to and from any other station/module.
c Built-in diagnostics shall be provided for easy fault detection. Communication error
detection and correction facility (ECC) shall be provided at all levels of
communication. Failure of one bus and changeover to the standby system bus
shall be automatic and completely bump less and the same shall be suitably
alarmed/logged.
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e The design and installation of the system bus shall take care of the environmental
conditions as applicable.
f Data transmitting speed shall be sufficient to meet the responses of the system in
terms of displays, control etc. plus 25% spare capacity shall be available for future
expansion.
g Passive coaxial cables or fibre optic cables shall be employed.
The Contractor shall furnish details regarding the communication system like
communication protocol, bus utilisation calculations etc.
5.02.00 The PLC system shall be provided with necessary hardware and software for dual fibre optic
connectivity & interconnection with station wide LAN (for scope of Station LAN refer Part-A)
for two - way transfer of signals for the purpose of information sharing. The plant information
shall be made available through an Ethernet link following TCP/IP standard. The system shall
be OPC compliant. The exact data structure shall be as decided during detailed engg. All
required plant data shall be transferred to/from through this ensuring complete security. The
exact number of points to be transferred through the above communication link and the
format of the data shall be finalised during detailed engineering. The Contractor shall provide
all assistance to the BOP C&I System (for scope of BOP C&I System refer Part-A) Supplier
including co-ordination and flow of required information etc. for display of all input points
under alarm, connected to PLC or generated by PLC, on various operating stations on BOP
C&I System (for scope of BOP C&I System refer Part-A) and various client PCs on station
LAN
6.00.00 SYSTEM REACTION TIME
6.01.00 The reaction time of the programmable control system from input signals at the input cards to
output of the associated signals or commands of the output card inclusive of programmed
logic processing, comprising a mixture of logic gates, arithmetic operations and other internal
operations shall be less than 100 milli seconds under the most arduous control system
7.00.00 OPERATOR INTERFACE DISPLAYS/LOGS/REPORTS
7.01.00 Suitable Operator Interface Displays/Logs/Reports for control operation & monitoring shall be
provided. The details shall be finalized during detailed Engg. stage.
7.02.00 Minimum quantities shall be as follows:-
1 Various displays on the OWS shall as a minimum include P&ID displays or mimic,
bar chart displays, X-Y & X-T plot (trend) displays, operator guidance message
displays, group displays, plant start-up/shutdown message displays, system
status displays etc. Number of displays and the exact functionality shall be on as
required basis and as finalised during detailed engineering subject to the
minimum quantities as given in subsequent clauses. For X-T & X-Y plots, the
facility of providing a background grid on operator request shall be variable with
adequate no. of divisions in both co-ordinates.
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2 The minimum quantity of major types of displays per unit shall be as follows:
a) Control displays (group/sub-group/
sequence/loop)
(On as reqd. basis
subject to 100
minimum)
b) P&ID/ mimic display 100
c) Bar chart 30
d) X-T Plot 30
e) X-Y Plot (with superimposed operating curves +
using user selectable stored data)
25 +25
f) Group displays 30
g) Operator guidance message 10

h) System status & other diagnostic display on as required
basis
The assignment for the above will be done by the contractor as per the requirement of
operation of Contractor's system as well as for maintenance. The balance displays shall
be left as spare for future modification/addition.
8.00.00 HISTORICAL STORAGE AND RETRIEVAL SYSTEM (HSRS)
8.01.00 The HSRS shall collect store and process system data from MMIPIS data base. The data
shall be saved online on hard disk and automatically transferred to erasable long term
storage media once in every 24 hours periodically for long term storage. Provision shall be
made to notify the operator when hard disk is certain percentage full. The disk capacity shall
be sufficient to store at least seven days data.
8.02.00 The data to be stored in the above system shall include alarm and event list, periodic plant
data, selected logs/reports. The data/information to be stored & frequency of storage and
retrieval shall be as finalised during detailed engineering. The system shall provide user-
friendly operator functions to retrieve the data from historical storage. It shall be possible to
retrieve the selected data on OWS or printer in form of trend/report by specifying date, time &
period. Further, suitable index files/directories shall also be provided to facilitate the same.
The logs/reports for at least last seven (7) days shall be available on the disk.
8.03.00 In addition to above, the system shall also have facility to store & retrieve important plant
data for a very long duration (plant life) on portable long term storage media). These data will
include any data from the database as well as processed/computed data based an various
calculations/transformation. The retrieved data from long term storage media should be
possible to be presented in form of X-T display, X-Y display, logs, reports, etc.

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9.00.00 CONTROL & POWER SUPPLY SCHEME
Necessary redundant transformers and redundant chargers with 24 V DC battery back-up
shall be provided by the Contractor to derive power supply from 415V, 3-phase 3-wire
incomers to be arranged by the Contractor at the input terminals of power supply cabinets.
The Contractor shall, however furnish all required hardware/ equipment/ cubicles for
conversion and/or stabilization of the power source provided by the Employer to all other
levels which may be necessary for meeting the individual requirements of equipments/
systems furnished by him within the Contractors quoted lump sum price.
The 24 V DC power supply system configuration shall be provided as per Appendix-1,
Section VI, Part A of specifications
10.00.00 CONTROL CABINETS / PANELS
10.01.00 The cabinets shall be IP-22 protection class. The Contractor shall ensure that the packaging
density of equipment in these cabinets is not excessive and abnormal temperature rise,
above the cabinet temperature during normal operation or air-conditioning failure, is
prevented by careful design. This shall be demonstrated to the Employer during the factory
testing of the system. The Contractor shall ensure that the temperature rise is limited to 10
deg. C above ambient and is well within the safe limits for system components even under
the worst condition as specified in Sub-section-basic Design criteria (Part-B, Section-VI) and
specification requirements for remote I/O cabinets. Ventilation blowers shall be furnished as
required by the equipment design and shall be sound proof to the maximum feasible extent.
If blowers are required for satisfactory system operation, dual blowers with blower failure
alarm shall be provided in each cabinet with proper enclosure and details shall be furnished
with proposal. Suitable louvers with wire mesh shall be provided on the cabinet.
10.01.01 The cabinets shall be designed for front access to system modules and rear access to wiring
and shall be designed for bottom entry of the cables.
10.01.02 The cabinets shall be totally enclosed, free standing type and shall be constructed with
minimum 2 mm thick steel plate frame and 1.6 mm thick CRCA steel sheet or as per
supplier's standard practice for similar applications, preferred height of the cabinet is 2200
mm. The cabinets shall be equipped with full height front and rear doors. The floor mounting
arrangement for other cabinets shall be as required by the Employer and shall be furnished
by the Contractor during detailed engineering.
10.01.03 Cabinet doors shall be hinged and shall have turned back edges and additional braking
where required ensuring rigidity. Hinges shall be of concealed type. Door latches shall be of
three-point type to assure tight closing. Detachable lifting eyes or angles shall be furnished at
the top of each separately shipped section and all necessary provisions shall be made to
facilitate handling without damage. Front and rear doors shall be provided with locking
arrangements with a master key for all cabinets. If width of a cabinet is more than 800 mm,
double doors shall be provided.
10.01.04 Two spray coats of inhibitive epoxy primer-surface shall be applied to all exterior and interior
surfaces. A minimum of 2 spray coats of final finish colour shall be applied to all surfaces.
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The final finished thickness of paint film on steel shall not be less than 65-75 micron for sheet
thickness of 2 mm and 50 microns for sheet thickness of 1.6 mm. The finish colors for
exterior and interior surfaces shall conform to following shades:
(a.) Exterior:- As per RAL 9002 ( End panel sides RAL 5012), to be finalized during
(b.) Interior:- Same as above.
10.01.05 Paint films which show sags, checks or other imperfections shall not be acceptable.
10.01.06 As an alternative, single coat of anodic dipcoat primer along with single textured powder
coating with epoxy polyester meeting the thickness requirement is also acceptable.
10.01.07 Refer Subsection Basic Design Criteria, Part B, and Section VI for grounding requirements.
10.01.08 The mimic shall be configured on the OWS and it shall be possible to control, monitor and
operate the plant from the same.
10.01.09 The technical specification covering panel fabrication details, wiring and termination details
etc. shall be as described under Sub-Section INST CABLE of this specification.
11.00.00 ANNUNCIATION SYSTEM
11.01.00 Only OWS based alarm system shall be provided with audio alarm facility (beep/tone
generator). No facia annunciation is envisaged in the control room. Hooters are to be
provided.
11.02.00 The system shall display history of alarms in chronological order on any of the OWS. The
HMIS shall have the capability to store a minimum of 500 alarms each with paging features
allowing the operator to view any page. The system shall have all alarm functions and
related function keys like alarm acknowledge, reset, paging, summaries etc. Other design
features like set point/dead band adjustments, provision of alarm priority, manual inhibition &
automatic inhibition based on predefined logic etc., shall be provided and shall be as finalised
during detailed engineering. The alarm display/report format shall be as approved by the
Employer.
11.03.00 Facility of audio annunciation shall be provided in OWS upon the occurrence OWS alarms
irrespective of whether alarms are displayed or not. Facility to disable the audio annunciation
shall be provided.
11.04.00 At least three levels of alarm priority shall be available which will be displayed in different
colour. It shall be possible to display & print alarms of any of the three levels.
11.05.00 The annunciator sequence shall conform to ISA sequence ISA-2A..
12.00.00 SOFTWARE DOCUMENTATION AND SOFTWARE LISTINGS
12.01.00 All technical manuals, reference manuals, users guide etc., in English required for
modification/editing/addition/deletion of features in the software of the PLC System shall be
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furnished. The Contractor shall furnish a comprehensive list of all system/application
software documentation after system finalization for Employers review and approval.
12.02.00 All The software listings including Source code for application software, All special - to-
project data files etc. shall be submitted by the Contractor.
13.00.00 SOFTWARE LICENCES
The Contractor shall provide software license for all software being used in Contractors
System. The software licenses shall be provided for the project (e.g. organisation or site
license) and shall not be hardware/machine-specific. That is, if any hardware/machine is
upgraded or changed, the same license shall hold good and it shall not be necessary for
Employer to seek a new license/renew license due to upgradation/change of
hardware/machine in Contractors System at site. All licenses shall be valid for the
continuous service life of the plant.
As a customer support, the Contractor shall periodically inform the designated officer of
the Employer about the software upgrades/new releases that would be taking place after
the system is commissioned so that if required, same can be procured & implemented at
site.
14.00.00 (A) SPECIFICATIONS OF OWS
The minimum requirement for PC based OWS shall be as below:
CPU Latest generation CPU
Main memory 1 GB expandable to 4 GB
Drives 3 1/2" floppy drive, 48 x CD ROM drive
Hard disk 80 GB
Removable bulk storage
drive (MOD / DVD / DAT)
8 GB (minimum)
Removable Bulk Storage
Media for above
10 nos
Monitor 19" Full Flat TFT Resolution 1600 x 1280, refresh rate
min 85 Hz.
Graphic Memory 16 MB
Communication port 2 serial plus, one parallel, 4 USB port, Dual 100 Mbps
Ethernet.
Expansion slots 3
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Other Features 101 Keys Keyboard and Optical Mouse
UPS 1 no. On-line Interactive UPS with 30 mins. battery
backup on machine load (for PC & its printer)
a General MS Windows latest version, MS-Office,
Microsoft Visual Studio, Adobe Acrobat, anti-virus
McAfee or equivalent, etc.
Software
b Application software - to suit project specific
requirement
Accessories
Required furniture for mounting of HMI peripherals
shall be provided.
(B) GIU Refer Appendix to Part-A FOR QTY.
15.00.00 PRINTER
15.01.00 One number A4 size color laser printer at hydrogen generation plant control room shall be
provided as a part of the HMIS system. It shall print out all alarm/trip conditions and event
changes in plant status along with date and time of occurrence.

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IIIC - 010
TYPE TESTS REQUIRMENTS
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TYPE TEST REQUIREMENTS
1.00.00 TYPE TEST REQUIREMENTS
1.01.01 The Contractor shall furnish the type test reports of all type tests as per relevant standards
and codes as well as other specific tests indicated in this specification. A list of such tests are
given for various equipment in table titled 'TYPE TEST REQUIREMENT FOR C&I
SYSTEMS' at the end of this chapter and under the item Special Requirement for Solid State
Equipments/Systems. For the balance equipment instrument, type tests may be conducted
as per manufactures standard or if required by relevant standard.
(a) Out of the tests listed, the Bidder/ sub-vendor/ manufacturer is required to conduct
certain type tests specifically for this contract (and witnessed by Employer or his
authorized representative) even if the same had been conducted earlier, as clearly
indicated subsequently against such tests.
(b) For the rest, submission of type test results and certificate shall be acceptable
provided.
i. The same has been carried out by the Bidder/ sub-vendor on exactly the same
model /rating of equipment. ( For control valves, this shall be same size, type &
design).
ii. There has been no change in the components from the offered equipment &
tested equipment.

iii. The test has been carried out as per the latest standards alongwith
amendments 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 grounds, then the tests have to be
repeated and the cost of such tests shall be borne by the Bidder/ sub-vendor within
the quoted price and no extra cost will be payable by the Employer on this account.
1.01.02 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 the balance
have to be approved by the Employer.
1.01.03 The schedule of conduction of type tests/ submission of reports shall be submitted and
finalized during pre-award discussion.
1.01.04 For the type tests to be conducted, Contractor shall submit detailed test procedure for
approval by Employer. This shall clearly specify test setup, instruments to be used,
procedure, acceptance norms (wherever applicable), recording of different parameters,
interval of recording precautions to be taken etc. for the tests to be carried out.
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1.01.05 The Bidder shall indicate in the relevant BPS schedule, the cost of the type test for each item
only for which type tests are to be conducted specifically for this project. The cost shall only
be payable after conduction of the respective type test in presence of authorize
representative of Employer. If a test is waived off, then the cost shall not be payable.
2.00.00 SPECIAL REQUIREMENT FOR SOLID STATE EQUIPMENTS/ SYSTEMS
2.01.00 The minimum type test reports, over and above the requirements of above clause, which are
to be submitted for each of the major C&I systems shall be as indicated below:
i) Surge Withstand Capability (SWC) for Solid State Equipments/ Systems
All solid state systems/ equipments shall be able to withstand the electrical noise
and surges as encountered in actual service conditions and inherent in a power
plant. All the solid state systems/ equipments shall be provided with all required
protections that needs the surge withstand capability as defined in ANSI 37.90.1/
IEEE-472. Hence, all front end cards which receive external signals like Analog
input & output modules, Binary input & output modules etc. including power supply,
data highway, data links shall be provided with protections that meets the surge
withstand capability as defined in ANSI 37.90.1/ IEEE-472. Complete details of the
features incorporated in electronics systems to meet this requirement, the relevant
tests carried out, the test certificates etc. shall be submitted along with the proposal.
As an alternative to above, suitable class of EN 61000-4-12 which is equivalent to
ANSI 37.90.1/ IEEE-472 may also be adopted for SWC test.
ii) Dry Heat test as per IEC-68-2-2 or equivalent.
iii) Damp Heat test as per IEC-68-2-3 or equivalent.
iv) Vibration test as per IEC-68-2-6 or equivalent.
v) Electrostatic discharge tests as per EN 61000-4-2 or equivalent.
vi) Radio frequency immunity test as per EN 61000-4-6 or equivalent.
vii) Electromagnetic Field immunity as per EN 61000-4-3 or equivalent.
Test listed at item no. v, vi, vii, above are applicable for electronic cards only as defined
under item (i) above.
3.00.00 TYPE TEST REQUIREMENT FOR C&I SYSTEMS
Sl.
No
Item Test
Requirement
Standard Test To Be
Specifically
Conducted
NTPCs Approval
Req. On Test
Certificate
Col 1 Col 2 Col 3 Col 4 Col 5 Col 6
1 Elect.
Metering
As per
standard
IS-1248 No Yes
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instruments (col 4)
2 Thermocouple Degree of
protection test
IS-2147 No No
3 CJ C Box Degree of
protection test
IS-2147 No No
4 RTD As per
standard
(col 4)
IEC-60751 No No
5 Electronic
transmitter
As per
standard
(col 4)
BS-6447 /
IEC-60770
No Yes
6 E/P converter As per
standard
(col 4)
Mfr.
standard
No Yes
7 Instrumentation Cables Twisted & Shielded (Refer Note-B below)
-Conductor Resistance
test
VDE-0815 No Yes
Diameter test IS-10810 No Yes
Tin Coating
test (Persul-
phate test)
IS-8130 No Yes
-Insulation Loss of mass

VDE 0472 No Yes
Ageing in air
ovens**
VDE 0472 No Yes
Tensile
strength and
elongation
test before
and after
ageing**
VDE 0472 No Yes
Heat shock VDE 0472 No Yes
Hot
deformation
VDE 0472 No Yes
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Shrinkage VDE 0472 No Yes
Bleeding &
blooming
IS-10810 No Yes
-Inner
sheath***
Loss of mass VDE 0472 No Yes
Cold bend/
cold impact
test
VDE 0472 No Yes
Hot
deformation
VDE 0472 No Yes
-Outer sheath Loss of mass VDE 0472 No Yes
Ageing in air
ovens**
VDE 0472 No Yes
Tensile
strength and
elongation
test before
and after
ageing**
VDE 0472 No Yes
Hot
deformation
VDE 0472 No Yes
Bleeding &
blooming
IS-10810 No Yes
Colour
fastness to
water
IS-5831 No Yes
Cold bend/
cold impact
test
VDE-0472 No Yes
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Oxygen index
test
ASTMD-
2863
No Yes
Smoke
Density Test
ASTMD-
2843
No Yes
Acid gas
generation
test
IEC-60754-1 No Yes
-fillers Oxygen index
test
ASTMD-
2863
No Yes
Acid gas
generation
test
IEC-60754-1 No Yes
-AL-MYLAR
shield
Continuity test No Yes
Shield
thickness
No Yes
Overlap test No Yes
-Over all cable Flammability
Test

IEEE 383 No Yes
Swedish
Chimney Test
SEN
4241475
No Yes
Noise
interference
IEEE Trans-
actions
No Yes
Dimensional
checks
IS 10810 No Yes
Cross talk VDE-0472 No Yes
Mutual
capacitance
VDE-0472 No Yes
HV test VDE-0815 No Yes
Drain wire
continuity
No Yes
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* For Drain wire only
**These tests shall be carried out as per VDE0207 Part 6 & ASTMD-2116 for
TEFLON insulated & outer sheathed cables
***Applicable for armoured cables only
8 DC Power Supply System
The Type Test Reports for offered rectifier module and controller module irrespective
of the rectifier bank rating shall be acceptable.
Surge
Withstand
Capability
(SWC)
ANSI
37.90.1/
IEEE-472,
EN-61000-
4-12
No Yes
Degree of
Protection
IS-13947
or
equivalent
No Yes
Dry Heat Test IEC-68-2-2
or
equivalent
No Yes
Damp Heat
test
IEC-68-2-3
or
equivalent
No Yes
Vibration test IEC68-2-6
or
equivalent
No Yes
Electromagneti
c field immunity
EN 61000-
4-3 or
equivalent
No Yes
Electrostatic
discharge test
EN 61000-
4-2 or
equivalent
No Yes
Radio
frequency
immunity test
EN-61000-
4-3 or
equivalent

No Yes
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9 Battery (Refer
Note-A below)
As per
standard
(col 4)
IS-10918 No Yes
10 Voltage
Stabiliser
Over Load Test Approved
procedure
No Yes
Temp rise test
without
redundant fans
Approved
procedure
No Yes
Input voltage
variation test
Approved
procedure
No Yes
11 DDCMIS
CLCS
Systems
Model test Approved
procedure
No No
BMS Safety
requirements
VDE0116
Sec 8.7
No Yes
12 Conductivity
Type Level
Switch
Degree of
protection test
IS-2147 No No
13 Local Gauges Degree of
protection test
IS-2147 No No
14 Process
actuated
Switches
Degree of
protection test
IS-2147 No No
15 Control Valves CV test ISA 75.02 No Yes
16 PLCs As per
standard (Col
4)
IEC 1131 No No
17 LIE / LIR Degree of
protection test
IS-2147 No Yes
18 Flue gas O2
analyser,
other Flue
Gas analysers

Degree of
protection test
IS-2147 No Yes
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19 Flow Nozzles
& Orifice
plates
Calibration ASME PTC
BS 1042
No Yes
Note:
Type Tests are to be conducted only for the items, which are being supplied as a part of this
Package.
A. For batteries with electric power supply system of TG C&I, the contractor shall
submit for Employers approval the reports of all the type tests as per IS-10918
carried out within last five years from the date of bid opening and the tests should
have been either conducted at an independent laboratory or should have been
witnessed by a client. The complete type test reports shall be for any rating of battery
in a particular group, based on plate dimensions being manufactured by supplier.
For batteries with electric power supply system of auxiliary plants, type test reports
for batteries shall be as per standard practice of manufacturer.
B. All cables to be supplied shall be of type tested quality. The Contractor shall submit
for Employer's approval the reports of all the type tests pertaining to cables as listed
in this specification and carried out within last five years from the date of bid opening.
These reports should be for the tests conducted on the cables similar to those
proposed to be supplied under this contract and the test(s) should have been either
conducted at an independent laboratory or should have been witnessed by a client.
In case the Contractor is not able to submit report of the type test(s) for cables
conducted within last five years from the date of bid opening, or in case the type test
report(s) are not found to be meeting the specification requirements, the Contractor
shall conduct all such tests under this contract free of cost to the Employer and
submit the reports for approval.
SECTION-VI
PART-B
CIVIL WORKS
SECTION-VI
PART-B
D - 1
CIVIL WORKS
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Civil Works
1.00.00 GENERAL
1.01.01 This section of the Specification covers the technical requirements for Design,
preparation of General Arrangement Drawings, Design Drawings, civil task
drawings (for the engineering by Employer) for areas covered under
Employer's scope, Supply of Labour, Materials, plant and equipment,
Construction and Erection of Civil and Structural works included in Bidder's
scope.
1.01.02 Description of various items of work under this Specification and nature of
work in detail are given hereinafter. The complete works under this
Specification is referred to as "Civil Works". Various Structures, Plant, Systems,
Facilities, etc., covered under the Scope of this Specification is given in Part -
A and herein.
1.01.03 The work to be performed under this Specification shall also include Design,
Engineering and providing of all Labour, Materials, plant and equipments,
Consumables, Construction Facilities and all Incidental Items though not shown
or specified but are reasonably implied and / or are necessary for the
completion and proper functioning of the Plant, Systems and Facilities, all in
strict accordance with the Specifications, including revisions and amendments
thereto.
1.01.04 All Materials required for works under the Bidder's scope shall be arranged
and supplied by the Bidder.
1.01.05 All support structures (as covered under the Scope) for Pipes/Cables/Ducts
shall be of Steel and shall be supplied and provided by the Bidder.
1.01.06 All Operating and Maintenance Platforms at any elevations other than the Main
Floor Levels, Interconnecting Platforms, along with the associated Ladders to
and/or from the Main Floor Levels shall be supplied and provided by the
Bidder.
1.01.07 EOT Crane, Crane Rails, all Mono Rails required for Equipment Handling, etc.
shall be supplied and provided by the Bidder.
1.01.08 Staircase, Landings etc shall be of Grating and shall be supplied and provided
by the Bidder.
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1.01.09 Foundation Bolts along with templates, inserts and embedments along with
lugs, pipe sleeves, etc. whatsoever required in concrete for supporting
Equipment and Structures shall be supplied by the Bidder and placed by
Employer. However the accuracy of alignment & level of these fixtures shall
be checked and ensured by the Contractor during placement. Any modification
required on these fixtures subsequent to their placement shall be done by
Contractor.
1.01.10 Turbo Generator Structure and Boiler Feed Pumps shall be supported on
spring supported RCC foundation. The steel helical springs and viscous
dampers shall be provided by the Contractor. However, the RCC deck shall
be provided by the Employer.
1.01.11 All other structures shall be supported by Bidder on Foundation through Anchor Fas-
teners. For such Structures, the Employer shall provide the Foundation, on which the
Bidder shall supply and install, the Anchor Fasteners of requisite capacity to support
his Structures.
1.01.12 Anchor Fasteners shall be used for supporting all such equipment, where the
Static and Dynamic Loads due to Equipment is within the Safe Load Carrying
Capacity of the Anchor Fasteners. For such equipment, the Employer shall
provide the Foundation, on which the Bidder shall supply and install the Anchor
Fasteners of requisite capacity to support his equipment.
1.01.13 The Employer shall provide the pockets in foundations only for those
Equipment and structures, where the Loads to be transferred to the
foundations are beyond the Safe Load Carrying Capacity of Anchor Fasteners.
For such Equipment / structure, subsequent supply and installation of
Foundation Bolts including Grouting of pockets shall be done by the Bidder. In
case, it is required that Foundation Bolts are required to be embedded during
the first stage of concreting, then the Bidder shall make the Bolts available
at Site (before casting of foundation) for installation by Employer at the time of
the concreting stage itself. During concreting, Bidder shall depute his engineers
to verify that all foundation bolts / sleeves / embedments / etc. are installed
correct to layout and levels as per their design drawings. Any modification
required on these fixtures subsequent to their placement shall be done by
Bidder.
1.01.14 All inserts and embedments whatsoever required by the Bidder on the
Concrete and other similar surfaces, for supporting their Structures /
Equipment etc. shall be installed by the Bidder using Anchors Fasteners. All
small size Openings having size (within 150 mm X 150 mm area) which are
required on Floors, Walls, Cladding, Roof etc. shall be neatly created and
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finished by the Bidder using appropriate tools. The Employer shall however
provide larger size Openings.
1.01.15 All Grouting of pockets, Underpinning of Base Plates, filling and finishing of
Openings etc. shall be done by the Bidder. The Employer shall do
encasement of Base Plates. Anchor Fasteners shall be fixed in position by
bidder as recommended by the manufacturer and approved by the Employer.
1.01.16 The work shall be carried out according to the Design / Drawings, to be
developed by the Bidder and got approved by the Employer. For all Plant,
Systems, Facilities, Structures, etc., necessary Layout and details are to be
developed by the Bidder keeping in view the statutory and functional
requirements and providing enough space and access for Operation, use and
Maintenance. The Bidder's work shall cover the complete requirements as per
IS Codes, requirements of various Statutory Bodies, International Standards,
best prevailing practices and to the complete satisfaction of the Employer.
1.01.17 The Bidder shall make the Layout and Levels of all Structures from the
general grid of the plot and the nearest GSI Benchmark or other acceptable
Benchmark of Government Department, as per the directions of the Engineer.
The Bidder shall be solely responsible for the correctness of the Layout and
Levels and shall also provide necessary instruments, materials, access to
works, etc., to the Engineer for general checking of the correctness of the
Civil works.
1.01.18 All quality standards, tolerances, welding standards and other technical
requirements shall be strictly adhered to.
1.01.19 The Bidder shall fully appraise himself of the prevailing conditions at the
proposed Site, Climatic Conditions including Monsoon Pattern, Soil Conditions,
Local Conditions and Site Specific Parameters and shall provide for all such
conditions and contingent measures, including those which may not have been
specifically brought out in the Specifications but required for successful
execution of work.
1.01.20 In case of any conflict between stipulations in various portions of the
Specifications, most stringent stipulation would be applicable for implementation
by the Bidder without any extra cost to the Employer.
2.00.00 SUBMISSIONS
2.01.01 Commencement of Fabrication, Erection and Construction shall be done after
approval of the relevant Design Documents and Drawings. All Drawings shall
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PART-B
be of standard sizes (Metric System) and shall be made under AutoCAD,
whereas all Documents shall be made either in MS Excel or in MS Word.
2.01.02 The Design Documents and Drawings for the following areas shall be
submitted for approval of the Employer.
(a.) Turbo Generator and Auxiliaries.
(b.) Boiler Feed Pumps.
(c.) Condenser, Air Evacuation System and On Load Tube Cleaning
System.
(d.) Condensate Extraction Pumps.
(e.) Heaters and De-Aerators.
(f.) HP and LP By-Pass System, including HP and LP By-Pass Valves.
(g.) Chemical Dosing System
(h.) Central Turbine Lubricating Oil Storage and Purification System.
(i.) TG Integral and any other Miscellaneous Piping for various Systems
(j.) Plant and Instrument Air Compressors along with associated System.
(k.) Hydrogen Generation Plant.
(l.) Equipment Cooling Water System for Turbo Generator & Aux. Raw
water cooling systems..
(m.) EOT Cranes for Turbine Hall, including Hoisting Equipment, Elevators,
Cranes, Mono Rails, etc.
(n.) Elevators for Service Building & Administrative Fire Building.
2.01.03 The Design Documents and Drawings submitted by the Bidder shall contain at
least the following Minimum information :
(a.) General Arrangement for Equipment, Piping / Cables / Ducts.
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(b.) Loading Plans indicating Floor Imposed Loads, Equipment Loads, Piping
/ Cables / Ducts Loads.
(c.) Openings in Floor/ Walls / Cladding / Roof.
(d.) Equipment Mounting Details ( where Supporting Structures are provided
by the Employer ).
(e.) General Arrangement of Foundations including Loading Data, Bolt
Details, Pocket Details, etc.
(f.) Insert Details, Anchor Fastener Details along with their General
Arrangements.
(g.) Project Design Intent Document covering Design Criteria for machine
foundations for TG Deck etc. including Loading assumptions, references,
structural idealisation / Mathematical Model, Loading Cases, Loading
Combinations, etc.
(h.) Analysis and structural Design Calculations.
(i.) 3-D Modeling of Structures, including Typical 2-D Structural Frame
Analysis.
(j.) Details of Corrosion Protection Measures
(k.) Any other submission, as indicated elsewhere in these Specifications
and / or as required by the Employer.
3.00.00 DESIGN CRITERIA
3.01.00 GENERAL
3.01.01 The Design criteria given herein are applicable for all Structures.
3.01.02 Structures shall be Designed for the most critical Combinations of Dead
Loads, Imposed Loads, Equipment Loads, Crane Loads (if any), Pipe Loads
(Static, Friction and Dynamic), Cable / Ducts Loads, Wind Loads, Seismic
Loads, Temperature Loads, Erection Loads, Loads due to Differential
Settlement, etc.
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3.02.00 MATERIAL
3.02.01 Structural Steel (including embedded Steel) shall be straight, sound, free from
twists, cracks, flaw, laminations and all other defects.
3.02.02 Mild Steel (Rolled Sections and Plates) shall conform to Grade 'A' of IS :
2062 for thickness up to and including 20 mm and shall conform to Grade 'B'
of IS : 2062 for thickness beyond 20 mm thickness.
3.02.03 Medium and High Strength Steel shall conform to grade 'Fe-490B' of IS : 8500
or equivalent and shall be killed condition.
3.02.04 Pipes shall conform to IS : 1161. Hollow (Square and Rectangular) Steel
Sections shall be Hot Formed conforming to IS : 4923 and shall be of
Minimum grade Yst 240.
3.02.05 Chequered Plate shall conform to IS : 3502 and shall be Minimum 6 mm
thick excluding projection. Steel for chequered Plates shall conform to Grade
'A' of IS : 2062.
3.02.06 Rolled Sections and Plates up to and including 20 mm thickness shall be
Semi-killed condition.
3.02.07 All Steel up to and including 40 mm thickness shall be in as Rolled condition.
3.02.08 Plates beyond 40 mm thickness shall be normalised and Ultrasonically tested.
3.02.09 All other Materials shall be as per applicable Standards and Codes.
3.02.10 All Materials brought for incorporation in works shall be of best quality as per
IS, unless specified otherwise
3.03.00 LOADING
3.03.01 Dead Loads
(a.) Dead Loads are Permanent Loads which shall include the weight of
Structure complete with finishes, fixtures, partitions, etc. and shall be
taken as per IS : 875 (Part-I).
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3.03.02 Imposed Loads
(a.) Imposed Loads in different areas shall include Live Loads, Erection,
Operation and Maintenance Loads.
(b.) Equipment Loads (which constitute all Loads of Equipment to be
supported, as given by Equipment Supplier), Pipe Loads (Static, Friction
and Dynamic), Cable / Ducts Loads, wherever applicable, are not
included in the Imposed Loads as furnished below and these Loads
shall be considered in addition to Imposed Loads.
(c.) For consideration of Imposed Loads on Structures, IS:875 (Part-2) in
general shall be followed. However, for the following areas, Minimum
Imposed Loads as indicated below shall be considered for the Design.
If the actual expected Imposed Loads are more than the specified
Minimum Imposed Loads, then actual Imposed Loads shall be
considered.
Sl.No. Description Minimum specified Imposed
Loads (T/Sq.M.)
1. Cable/Pipes/Ducts Supports 0.40 for walkway
Note : Additionally Loads for Cable / Piping / Ducting, shall be considered, as
applicable
2. General
i) Stairs and Landings 0.50
3.03.03 Equipment, Piping / Cables / Ducts and associated Loads
(a.) The Equipment, Piping/Cables/Ducts and associated Loads shall be
considered as given by the Equipment Supplier. Equipment Loads,
which are of permanent nature, shall be treated as Dead Loads.
3.03.04 Seismic Loads
(a.) All Structures shall be Designed for Seismic forces as per the criteria
specified in Annexure-EQ to Part-A Sub-section-D01 of specification.
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3.03.05 Wind Loads
(a.) All Structures shall be Designed for Wind forces as per the criteria
specified in Annexure-WL to Part-A Sub-section-D01 of specification..
3.03.06 Damping in Structures
(a.) The damping factor to be adopted shall not be more than as indicated
below :
Sl.No. Type of Structure Wind Loads Seismic Loads
a) Welded Steel Structure 1.0% 2.0%
b) Bolted Steel Structure 2.0% 2.0%
3.03.07 Temperature Loads
(a.) For temperature Loading, the total temperature variation shall be
considered as 2 / 3 of the average maximum annual variation in
temperature. The average maximum annual variation in temperature for
this purpose shall be taken as the difference between the mean of the
daily Minimum ambient temperature during the coldest month of the
year and mean of daily maximum ambient temperature during the
hottest month of the year. The Structure shall be Designed to withstand
Stresses due to 50% of the total temperature variation.
(b.) Suitable expansion joints shall be provided in the Longitudinal direction
wherever necessary with provision of twin columns. The maximum
distance of the expansion joint shall be as per the provisions of IS :
800 for Steel Structures.
(c.) Frictional forces due to temperature variation shall be considered
between the Pipes and the supporting Structures along Longitudinal
direction.
3.04.00 DESIGN CONCEPTS
3.04.01 Individual members of the frame shall be Designed for the worst Combination
of forces such as bending moment, axial force, shear force, torsion, etc.
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3.04.02 The different Loading Combinations shall be taken as per IS:875 (Part-5) and other
relevant IS Codes.
(a.) Wind and Seismic forces shall not be considered to act simultaneously.
(b.) Frictional forces from the Pipes and supporting Structure in Longitudinal
direction need not be considered along with Seismic or Wind forces.
(c.) The Structures shall be Designed for most unfavorable Combination of
Dead Loads, Imposed Loads, Equipment Loads, Piping / Cables /
Ducts Loads, Wind / Seismic Loads, Temperature Loads, and other
applicable Loads without exceeding the Permissible Stresses.
(d.) Permissible Stresses for different Loading Combinations shall be taken
as per IS 800.
(e.) For checking against uplift / tension case, 75% of Dead Loads with no
Imposed Loads shall be considered along with other Loads.
(f.) In all Loading Combinations, the Loads that have reduction effect shall
not be taken into account in the Combination concerned.
(g.) Where Wind is the main Load acting on the Structure, no increase in
Stresses is to be considered for Design of Structures and Foundation
Bolts.
(h.) Dynamic Piping Loads need not be considered acting simultaneously
with Wind or Seismic Loads.
(i.) Increase in Permissible Stresses shall be allowed in Loading
Combinations where Dynamic Piping Loads are considered and shall be
as permitted under Seismic Loading conditions.
3.04.03 The Design of Steel Structures shall be done by Working Stress Method.
Design shall be as per the provisions of IS : 800 and other relevant IS
standards.
3.04.04 Deflection Criteria
The maximum Deflection for various Structures shall not exceed and be
limited to the following :
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Sl.No. Description Maximum value of
1. For all Structures Span/325 or Height/325, as the case may
be unless noted otherwise.
2. For all Grating/Chequered Span/250
Plates
(However, the maximum vertical Deflection of Grating / Chequered Plate
shall be limited to 6 mm).
3.04.05 All Structures of the Bidder shall be independent of the Employer's Structures.
In case any vertical Loads from the Bidders' Structures are required to be
transferred to the Employer's Structures, the same shall be through PTFE
bearings. In no case any horizontal Loads shall be transferred to the
Employer's Structures from the Bidder's Structures.
3.04.06 Welding shall be used for fabrication and Erection. Site connections shall be
with Welding / Bolts. For Bolt connection, IS : 4000, IS : 3757, IS : 6623 and
IS : 6649 shall be followed. For Welding of Structures IS : 814, IS : 816, IS :
1024, IS : 4353 and IS : 9595 shall be followed.
3.04.07 Pipes, Cables and Ducts Supports
(a.) All Pipes, Cables and Ducts shall generally be routed above ground.
(b.) A Minimum clearance (clear Headroom) of 8 m shall be kept for all
over-ground Pipes/Cables/Ducts for all road / rail crossings. For other
areas, the requirement of Minimum clearance shall be as specified
elsewhere in the Specifications. All Pipes/Cables/Ducts supports shall
be provided with continuous walkway of Minimum 750 mm Width with
handrails and toe-guards, all along the length with approach ladders
near roads, passageways, etc. Before and after the road/rail crossings,
a barrier of suitable Height shall be constructed so as to prevent the
approach of Cranes (having Height more than 8 m) etc., upto the Pipes/
Cables/Ducts supports.
(c.) In case any main Steel framed Structure of the Employer is existing in
close vicinity of the Bidder's Pipes/Cables/Ducts supports, support only
from the main framing Structure of the Employer may be permitted by
the Employer to the Bidder, for supporting his Pipes/Cables/Ducts.
Levels and detail of such supports shall be finalised by the Bidder in
consultation with the Employer during his detailed Engineering stage.
The Bidder shall supply and erect all such supports.
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PART-B
3.04.08 Whenever the Bidder is taking any support from any of the Employer's
Structures, the Bidder shall ensure that no damage is done to the Employer's
Structures including Painting thereof. In case of any damage to the Employer's
Structure and/or Painting, the Bidder shall rectify the same at his cost to the
complete satisfaction of the Employer.
3.04.09 The bracing in Structures shall be provided such that under no circumstances
normal / convenient access to any points is blocked or obstructed.
3.04.10 The Employer proposes to encase Base Plates of all power house columns.
Top of the encasement Concrete shall match with the surrounding finish
Paving Level. All stiffeners provided with Base Plate shall also be fully
encased and for this purpose the top Level of stiffeners shall be kept by
Bidder at least 200 mm below the surrounding finished Paving Level.
3.04.11 Propping/supporting of any Beam on the bracing members shall not be
permitted.
3.04.12 All Structures close to railway line shall have clearance conforming to Railway
norms. Further, load from the railway line shall be considered in the design,
wherever applicable.
3.04.13 All Stairs shall have a maximum Riser Height of 180 mm and a Minimum
Tread Width of 250 mm. Minimum clear Width of Stairs shall be 1200 mm,
unless specified otherwise.
3.04.14 Minimum headroom (free Height) under all Floors, walkways and Stairs shall
be 2.30 M.
3.04.15 All Foundation Bolts shall conform to IS : 5624.
3.05.00 STEEL HELICAL SPRINGS AND VISCOUS DAMPLERS
3.05.01 General Requirement
This part of the specification covers the requirement for the manufacturing,
testing, supply, transport to site, pre-stressing erection, supervision of erection
by the vendor, release of pre-stress, alignment, commissioning, etc. of Steel
helical springs and viscous dampers.
The Steel helical springs and viscous dampers supplied should be of proven
make. The qualifying requirement for sub-vendor / supplier for Steel helical
springs and viscous dampers is specified elsewhere in the specification.
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PART-B
The information about the entire range of spring units, damper units and
spring-cum-damper units manufactured by sub vendor shall be furnished to
enable the Employer to do the engineering of the foundations along with
appropriate type and quantity of spring units for different machines. The infor-
mation to be furnished should include the load carrying capacity, stiffness
(vertical & horizontal), damping resistance, dimensions of spring and damper
units.
3.05.02 Codes and Standards
Some of the relevant applicable Indian standards and codes, etc, applicable to
this section of the specification are listed below:
DIN : 4024 Machine foundations; Flexible supporting structures for
machine with rotating masses.
DIN : 2089 Helical compression springs out of round wire and rod :
calculation & design.
DIN : 2096 Helical compression springs out of round wire and rod;
quality requirements for hot formed compression springs.
VDI : 2056 Criteria for assessing mechanical vibrations of machine.
VDI : 2060 Criteria for assessing the state of balance of rotating rigid
bodies.
3.05.03 Design & Supply of Material
i) Supply
Steel helical springs and viscous dampers and associated auxilliaries
shall consist of:
(a) Steel helical spring units and viscous dampers along with
viscous liquid including associated auxiliaries for installation of
the spring units and dampers like steel shims, adhesive pads,
etc.
(b) Frames for pre-stressing of spring elements.
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(c) Suitable hydraulic jack system including electric pumps, high-
pressure tubes etc. required for the erection, alignment etc., of
the spring units. One set of extra hydraulic jacks, and hand
operated pumps shall also be provided.
(d) Any other items which may be required for the pre-stressing,
erection, release of pre-stress, alignment, and commissioning of
the Steel helical springs and viscous dampers.
ii) Design
The design of the supporting arrangement for the equipment supported
on Steel helical springs and viscous dampers shall be done by Em-
ployer. The supporting arrangement shall consist of an RCC deck sup-
ported on steel helical spring units and viscous dampers which in turn
shall be supported on RCC substructure for TG & steel structure for
BFP. The RCC deck and substructure shall be provided by the Em-
ployer
.
The spring units should have stiffness in both vertical and horizontal directions
with the horizontal stiffness not less than 50% of vertical stiffness. The stiffness
should be such that the vertical natural frequency of any spring unit at its rated
load carrying capacity is not more than 3 Hz.
The damper units or spring-cum-damper units should be of viscous type offer-
ing velocity proportional damping. The damper units should be suitable for tem-
peratures ranging from 0 to 50C. The damping resistance of individual damper
units should be such that the designed damping can be provided using reason-
able number of Units. Damper Units shall have damping resistance ranging
from 40 KN Sec / M to 750 KN Sec / M.
The sizes of the spring units, damper units and spring-cum-damper units
should be such that groups of such units can be accommodated on column
head or on top of beam flange, in case of elevated foundations and on pedes-
tals / walls in case of foundations at ground level.
The Steel helical springs and viscous dampers shall be designed for a mini-
mum operating life of 30 years.
3.05.04 Manufacturing & Testing
Complete manufacturing and testing of the Steel helical springs and viscous
dampers shall be done at the manufacturing shop of the approved sub vendor
/ supplier. For this purpose the contractor / sub vendor shall submit the de-
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tailed quality plan for approval of engineer and take up the manufacturing / test-
ing after approval of such quality plan. The quality plan shall include
(a) Manufacturing schedule and quality check exercised during
manufacturing.
(b) Detail of test to be carried out at the manufacturing shop with their
schedule.
(c) Special requirements, if any, regarding concreting of top deck.
(d) Complete step-by-step procedure covering the installation and
commissioning of the spring system.
(e) Manuals for erection, commissioning, testing and maintenance of the
Steel helical springs and viscous dampers.
(f) A checklist for confirming the readiness of the civil fronts for erection of
Steel helical springs and viscous dampers.
(g) Checklist for equipment required at each stage of erection.
(h) Bill of materials and data sheet of various elements such as spring
units, viscous dampers, with their rating, stiffness etc. included in the
supply.
(i) Bill of material and data sheet for frames for pre stressing, hydraulic
jack including electric pump, high pressure tubes, hand operated pump
etc., with their rating and numbers.
(j) Any other details which may be necessary to facilitate design and con-
struction of the foundations / structures.
3.05.05 The Springs shall conform to codes DIN 2089 and DIN 2096. The quality as-
surance and inspection procedure shall be finalised on the basis of the above
codes and the quality plans be drawn accordingly.
3.05.06 Transportation
Steel helical springs and viscous dampers shall be suitably protected, coated,
covered, boxed and crated to prevent damage or deterioration during transit,
handling and storage at site till the time of erection.
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The contractor shall be responsible for any loss or damage during
transportation, handling and storage.
3.05.07 Erection and Commissioning
Complete erection and commissioning of the Steel helical springs and viscous
dampers including pre-stressing of elements, placing of elements in position,
checking clearances on the shuttering of the RCC top deck, releasing of pre-
stress in spring elements, making final adjustments and alignments etc. shall
be carried out by a specialist supervisor of vendor.
The scope of work shall be deemed to include all the above activities, which
may not have been explicitly mentioned but are reasonably implied for the
successful commissioning of Steel helical springs and viscous dampers.
The contractor shall guarantee the performance of the Steel helical springs and
viscous dampers for 24 months from the date of commissioning of each
machine which shall be termed as Guarantee Period.
3.05.08 Supervision
The supervision of installation of Steel helical springs and viscous dampers in-
cluding pre-stressing, placing, releasing and alignment of spring units shall be
done by a specialist supervisor of sub vendor / supplier, trained for this
purpose.
3.05.09 Realignment of Spring System
If any realignment of the Steel helical springs and viscous dampers is required
to be done for aligning the shaft or for any other reasons during the first one
year of operation from the date of commissioning of the machine, the same
shall be done by the contractor.
3.05.10 Acceptance Criteria
Stiffness values shall be checked. The permissible deviations shall be as per DIN
2096.
Following acceptance criteria shall be followed:
General workmanship is being good as recommended by the manufacturer
and approved by the Engineer.
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Tolerances are within the specified limit.
Material test certificate ( MTC ) is in compliance with the applicable codes /
standards.
Bought out material is from the approved manufacturer / vendor.
Bought out material is matching with the approved sample.
4.00.00 MISCELLANEOUS REQUIREMENTS
4.01.00 CORROSION PROTECTION
4.01.01 General
(a.) All equipment, pipes, etc. shall be painted as per the requirements
specified in the relevant mechanical sections. EOT crane shall,
however, be painted as per the scheme mentioned below.
(b.) All Steel structures (except those embedded in Concrete) shall be
provided with Painting as given below which is designed for a minimum
maintenance free life of Ten (10) years (expected life, long range Ten
(10) to Twenty (20) years, as per BS : 5493.
(c.) All Paints shall be of high build constitution.
(d.) All Painting shall be done as per approved Painting scheme of the
Vendors / Manufacturers, which shall be submitted by the Bidder and
as approved by the Employer. Painting scheme shall also include Item
codification/Description of all Coats of Paints for manufacturer's, from
whom the Paint is intended to be procured.
4.01.02 Painting of Steel Surfaces embedded in Concrete.
(a.) For the portion of Steel surfaces embedded in Concrete, the surface
shall be prepared by Manual Cleaning and provided with Primer Coat of
Chlorinated Rubber based Zinc Phosphate Primer of Minimum 50
Micron Dry Film Thickness (DFT).
4.01.03 Painting of Steel Surfaces (other than those embedded in Concrete).
(a.) All Steel surfaces shall be provided with self curing Inorganic Zinc
Silicate Primer Coat (Solid by Volume Minimum 60%) of Minimum 75
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Micron Dry Film Thickness (DFT) applied over blast cleaned surface to
near white metal conforming to Sa 2 finish of Swedish standard
SIS-05-5900. The Primer Coat shall be applied in Shop immediately
after blast cleaning by Airless spray technique.
(b.) Primer Coat shall be followed with the application of Intermediate Coat
of Polyamide Cured pigmented Titanium Dioxide (TiO
2
) or Micaceous
Iron Oxide (MIO) Epoxy based Paint (Solid by Volume Minimum 60%)
of Minimum 75 Micron DFT. This Coat shall be applied in Shop after
an interval of Minimum overnight (after the application of Primer Coat)
by Airless spray technique.
(c.) Intermediate Coat shall be followed with the application of Finish Coat
of Polyamide Cured colour pigmented Epoxy based Paint (Solid by
Volume Minimum 60%) of Minimum 75 Micron DFT. This Coat shall be
applied after an interval of Minimum overnight and maximum indefinite
(after the application of Intermediate Coat) either before Erection by
Airless spray technique or after Erection by brush and / or spray.
Colour and shade of the Coat shall be as approved by the Employer.
The Finish Coat thickness of 75 Micron can be built up either in Single
application at Shop or in two applications one at Shop and the other at
Site.
(d.) Finish Coat shall be followed with the application of Final Finish Coat of
Polyurethane based colour pigmented Paint (Solid by Volume Minimum
40%) of Minimum 25 Micron DFT. This Coat shall be applied within
Seven (7) days (after the completion of Finish Coat), after Erection by
brush and/or spray. Colour and shade of the Coat shall be as
approved by the Employer.
4.01.04 Touch-up Painting on damaged areas
(a.) For Coatings damaged up to metal surface
Surface preparation shall be carried out by Manual Cleaning. Minimum 6
inches adjoining area with existing Coating shall be roughened by Wire
brushing, emery paper rubbing etc., for best adhesion of patch Primer.
Primer Coat of self-priming Epoxy Touch-up Primer applied by brush
immediately after the surface preparation. (Minimum DFT 100 Microns).
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Over this Primer Coat, Intermediate Coat, Finish Coat and Final Finish
Coat shall be applied as covered above by brush with Intermediate
Coat applied within maximum seven ( 7 ) days of application of touch
up Primer.
(b.) For Coatings damaged upto Intermediate Coatings (i.e. where Primer
Coat is intact).
Damaged area including Minimum 6 inches adjoining area with existing
Coating should be roughened by wire brushing, emery paper rubbing
etc., for best adhesion of patch Primer without damaging the Primer
Coat.
Touch-up Primer, Intermediate, Finish and Final Finish Coats shall be
applied as specified above for Coatings damaged up to metal surface.
4.01.05 Painting of Welded areas / Painting of areas exposed after removal of
temporary supports / Touch-up Painting on damaged areas of the Employer's
Structures, where inter-connection, Welding / modification etc. has been carried
out by the Bidder.
(a.) Clean the surface to remove flux spatters and loose rust, loose
Coatings in the adjoining areas of Weld seams by wire brush and
emery paper.
(b.) Painting procedure to be followed as mentioned above for Touch-up
Painting on damaged areas.
4.01.06 Coating for Mild Steel parts in contact with Water.
(a.) All mild Steel parts coming in contact with water or water vapour shall
be hot dip galvanised. The Minimum Coating of Zinc shall be 610 Gms
/ Sq. M. for galvanised Structures and shall comply with IS : 4759 and
other relevant Codes. Galvanising shall be checked and tested in
accordance with IS : 2629.
4.01.07 Gratings
All gratings shall be blast cleaned to Sa 2 finish of Swedish standard SIS-
05-5900 and shall be hot dip galvanised at the rate of 610 Gms / Sq. M.
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4.01.08 Hand Railings and Ladders
All handrails and ladders shall be galvanised at the rate of 610 Gms/Sq. as
per IS : 4736.
4.01.09 Sea Worthiness
All Steel Sections and fabricated Structures, Steel helical springs & viscous
dampers which are required to be transported on sea, shall be provided with
anti corrosive Paint before shipment to take care of sea worthiness.
4.02.00 HAND RAILING
4.02.01 Minimum 1000 mm high hand railing shall be provided around all Openings,
projections / balconies, walkways, platforms, Steel Stairs, etc., All handrails and
ladder Pipes shall be 40 mm nominal bore MS Pipes (medium class).
4.02.02 Handrails shall have top and middle rails at a height of 1000 mm and 500
mm and the vertical post spacing shall not exceed 1.50 M, with provision of
kick Plates (100 mm high and 6 mm thick).
4.03.00 GRATING
4.03.01 All gratings shall be Electro-forged type. Minimum thickness of the grating shall
be 40 mm for indoor installation and 32 mm for outdoor installation.
4.03.02 The Opening size shall not be more than 30 mm X 100 mm. The Minimum
thickness of the main bearing bar shall be 5 mm.
4.03.03 Cutting of gratings shall not be carried out at Site. Any cutting of gratings
required to provide passage for Columns/Pipes/Cables/Ducts etc shall be done
by the Contractor in shop and cut edges of Grating shall be suitably
reinforced with binding strips.
4.04.00 FIRE EXITS
4.04.01 All fire exits shall be Painted with P O Red / signal Red colour shade, which
shall not be used anywhere except to indicate the emergency or safety
measures. Fire safety norms shall be followed as per National Building Codes
and requirements of various statutory bodies shall be followed for providing
Fire Exits, Escape Stairs and Fire Fighting Equipment.
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4.05.00 OPENINGS
4.05.01 Details / Data of all Openings required by the Contractor in Floors/Walls/
Cladding/Roof to be provided by the Employer shall be given by the Contractor
progressively within 24 (Twenty Four) weeks of award. Within this period the
Contractor shall also furnish all Foundation Loads to be considered by the
Employer for the Design of Foundations to support the Contractors Structures
/ Equipment. Accordingly, the same shall be listed in Engineering Information
Flow Schedule to be furnished by the Contractor.
4.05.02 If the details/data of all Openings required by the Contractor in Floors/Walls/
Cladding/Roof are not furnished by the Contractor, as per the Engineering
Information Flow Schedule then all such required Openings shall be created by
the Contractor himself, at a later date in Floors/Walls/Cladding/Roof by using
special tools, as required. In this case edge protection to the Openings shall
also be provided by the Contractor using Anchor Fasteners.
4.05.03 For routing of Pipes/Cables/Ducts, the Employer shall only provide suitable
passage / Opening in Floors/Walls/Cladding. Any Pipe sleeves or embedments
required by the Contractor in these passages/Openings shall be provided by
the Contractor himself. These passage/Openings shall be suitably sealed by
the Contractor after completion of Erection works.
4.06.00 GROUTING
4.06.01 Non-shrink Cementitious flowable grout shall be used for Grouting of pockets
and under-pinning work below Base Plate of columns. Nominal thickness of
grout shall be 50 mm. Non-shrink cum plasticizer admixture shall be added in
the grout. Crushing Strength of the grout shall generally be one grade higher
than that of the base Concrete which is indicated in the civil construction
drawings released by the Employer. Minimum grade of grout shall be M30.
4.06.02 However, for Equipment Foundations, high Strength (Minimum Characteristic
Compressive Strength of 60 N/mm
2
at 28 days) ready mix non-shrink, Chloride
free, Cement based, free flowing, non-metallic grout as recommended by
Equipment manufacturer shall be used. The ready mix grout shall be of
reputed make as approved by the Employer.
4.06.03 The surface to be grouted shall be properly cleaned by using compressed air.
Contractor shall provide the required shim plates.
4.06.04 Contact area between the grout and the Base Plate shall not be less than
80%.
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4.07.00 NUTS AND BOLTS
4.07.01 M.S. Nuts and Bolts shall conform to IS:1363, IS:1364, IS:1367.
4.07.02 High Tensile fixing with Bolts and nuts shall respectively be as per IS:3757
and IS:6623.
4.07.03 Washers shall conform to IS 5369, IS:5370, IS:5372, IS 5374, IS:6610,
IS:6649, as appropriate.
5.00.00 STATUTORY REQUIREMENTS
5.01.00 The Bidder shall comply with all the applicable statutory rules pertaining to
Factories Act, Fire Safety Rules, Water Act for pollution control, Explosives
Acts, etc.
5.02.00 Provisions of safety, health and welfare according to Factories Act shall be
complied with. These shall include railing, fire escape, etc.
5.03.00 Provisions for Fireproof Doors, number of Staircases etc. shall be made in the
layout/schemes according to the requirements of Statutory Bodies.
5.04.00 Statutory clearances and norms of State Pollution Control Board shall be
followed.
6.00.00 PERMISSIBLE TOLERANCES
6.01.00 All Structural Steel work shall be Shop fabricated outside the Plant area.
6.01.01 Tolerances on dimensions for fabrication of Steel Structures shall be according
to IS : 7215.
6.01.02 Tolerances on dimensions for Erection of Steel Structures shall be according to
IS : 12843.
6.01.03 Tests on Welds shall be as per ASTM standards, IS : 816 and IS : 9595.
6.01.04 Dimensional and weight tolerance of Rolled Steel shapes shall be as per IS :
1852.
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7.00.00 LIST OF CODES AND STANDARDS
7.01.00 All applicable standards, references, Specifications, Codes of Practice, etc.,
shall be the latest edition including all applicable official amendments and
revisions. A complete set of all these documents shall be available at Site
with the Contractor.
SECTION-VI
PART-B
QUALITY ASSURANCE
SECTION-VI
PART-B
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CLAUSE NO. QUALITY ASSURANCE
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STEAM TURBINE & AUXILIARIES
Refer QA & I portion of General Technical conditions of technical specification.
(a) Shop Tests
Shop tests shall include all tests to be carried out at Contractor's works, at
works of his sub-contractor and at works where raw material supplied from
manufacture of equipment is manufactured. Testing requirement of major
equipment over and above the respective code/standard requirements are given
for ST & Aux. including Condenser, HP Bypass System & Vibration Isolating
System.
(b) Site Tests
The Contractor shall prepare and submit detailed field quality plans in the
format prescribed by NTPC setting out the quality practice and procedures to
be adopted by him for assuring quality for each equipment of material at this
specification from the receipt of material at site, during storage erection, pre-
commissioning to final commissioning of the plant. These procedures shall
necessarily include all checks/tests conducted at site for preservation, assembly,
alignment, positioning of the equipment, foundation preparation, welding/bolting
heat treatment, non-destructive examination, hydraulic test, running test,
performance test etc. The Contractor shall also furnish detailed quality
procedure proposed by him for storage, preservation, painting, acid cleaning,
alkali boil out, steam blowing, hydraulic test air/gas tightness test etc. to the
Employer. The same shall be discussed and finalised with the Employer and
six numbers of such finalised copies shall be submitted.
1.01.00 STEAM TURBINE AND ASSOCIATED EQUIPMENT
1.01.01 High Pressure & Intermediate Enclosure :
High pressure Cast Steel Enclosures (for example High pressure and Intermediate
Pressure 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 made availabe at OEMs works to enable the properties of material to
be determined.
Creep requirements:
a) Steels chosen for design metal temperatures less than 400C are exempt
from creep /stress rupture testing.
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b) Steels chosen for design metal temperatures between 400C to 540C AND
having less than 3% chromium, shall require 5 years performance feed back
experience 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 NTPC approval.
c) Steels chosen for design metal temperatures above 540C AND/OR having more
than 3% chromium, shall require 10 years performance feed back experience
OR adequate stress 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 NTPC approval.
d) Unspecified alloying elements shall be controlled as per the applicable standard.
(2) Each casting shall be subjected to magnetic particle examination on the entire
inner and outer surfaces after heat treatment.
(3) Each casting shall be subjected to a 100% examination for internal flaws by
ultrasonic/ radiographic method after heat treatment and suitable preparation.
(4) Cast enclosure shall be subjected to a hydraulic pressure test based on
established practice of manufacturer unless there is a geomtrical constraint for
doing hydro test. Bidder to furnish their practice in this regard for Employer's
approval.
(5) Excavated area of all the defects shall be subjected to MPI to ensure
excavation up to sound area. All the areas repaired/upgraded by welding shall
be examined by UT, RT (to confirm findings of UT wherever required) and MPI.
Sketches/reports of location of repair and reports of NDT carried out on
repaired areas shall be submitted alongwith certificates. Hardness survey shall
be carried out on the repaired area.
(6) Where stub pipes and transition pieces are welded to the main body of an
enclosure the following shall be carried out:
(i) Radiographic examination and Magnetic particle or dye penetrant
examination of weld preparation.
(ii) Magnetic particle examination of finished welds after stress relief.
(iii) Radiographic or ultrasonic examination of finished welds.
(iv) Before despatch to site, the site weld preparations on the stub pipes
and transition pieces shall be subjected to 100% RT/UT and magnetic
particle examination / Dye penetration test.
(v) Hardness survey on the weld joint, HAZ and parent material.
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(7) Wall thickness measurement by ultrasonic for critical and highly stressed zones
of the casting shall be carried out.
(8) Colour matching of castings by putting two halves together or feeler gauge
tightness check from outside to ensure required contact area and joint tightness
shall be carried out.
1.01.02 Low Pressure Enclosure (Fabricated)
(a) Where welds are made by chipping and grinding back to the first side weld
before completing the weld from second side, a magnetic particle or dye
penetrant examination of the chipped area shall be carried out.
(b) Bidder to furnish their practice regarding stress relieving of the fabricated
enclosures for Employer's approval.
(c) Bidder to furnish their standard practice regarding NDT on welds for Employer's
approval, however following are minimum NDT requirements:
Butt welds 10% RT or UT
and 10%
MPE/DP test
Fillet welds 10% MPE/DPT
Nozzle welds 10% MPE/DPT
Lifting lug & other load bearing fillet welds 100% MPE/DPT
Site weld edge preparations 10% MPE/DPT
(d) Bidder to furnish his proven practice for hydraulic pressure tests. If it is not
their practice, the justification for not carrying out hydraulic test shall be
furnished for Employer's approval.
(e) Feeler gauge tightness check from inside and outside to ensure required joint
tightness shall be carried out.
1.01.03 Rotors
(a) Forgings
Rotor forgings (monoblock and/or discs), Impulse Wheel & Nozzle Box and
coupling forgings :
(1) Fully representative tangential or radial test pieces shall be provided at
each end of the body, at each shaft end and radial test piece from the
trepanned core (when a core is trepanned) respectively to determine
mechanical properties including impact, brinell hardness etc. and tests
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for notch toughness i.e. FATT (both transition temperature and room
temperature impact values).
(2) Creep requirements:
a) Steels chosen for design metal temperatures less than 400C are
exempt from creep /stress rupture testing.
b) Steels chosen for design metal temperatures between 400C to 540C
AND having less than 3% chromium, shall require 5 years performance
feed back experience in the absence of which, creep rupture test will
be required to be carried out for maximum test duration of 1000 hrs/
c) Steels chosen for design metal temperatures above 540C AND/OR
having more than 3% chromium, shall require 10 years performance
feed back experience OR adequate stress 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
NTPC approval.
d) Unspecified alloying elements shall be controlled as per the applicable
standard.
(3) Heat treatment should be carried out in such a way so as to ensure
minimum residual stress in the rotor. Residual stress measurement will
be carried out.
(4) Each forging shall be subjected to a 100% ultrasonic examination.
Normal probes and angular probes with different probe angles shall be
used for thorough examination to ensure complete soundness of the
forging. Supplier should furnish the proposal, alongwith scanning plan
and probe angles to be used, for Employer's approval.
(5) When a rotor forging is bored, a visual and magnetic particle
examination of the bore shall be carried out.
(6) Thermal stability tests shall be carried out on HP and IP rotor forgings
to ensure the thermal stability of the rotors in service and at
overspeed.
(7) Following tests shall be carried out on the rotor welds:
(i) Ultrasonic examination with normal and angular probes of the
weld to ensure complete coverage and freedom from harmful
defects.
(ii) Run out of rotor before and after welding
(iii) MPE on finish welds.
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(iv) Hardness survey on the welds.
(v) Stress relieve annealing.
(vi) Test reports of filler material used.
(vii) Dimensional record of weld preparation.
(8) Dimensional Examination of the rotor blade grooves and other important
dimensions to be carried out to ensure the conformance to drawing
dimensions, Log sheets/records shall be prepared for all important
dimensions.
(b) Complete Rotors
(1) Axial & radial run-outs and surface finish checks shall be carried out
before and after blading and after overspeed tests. Run out examination
will be carried out at blade shrouds also.
(2) Check for clearance between rotor groove and blade at the root in line
with manufacturere's standard and proven practice being followed.
(3) Rotors shall be dynamically balanced at rated speed.
(4) An overspeed test shall be carried out during which the rotor shall
withstand an overspeed of 120% for five continuous minutes. If bidder's
practice is different from as stated above, then same shall be furnished
to Employer's approval. During this test vibration measurement and
analysis shall be carried out.
(5) After blading rotor stages with blades over 225 mm of active length are
to be given standing vibration tests to determine natural frequencies in
various vibration modes to ensure that the ranges are outside operating
frequencies. The modes to be tested are: Bucket group tangentials,
wheel axials and group axials.
(6) In case, impulse stage and or blade discs are fitted on the rotor, fit
up between such disc and rotor to be checked up before and after
overspeed.
(7) Lock blade lift after the overspeed, if applicable based on manufacturer's
standard design & practice shall be checked and record for same shall
be maintained.
1.01.04 Stator & Rotor Blades and Shroud Bands
(a) Fully representative test pieces shall be made availabe at OEMs works to
enable mechanical properties of the material to be determined. In case of
blades machined from bar stock, mechanical tests shall be carried out on the
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hardest and softest specimens of each heat treatment batch. Hardness test
will be carried out on 100% basis.
(b) Each bar stock for machining blades and forging shall be subjected to 100%
ultrasonic examination.
(c) When erosion shielded, the erosion shield and blade joint shall be
radiographed.
(d) Dye penetrant checks shall be made on the erosion shield and blade joint in
manufacture prior to fitting to the wheel and after overspeed tests.
(e) Magnetic particle inspection or dye-penetrant examination (when MPI is not
applicable) shall be carried out on finish machined blade profile, roots and
shrouds.
(f) All moving blades of over 225mm active length are to be moment weighed and
assembled on shaft in a prescribed sequence to ensure optimum balancing of
rotor.
(g) Natural frequencies of the L.P.Turbine blades shall be determined before
mounting on rotors to ensure that the same are outside operating fre-quency
range.
(h) Shroud bands after punching and after rivet-ting shall be subjected to 100%
DPT to ensure 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/
DPT.
(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 case of repair is allowed, manufacturer shall submit WPS/PQR and
defectogram for Employer's approval before welding. After weld repair, RT
shall be carried out on repaired area.
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1.01.05 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 Project Manager's approval.
(3) A 100% ultrasonic examination shall be carried out on diaphragm
materials. Blade junction 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.
1.01.06 Stop, Control and bypass valves, actuators/servo-motors and steam strainers
(a) Test pieces shall be made availabe at OEMs works to enable the mechanical
properties of valve bodies, bonnets, valve disc and seat, and valve spindle
material to be determined.
Test Creep requirements:
i) Steels chosen for design metal temperatures less than 400C are
exempt from creep /stress rupture testing.
ii) Steels chosen for design metal temperatures between 400C to 540C
AND having less than 3% chromium, shall require 5 years performance
feed back experience in the absence of which, creep rupture test will
be required to be carried out for maximum test duration of 1000 hrs/
iii) Steels chosen for design metal temperatures above 540C AND/OR
having more than 3% chromium, shall require 10 years performance
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feed back experience OR adequate stress 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
NTPC 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 the finish ground or honed condition.
Hardness check shall be carried out to ensure required hardness on test
sample.
(c) Valve body and bonnet castings/forgings shall be subjected to 100% radiography
or 100% ultrasonic examination. Body and bonnet shall also be subjected to
100% magnetic particle examination on entire surface. All pressure containing
welds in body and bonnet 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 testing shall be carried out on valve operators/ actuators to check
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.
1.01.07 Cast and Forged Steel Components such as LP casing, in case of cast design, inlet
& extraction/exhaust connections, shaft seal covers and rings, governor shaft, breach
nut, 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
(a) Results of tests conducted to determine mechanical properties, chemical
analysis, metallurgical/ metallographic examination for nodular cast iron, if any
and heat treatment procedures recommended and actually followed shall be
recorded on certificates.
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(b) Each pressure containing enclosure shall be subjected to a hydraulic pressure
test at 1.5 times the design pressure.
(c) Each casting/forging shall be subjected to suitable non-destructive examination
by Radiographic or ultrasonic and magnetic particle or dye penetrant
examination methods to ensure freedom from harmful defects.
1.01.08 Bolts and nuts for pressure Retaining enclosures and Rotor Couplings
(a) Bar stock greater than or equal to 50 mm in diameter for bolts shall be
subjected to ultrasonic examination.
(b) Finish machined bolts shall be subjected to magnetic particle examination /DPT
for surface defect examination.
(c) Coupling bolts and nuts shall be suitably identified after weight control checks.
1.01.09 Governing and Protection System Equipment such as Electro-hydraulic Controller,
Hydraulic Amplifier, Hydraulic Controller, Electro hydraulic Convertors, Hydraulic
Convertors, Hydraulic Speed Governor, Trip Devices etc.
(a) All pressure retaining parts shall be subjected to hydraulic testing.
(b) All the major castings/forgings shall be subjected to suitaitable NDT methods
depending upon their application and criticality to ensure the freedom from
harmful defects.
(c) All the main assemblies and sub-assemblies shall be subjected to functional
test.
(d) All butt welds shall be subjected to minimum 10% RT/UT and all fillet and
corner welds shall be subjected to MPI/DPT.
(e) All control equipment shall be subjected to rig testing, if it is not possible to
test it on the steam turbine light run. The purpose of rig testing shall be as
far as practical to prove that the functioning of the con-trol equipment is in
accordance with the approved design.
(f) Nitrided and stellited components will be subjected to DPT and hardness check
shall be carried out on test sample.
1.01.10 Inspection of Completed Turbine
The steam turbine shall be assembled in the manufacturer's works to such an extent
that a thorough inspection can be carried out. The purpose of this inspection will be to
ensure that the fit between mating components is correct and that all clearances are
in accordance with the design requirement. Contractor will prepare the checklist in this
regard and submit the same for Employer's approval. However, minimum clearances
which are required to be checked and records to be maintained during assembly of
Inner Casing - Rotor, Inner Casing - Outer Casing, Rotor - Outer Casing, Gland Steam
Housing - Shaft - Casing etc. are shroud diameters, axial distances for shroud bands
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for casings, clearance between shaft seal casings and shaft seal rings, radial and axial
blade clearance in blading section, axial and radial alignment of rotor in respect of
shaft seals, alignment of overspeed governor etc. This is indicative check only. However,
the details shall be finalised during QP finalisation stage.
These check lists shall be designed so that a comparison can be made between the
design clearances, the clearances measured during works assembly, and those
measured during the site turbine build. The vendor shall state, in his proposal, whether
or not it is his practice to carry out no load works running tests on the steam
turbine. (To this end the vendor shall give details of their normal works practice. In
order to prove the compliance with design of the steam turbine control and emergency
control equipment, functional tests shall be carried out in the manufacturer's works).
These tests shall be:
(a) Part of a no-load run under steam and / or
(b) By approved rig tests.
1.02.00 AUXILIARIES OF STEAM TURBINE
1.02.01 Bearing Pedestals and Bearings
(a) Cast Pedestals & Housing
Leakage tests shall be conducted on pedestals.
(b) Fabricated Pedestals & Housing
(1) Leakage test shall be conducted on pedestals.
(2) 10% weld shall be checked after stress relieving by magnetic particle
test and minimum 10% of the butt welds will be checked by RT or
UT.
(c) Bearings shell
(1) The shell and castings \ forgings shall be subjected to suitable non
destructive examination like RT\UT & MPI as applicable.
(2) Colour matching of the shells by putting two halves together and feeler
gauge tightness checks from inside and outside to ensure required
contact area and joint tightness shall be carried out.
(3) The shell shall be subjected to hydraulic pressure test.
(4) Chemical analysis of white metal shall be carried out. The
effectiveness of the white metal adhesion shall be checked by
ultrasonic or other approved method and the exposed edges of the
white metal shall be subjected to a dye penetrant examination.
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PART-B
1.02.02 Cross around pipes
(a) Weld edge preparation of shop and site welds shall be checked by magnetic
particle examination.
(b) All buttwelds shall be subjected to 100% Radiographic examination.
(c) Magnetic particle examination shall be carried out on all welds.
1.02.03 LUBRICATING OIL, JACKING OIL AND CONTROL OIL SYSTEMS
(a) Pumps
(1) Main oil pump shaft shall be subjected to ultrasonic examination. Butt
welds shall be subjected to RT/UT.
(2) Pump impeller shall be subjected to suitable NDT method like MPI/DPT
for surface defect examination. Impeller of main oil pumps shall also
be subjected to an over speed test at 120% of rated speed for 5
minutes.
(3) Pump casing shall be subjected to hydraulic pressure test at 2 times
the working pressure or 1.5 times the pump shut off head whichever is
higher. Rotor assemblies shall be dynamically balanced.
(4) All pumps shall be performance tested at the manufacturer's works.
Test shall include check for vibration and noise levels also. Procedure
for performance testing shall be submitted to Employer for approval.
(b) Oil purifiers.
(1) All pressure parts will be subjected to hydraulic pressure test.
(2) Components/parts of the equipment shall be subjected to suitable NDT
depending upon the criticality of the application to ensure freedom from
surface and sub surface defects.
(3) All rotating parts like bowl assembly etc, shall be subjected to static
and dynamic balancing test.
(4) The complete purifier shall be tested at manufacturer's works for
capacity, mechanical running sequential operation and interlocks,
moisture content, vapour tightness, vibration, noise level, quality
improvements etc. Sample shall be drawn from inlet and outlet of
purifier after works test and shall be tested for moisture content,
chemical tests and particle size of impurities.
(c) REFER RELEVANT CLAUSES OF THE SPECIFICATION FOR OTHER ITEMS
SUCH AS PIPING, HEAT EXCHANGERS, VALVES, FILTERS, BLOWERS /
EXHAUSTERS ETC IN THIS SYSTEM.
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SECTION-VI
PART-B
1.03.00 STEAM SURFACE CONDENSERS FOR MAIN TURBINE CONDENSER AND DRIVE
TURBINE CONDENSER (IF OFFERED)
1.03.01 SHELL, HOTWELL, WATER BOXES, DOORS AND TUBESHEETS
(a) All welds shall be visually examined. Radiographic examination of 10% of
buttwelds shall be carried out. However, for vacuum containing welds, R.T on
atleast 10% of each buttweld shall be carried out. Surface defect examination
by magnetic particle inspection or equivalent test method shall be carried out
for minimum 10% weldments. This shall apply to site welds also.
(b) All edge preparations shall be examined for surface defects. Edge preparation
for welds to be carried out at site shall be checked by magnetic particle
inspection method before despatch.
(c) In case of fabricated flanges, welds shall be checked by 100% radiographic/
ultrasonic and 100% magnetic particle inspection methods to ensure freedom
from internal and surface defects.
(d) To ensure dimensional control of condenser, parts\sub assemblies shall be trial
assembled at shop.BIDDER shall furnish his proposal in this regard, which will
be subject to Employer's approval. Trial insertion of a few tubes through
main tube plates and support plates shall be carried out to ensure alignment
of tube plates and proper fitting and matching of parts\sub-assemblies.
(e) Bidder to furnish his practice regarding stress relieving of the water boxes and
water chambers.
1.03.02 Condenser Tubes shall be tested as per the requirements of relevant codes and
standards.
1.03.03 Steam Throw Off Device
(a) Edge preparations shall be examined for surface defects by MPI/DPT. 10%
radiographic or ultrasonic examination shall be carried out for all weldments.
(b) Welds shall be subjected to surface defect examination by 10% magnetic
particle\dye penetrant examination.
1.03.04 SPRING ASSEMBLY
(a) Static load testing of the springs shall be carried out and spring characteristics
shall be drawn and verified.
(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.
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PART-B
1.04.00 Condenser air evacuation system for main turbine condenser and drive turbine
condenser (if offered)
1.04.01 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 shall demonstrate by carrying out visual cavitation test that pump will
be operating under all operating condition including blank off condition without
cavitation.
(f) REFER RELEVANT CLAUSES OF THE SPECIFICATION FOR OTHER ITEMS
SUCH AS HEAT EXCHANGERS, FILTERS, PIPING, VALVES, ETC. IN THIS
SYSTEM.
1.04.02 The complete package shall be subjected to hydraulic pressure and leakage test and
shop tested to check interlocks and functional requirements. The one complete unit
shall also be subjected to demonstrate successful operation and performance testing,
with saturated 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.
1.05.00 FEED WATER HEATER, DRAIN COOLERS, GLAND STEAM CONDNSER, HEAT
EXCHANGERS & PRESSURE VESSELS / STORAGE TANKS
1.05.01 All raw materials used shall have co-related mill test certificate meeting mandatory and
supplementary checks of material specification.
1.05.02 Material for Tube plates shall be ultrasonically tested. Finished plates shall be
subjected to suitable NDT. For cladded plates, bonding shall be checked by UT. Vendor
shall furnish their practice regarding manufacturing & NDT for supply of cladded plates
for Employer's review. Drilled Tube plates shall be checked for ovality of holes,
ligaments, surface finish etc.
1.05.03 Dished ends shall be subjected to 100% MPI and RT/UT on welded joints. Knuckle
portion shall be checked by MPI for surface defects and thinning shall be checked by
UT.
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PART-B
1.05.04 Butt Welded / Full penetration joints shall be checked by suitable RT / UT. Fillet
welds shall be checked by MPI / DPT.
1.05.05 Tubes shall be tested as per the relevant codes / specification / standards.
1.05.06 Before tubes expansion in the tube sheets, the mockup test for expansions shall be
carried out, in case not done earlier. Torque setting of expander shall be based on
mock up tests. J oints shall be checked for tube thinning.
1.05.07 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.
1.06.00 PIPING, BELLOWS AND THERMAL INSULATION FOR TURBINE & AUX SYSTEMS
1.06.01 Piping and Fittings
(a) All raw materials used shall have co-related mill test certificate meeting
mandatory and supplementary checks of material specification.
(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 statuatory requirement,
wherever applicable shall also be complied with.
(1) Temperature > 400
0
C And / Or pressure exceeding 71 bar.
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PART-B
(i) 100% RT/UT on butt welds and full penetration branch welds.
(ii) 100% MPE.
(2) Temperature > 175
0
C up to 400
0
C 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.
(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 J acking 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.
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SECTION-VI
PART-B
1.06.02 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 (EJ MA). In case these tests have
already been accepted by NTPC on a prototype expansion bellow, as defined
in Sec.D Clause 3.2 of Expansion J oints Manufacturers Association (EJ MA)
test reports may be furnished by manufacturer for consideration and approval
of Employer.
1.06.03 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.
(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.
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.
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PART-B
(e) 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 Project Manager.
(f) 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.
(g) 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%.
(h) 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 NTPC in
earlier projects for the same type / size /design, test certificate for the
same may be furnished for approval of Employer.
1.06.04 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.
(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.
1.07.00 VALVES
1.07.01 Inspection and testing requirements for valves other than extraction line valves and
butterfly valves shall be as follows:-
(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.
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SECTION-VI
PART-B
(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 ANSI Class ANSI Class ANSI Class ANSI Clas
NB in mm upto 300 above 300 above 600 900 & above
upto 600 below 900 & below 4500
Less than 50 Visual Visual Visual MPI
50 & above but Visual Visual MPI MPI & RT (on
below 100 10% of valves
on 100% area)
100 & above Visul MPI MPI & RT (on 10% MPI & RT
but less than of valves on change (on 100% area)
300 of section & weld ends)
300 and above MPI MPI MPI & RT (on change MPI, RT (on 100%
of sections & weld ends) area)
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
1.07.02 Extraction Line Valves
(a) Surface crack examination and hardness check shall be carried out on all hard
faced/stellieted surfaces, if any.
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PART-B
(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.
1.07.03 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
Project Manager.
(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.
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SECTION-VI
PART-B
(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
checked. The test shall be conducted for three consecutive cycles with valve
shaft both in vertical and horizontal planes.
1.08.00 MISC. ITEMS / EQUIPMENTS
1.08.01 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.
1.08.02 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.
1.08.03 LP CHEMICAL DOSING SYSTEM
(a) Pumps of chemical doing system shall be preformance 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
NTPC, then TCs for same shall be reviewed.
(c) Dosing skid shall be subejected to leakage test and functional test.
1.09.00 Electrical and Control & Instrumentation :
Refer Electrical and Control & Instrumentation Sections of QA&I specification.
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SECTION-VI
PART-B
1.10.00 SITE TEST:
Quality requirements for site activities shall be as a minimum, those specified
for corresponding shop activities.
1.10.01 Hydraulic Test of Pressure Parts :
On completion of erection of pressure parts of each steam tubine generator, the unit
with its fittings and mountings in position coming under purview of IBR shall be
subjected to hydaulic 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.
1.10.02 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 Project
Manager.
(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.
(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.
1.10.03 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.
SECTION-VI
PART-B
E - 2
CONDENSER ON LINE TUBE
CLEANING SYSTEM
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SECTION-VI
PART-B
1.00.00 CONDENSER ON LOAD TUBE CLEANING SYSTEM/DEBRIS FILTER FOR MAIN
TURBINE CONDENSER AND DRIVE TURBINE CONDENSER (IF OFFERED)
Refer QA & I portion of General Technical conditions of technical specification.
1.01.01 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.
1.01.02 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 sub-
surface 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.
1.01.03 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.
1.01.04 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 operation. Site test shall also include test to establish
pressure drop across the strainer section, proper functioning of DELTA-P system.
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SECTION-VI
PART-B
1.01.05 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.
1.01.06 Coating / lining
1.01.07 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.
1.01.08 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.
1.01.09 VALVES
Conventional gate/ globe/ check/ ball valves shall be tested as per relevant standard.
1.02.00 ELECTRICAL AND CONTROL & INSTRUMENTATION : Refer Electrical and Control
& Instrumentation Sections of QA&I specification.
SITE TEST : Qual i ty requi rements for si te acti vi ti es shal l be as a mi ni mum,
those specified for corresponding shop activities.
SECTION-VI
PART-B
E - 3
CONDENSATE EXTRACTION PUMP
QUALITY ASSURANCE
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CLAUSE NO.
SECTION-VI
PART-B
1.00.00 CONDENSATE EXTRACTION PUMPS AND DRIP PUMPS (IF OFFERED)
CONDENSATE EXTRACTION PUMP
INPROCESS TEST FINAL TESTS
TESTS
ITEMS
DESCRIPTION
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i
n
g
P
r
e
s
s
u
r
e

D
r
o
p

T
e
s
t
P
e
r
f
o
r
m
a
n
c
e

T
e
s
t
N
P
S
H

T
e
s
t
V
i
b
r
a
t
i
o
n
N
o
i
s
e
S
t
r
i
p

D
o
w
n

T
e
s
t
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17.
Pump Casing Y Y
- - - - Y - - Y -
Suction Bell Y Y
- - - - Y - - -
Shaft Y Y
Y Y Y - Y Y - Y
Impeller Y Y
Y - - - Y - Y -
Rotor - - - Y - - - - Y -
Fabricated Items Y Y
- - - Y
Y - - Y
CEP Y
Strainer
(a) Body Y Y - - - - Y* - - Y -
(b) Assembly Y**
Elect Items Tests as per relevant
portion of specification
Chemical/ Mechanical shall be one per heat/HT batch.
10% Random on Butt Welds
Pressure Containing Parts.
Performance Test on each Condensate Extraction Pump to determine the characteristic curve
(Head, Capacity, Efficiency & Power) at Design Speed and to ensure Compliance with design
requirements specified in the specification. Measurements shall be carried out at 0%,25%,
50%,65%, 80%, 100% and 125% of design flow with cold water.
NPSH (R) test shall be carried out on one Condensate Extraction Pump using cold water at
pump flows of 25%, 50%, 80%, 100% and 125% of Design Flow at Design Speed. This shall
be preferrably done at 1 % and 3% head break by Suction Throttling Procedure.
Vibration on all Condensate Extraction Pumps shall be measured in transverse, Horizontal
and Vertical Direction at all measuring points.
QUALITY ASSURANCE
E-3
CEP
PAGE
2 OF 2
CLAUSE NO.
SECTION-VI
PART-B
Noise Level on each Condensate Extraction pump shall be measured at a distance of 1.5
meter above floor level in elevation and 1 mtr horizontally from the nearest surface of the
equipment as per HIS. The measurement shall be taken at six points around the equipment for
each flow condition.
One Condensate Extraction Pump shall be dismantled for visual inspection after completion
of performance test and NPSH Test. For other Pumps strip down test shall be conducted only
in case abnormal performance such as Excessive Vibration, High noise, high bearing
temperature etc. is observed during performance test.
Note:
1) Quantum of In-Process Checks/ Tests is 100% until & unless specified otherwise.
2) Shop tests shall be conducted with soften Quality Water.
3) Bidder shall furnish details of proposed test procedures including test lay out, type and
level of accuracy of instruments, sample calculation etc.
4) Tests shall be done in accordance with latest edition of Hydraulic Instiute standard.
5) Tested Pump parameters shall be within following tolerances.
At design head : +10% of design capacity
At design capacity: +5% of design head (Under 152.4 meter)
+3 % of design head (for 152.4 meter and above)
* In case of fabricated construction
** One per type and size.
Results must show no minus tolerance with regard to flow and head.
No minus tolerance on efficiency or positive tolerance on power input at motor terminals shall
be allowed.
SECTION-VI
PART-B
E - 4
POWER CYCLE HEATERS
AND DEAERATOR
QUALITY ASSURANCE
E-4
POWER CYCLE
HEATERS &
DE-AERATOR
PAGE
1 OF 3
CLAUSE NO.
SECTION-VI
PART-B
P
O
W
E
R

C
Y
C
L
E

H
E
A
T
E
R
S

&

D
E
-
A
E
R
A
T
O
R
1
.
0
0
.
0
0
D
E
A
E
R
A
T
O
R
S
:
T
E
S
T
S
/
C
H
E
C
K
S
C
O
M
P
O
N
E
N
T
S
/
A
C
T
I
V
I
T
Y
C h e m i c a l A n a l y s i s
M e c h . P r o p e r t i e s
I m p a c t
H a r d n e s s
F l a t t e n i n g
F l a r i n g
U T
R T
M P I
D P T
E d d y C u r r e n t
H e l i u m L e a k T e s t
S R
H T
H y d r a u l i c
P n e u m a t i c
D i m e n s i o n s
W P S / P Q R / W Q R / A p p .
P e r f o r m a n c e t e s t
M o c k u p T e s t
1
S
h
e
l
l

&

D
i
s
h
e
d

E
n
d
Y
Y
Y
Y
(
a
)
Y
(
g
)
Y
(
a
)
Y
(
e
)
2
F
a
b
r
i
c
a
t
i
o
n
/

W
e
l
d
i
n
g
Y
Y
a
)
E
d
g
e

P
r
e
p
a
r
a
t
i
o
n
/

F
i
l
l
e
t

W
e
l
d
Y
(
b
)
Y
(
b
)
b
)
B
u
t
t

J
o
i
n
t
s
/

B
r
a
n
c
h

W
e
l
d
i
n
g
Y
(
c
)
Y
(
c
)
Y
Y
Y
Y
(
d
)
Y
3
C
o
m
p
l
e
t
e

D
e
a
e
r
a
t
o
r
Y
Y
4
S
a
f
e
t
y

&

S
a
f
e
t
y

R
e
l
i
e
f

V
a
l
v
e

&

o
t
h
e
r

v
a
l
v
e
s
Y
Y
Y
(
f
)
Y
(
f
)
Y
(
f
)
Y
(
f
)
Y
Y
(
h
)
QUALITY ASSURANCE
E-4
POWER CYCLE
HEATERS &
DE-AERATOR
PAGE
2 OF 3
CLAUSE NO.
SECTION-VI
PART-B
2
.
0
0
.
0
0
H
E
A
T
E
R
S
T
E
S
T
S
/
C
H
E
C
K
S
C
O
M
P
O
N
E
N
T
S
/
A
C
T
I
V
I
T
Y
I m p a c t
H a r d n e s s
F l a t t e n i n g
F l a r i n g
U T
R T
M P I
D P T
S R
H T
H y d r a u l i c
P n e u m a t i c
D i m e n s i o n s
W P S / P Q R / W Q R / A p p .
M o c k u p T e s t
1
T
u
b
e

S
h
e
e
t
Y
a
F
o
r
g
i
n
g
Y
Y
Y
Y
Y
Y
(
I
)
b
P
l
a
t
e
s
Y
Y
Y
Y
Y
Y
(
i)
c
C
l
a
d
i
n
g
Y
Y
Y
Y
Y
(
j)
2
S
h
e
l
l

P
l
a
t
e
s
Y
Y
Y
Y
3
F
e
e
d

N
o
z
z
l
e

M
a
n
h
o
l
e

f
o
r
g
i
n
g
Y
Y
Y
(
k
)
Y
(
l)
Y
(
k
)
Y
(
i)
Y
4
W
e
l
d
i
n
g

/

F
a
b
r
i
c
a
t
i
o
n
a
W
e
l
d

E
d
g
e

P
r
e
p
a
r
a
t
i
o
n
Y
(
b
)
Y
(
b
)
b
B
a
c
k

C
h
i
p
p
i
n
g
Y
(
b
)
Y
(
b
)
c
W
e
l
d

J
o
i
n
t
s

(
i
)
B
u
t
t
Y
(
c
)
Y
(
c
)
Y
Y
Y
Y
Y
(
i
i
)
F
i
l
l
e
t
Y
Y
Y
Y
Y
(
i
i
i
)
N
o
z
z
l
e

/

B
r
a
n
c
h
Y
(
c
)
Y
(
c
)
Y
Y
Y
Y
Y
(
i
v
)
T
u
b
e

t
o

t
u
b
e

s
h
e
e
t
Y
Y
Y
QUALITY ASSURANCE
E-4
POWER CYCLE
HEATERS &
DE-AERATOR
PAGE
3 OF 3
CLAUSE NO.
SECTION-VI
PART-B
T
E
S
T
S
/
C
H
E
C
K
S
C
O
M
P
O
N
E
N
T
S
/
A
C
T
I
V
I
T
Y
I m p a c t
H a r d n e s s
F l a t t e n i n g
F l a r i n g
U T
R T
M P I
D P T
S R
H T
H y d r a u l i c
P n e u m a t i c
D i m e n s i o n s
W P S / P Q R / W Q R / A p p .
M o c k u p T e s t
5
D
i
s
h
e
d

E
n
d

&

H
e
m
i

H
e
a
d
Y
Y
Y
Y
(
a
)
Y
(
b
)
Y
(
b
)
Y
Y
(
e
)
6
T
u
b
e
s
Y
Y
Y
(
q
)
Y
(
q
)
)
Y

Y
(
n
)
Y
Y
7
T
u
b
e

e
x
p
a
n
s
i
o
n

i
n

t
u
b
e

s
h
e
e
t
Y
(
o
)
8
C
o
m
p
l
e
t
e

H
e
a
t
e
r
Y
(
p
)
Y
3
.
0
0
.
0
0
R
E
M
A
R
K
S

F
O
R

D
E
A
E
R
A
T
O
R
S

A
N
D

H
E
A
T
E
R
S
(
a
)
A
f
t
e
r

f
o
r
m
i
n
g

o
f

p
l
a
t
e
s
.

F
o
r

d
i
s
h
e
d

e
n
d

a
n
d

H
e
m
i

h
e
a
d
.
(
b
)
D
P
T

m
a
y

b
e

u
s
e
d

a
s

a
n

a
l
t
e
r
n
a
t
e

t
o

M
P
I
.
(
c
)
U
T
/
R
T

t
o

b
e

d
e
c
i
d
e
d

a
c
c
o
r
d
i
n
g

t
o

c
o
n
f
i
g
u
r
a
t
i
o
n
/
a
c
c
e
s
s
i
b
i
l
i
t
y
.
(
d
)
(
i
)
F
o
r

p
l
a
t
e
s
(
i
i
)
F
o
r

w
e
l
d
i
n
g
(
i
i
i
)
F
o
r

w
a
l
l

t
h
i
c
k
n
e
s
s
(
e
)
I
n
c
l
u
d
i
n
g

w
a
l
l

t
h
i
c
k
n
e
s
s
(
f
)
(
i
)
1
0
0
%

R
T
/
U
T

s
h
a
l
l

b
e

c
a
r
r
i
e
d

o
u
t

o
n

b
o
d
i
e
s
,

b
o
n
n
e
t
s
,
n
o
z
z
l
e

a
n
d

s
t
e
m

o
f

v
a
l
v
e
s

o
f

H
P

h
e
a
t
e
r
.
(
i
i
)
1
0
0
%

D
P
T
/
M
P
I

o
n

m
a
c
h
i
n
e
d

s
u
r
f
a
c
e
s

o
f

v
a
l
v
e

b
o
d
y
,
b
o
n
n
e
t
,

s
t
e
m
,

d
i
s
c

&

s
p
r
i
n
g
s
.
(
g
)
O
u
t
e
r

s
u
r
f
a
c
e

(
D
i
s
h
e
d

e
n
d

K
n
u
c
k
l
e

P
o
r
t
i
o
n
)
(
h
)
I
n
c
l
u
d
i
n
g
-
S
e
a
t

l
e
a
k
a
g
e

-
R
e
l
i
e
v
i
n
g
C
a
p
a
c
i
t
y
-
p
o
p
p
i
n
g

t
e
s
t

a
t

s
e
t

a
n
d

b
l
o
w

d
o
w
n

p
r
e
s
s
u
r
e
(
i
)
I
n
c
l
u
d
e

o
v
a
l
i
t
y

o
f

h
o
l
e
s
,

s
u
r
f
a
c
e

f
i
n
i
s
h

a
n
d

s
i
z
e

o
f

h
o
l
e
s
.
(
j
)
F
o
r

c
l
a
d
d
i
n
g

b
o
n
d

a
n
d

c
l
a
d
i
n
g

t
h
i
c
k
n
e
s
s

d
u
r
i
n
g

b
o
n
d

c
h
e
c
k

a
n
d

a
f
t
e
r
d
r
i
l
l
i
n
g
(
k
)
F
o
r

f
e
e
d

n
o
z
z
l
e

(
p
i
p
e
s
)
(
l
)
F
o
r

f
o
r
g
i
n
g
s
(
m
)
A
f
t
e
r

b
e
n
d
i
n
g

a
l
s
o
(
n
)
D
i
m
e
n
s
i
o
n

t
o

i
n
c
l
u
d
e

w
a
l
l

t
h
i
n
n
i
n
g
(
o
)
B
o
t
h

t
u
b
e

a
n
d

s
h
e
l
l

s
i
d
e
.

A
f
t
e
r

H
y
d
r
o

t
e
s
t

d
r
y
i
n
g

a
n
d

n
i
t
r
o
g
e
n

f
i
l
l
i
n
g

t
o

b
e
d
o
n
e
.
(
p
)
A
s

p
e
r

t
h
e

c
o
d
e
.
(
q
)
F
o
r

H
P

H
e
a
t
e
r

&

G
l
a
n
d

s
t
e
a
m

c
o
o
l
e
r
s

t
h
e

s
t
a
t
u
r
o
y

r
e
q
u
i
r
m
e
n
t
s

a
s

p
e
r
I
B
R

t
o

b
e

e
n
s
u
r
e
d

a
n
d

t
o

b
e

c
e
r
t
i
f
i
c
a
t
i
o
n

o
r
i
g
i
n
a
l

t
o

b
e

f
u
r
n
i
s
h
e
d

a
s

p
e
r
I
B
R

s
t
a
t
u
t
o
r
y

r
e
q
u
i
r
e
m
e
n
t
s
.
N
o
t
e

:
(
1
)
Q
u
a
n
t
u
m

o
f

C
h
e
c
k
s

S
h
a
l
l

b
e

1
0
0
%

U
n
l
e
s
s

O
t
h
e
r
w
i
s
e
S
p
e
c
i
f
i
e
d
.
(
2
)
C
h
e
m
.
/
M
e
c
h
.

s
h
a
l
l

b
e

O
n
e
/

p
e
r

h
e
a
t

o
r

H
T

b
a
t
c
h
.
SECTION-VI
PART-B
E - 5
BOILER FEED PUMP
QUALITY ASSURANCE
E-5
BOILER FEED
PUMPS
PAGE
1 OF 3
CLAUSE NO.
SECTION-VI
PART-B
BOILER FEED PUMP
1.00.00 BOILER FEED PUMPS & DRIVE TURBINE
BFP + BOOSTER PUMP+TURBINE
INPROCESS TESTS
TESTS
ITEM/
DESCRIPTION
C
h
e
m
i
c
a
l

A
n
a
l
y
s
i
s
M
e
c
h
a
n
i
c
a
l

P
r
o
p
.
H
e
a
t

T
r
e
a
t
m
e
n
t
R
u
n

o
u
t
U
.
T
.
R
.
T
.
D
.
P
.
T
.
M
.
P
.
I
.
B
a
l
a
n
c
i
n
g
F
.
A
.
T
.
T
.
H
y
d
.

T
e
s
t
I
n
c
l
u
s
i
o
n

R
a
t
i
n
g
P
r
.

D
r
o
p
D
i
m
e
n
s
i
o
n
s
C he mi c a l /
Mechani cal
shall be one
per heat/HT
batch
# On BFP
Impeller as
per ASTME
446 Level 2
*** In case of
F abr i cated
Construction
^ One per type
and size.
+ Type of NDE
& quantum
of check
shall be as
per relevant
code & pres-
sure class
++ Include body
& seat leak-
age test and
functional test
Note :
Quantum of
Checks/ Tests is
100% untill &
unless specified
otherwise.
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.
(A) BFP+BOOSTER
PUMP
(i) Barrel Casing Y Y
Y - Y - - Y - - Y - - -
(ii) Discharge Branch Y Y
Y - Y - - Y - - Y - - -
(iii) Casing Cover Y Y
Y - Y - - Y - - Y - - -
(iv) Suction Branch Y Y
Y - - - Y - - - Y - - -
(v) Diffuser Y Y
Y - - - Y - - - - - - -
(vi) Ring Section Y Y
Y - Y - Y - - - - - - -
(vii) Impller Y Y
Y - - Y#Y - Y - - - - -
(viii) Shaft Y Y
Y - Y - Y Y - - - Y - -
(ix) Rotor - - - Y - - - - Y - - - - -
(B) STRAINER
(I) Body Y Y - - - - Y***- - - Y - - -
(ii) Assembly - - - - - - - - - - - - Y
^
-
(C) GEAR BOX AND
HYDRAULIC
COUPLING
(i) Gear Y Y
Y - Y - Y Y - - - - - -
(ii) Pinions Y Y
Y - Y - Y Y - - - - - -
(iii) Shaft Y Y
Y - Y - Y Y - - - - - -
(iv) Casing Y Y
- - - - - - - - Y
(v) Wheels Y Y
Y - Y - Y Y - - - - - -
(vi) Assembled Rota- - - - - - - - - Y - - - - Y
ting Component
(D) RECIRCULATION Y Y
Y - Y+ - Y+ Y+- - Y++- - Y
VALVE
(F) DRIVE TURBINE Tests as per relevant portion of specification
QUALITY ASSURANCE
E-5
BOILER FEED
PUMPS
PAGE
2 OF 3
CLAUSE NO.
SECTION-VI
PART-B
FINAL TESTS
TESTS
ITEM/
DESCRIPTION
P
e
r
f
o
r
m
a
n
c
e

T
e
s
t
N
P
S
H

T
e
s
t
V
i
b
r
a
t
i
o
n
N
o
i
s
e
P
r
e
s
s
u
r
e

P
u
l
s
a
t
i
o
n
A
x
i
a
l

t
h
r
u
s
t
D
r
y

R
u
n
n
i
n
g
N
o
t

U
s
e
d
V
i
s
u
a
l

C
a
v
i
t
a
t
i
o
n
S
t
r
i
p

D
o
w
n

T
e
s
t
M
e
c
h
.

R
u
n

t
e
s
t
O
t
h
e
r

T
e
s
t
s REMARKS
1 2 3 4 5 6 7 8 9 10 11 12
BFP
^ (a) (b) (c) (c) I I
Y Y Y Y Y Y Y - Y Y Y Y
Booster Pump
^ (a) (b) I
Y Y Y Y - - Y - - Y - Y
Gear Box Y
- Y Y - - - - - - Y
-
HYD Coupling - - - - - - - - - - Y
Drive Turbine Tests as per relevant portion of specification

Elect Items Tests as per relevant potion of specification
(a) Performance Tests on each Boiler Feed Pump to determine the characteristic curve
(Head, Capacity, Efficiency & Power) at Design Speed and to ensure compliance with
design requirements specified in the specification. Measurement shall be carried out
at 10%, 25%, 50%, 65%, 80%, 100% & 125% of Design Flow with loop water at
design temperature. Performance Test at other specified Conditions shall be carried
out on all Boiler Feed Pumps at their respective Speeds at design temperature.
(b) Performance Test on each Booster Pump to determine the characteristic curve (Head,
Capacity, Efficiency & Power) at Design Speed and to ensure Compliance with design
requirements specified in the specification. Measurements shall be carried out at
0%,25%, 50%,65%,80%, 100% and 125% of design flow with cold water.
^ NPSH (R) test shall be carried out on one Boiler Feed Pump and one booster pump
using cold water at pump flows of 25%, 50%, 80%, 100% and 125% of Design Flow
at Design Speed. This shall be preferably done at 1 % and 3% head break by
Suction Throttling Procedure.
(a) Vibration on all Boiler Feed Pumps and Booster Pumps shall be measured in
transverse, Horizontal and Vertical Direction at all measuring points.
(b) Noise Level on each Boiler Feed Pump and Booster Pump shall be measured at a
distance of 1.5 meter above floor level in elevation and 1 mtr horizontally from the
nearest surface of the equipment as per HIS. The measurement shall be taken at six
points around the equipment for each flow condition.
QUALITY ASSURANCE
E-5
BOILER FEED
PUMPS
PAGE
3 OF 3
CLAUSE NO.
SECTION-VI
PART-B
(c) Pressure Pulsation and Axial Thrust Measurement shall be carried out on one Boiler
Feed Pump at all measuring points. Pressure Pulsation shall be measured at
suction as well as at discharge in the operating range.
Dry running withstand capability shall be demonstrated and established on one Boiler
Feed Pump and its corresponding booster pump. Feed pump shall be capable of
accepting complete loss of water and must be capable of being shut down in a
controlled manner and brought down to rest after being tripped from design condition
with simultaneous closure of suction valve. To demonstrate the capability during shop
testing, suction valve actuation should be fast in order to ensure operation during
vapour phase. Pump shall then be restarted and bring it back to design condition.
I Visual Cavitation Test on one first stage production impeller of Boiler Feed Pump shall
be carried out to demonstrate absence of Cavitation at test speed in Cold Water. The
test will establish the cavitation characteristic of one production first stage impeller to
confirm that the cavity length under dynamically scaled site conditions corresponding to
test point will not exceed an agreed size. This test shall be carried out at 25%,
50%,65%,80%,100% and 125% of Design Flow
String Test:- Operational Test of One Motor Driven Boiler Feed Pump assembly using
contract Booster Pump, Drive Motor, Hydraulic Coupling and Main Boiler Feed Pump to
include test as specified at 1 & 3 (a) & (b). Dry Run Test shall preferably be carried
out during String Test.
I Complete Strip Down of Boiler Feed Pump which under goes Performance Test, NPSH
Test, Dry Run Test, etc. shall be done in order to check problems like Internal Rubbing
Damage, Excessive Wear etc. One Booster Pump shall be dismantled for visual
inspection after completion of performance test and NPSH Test. For other Pumps strip
down test shall be conducted only in case abnormal performance such as Excessive
Vibration, High noise, high bearing temperature etc. is observed during performance
test.
Full load full speed/back to back locked rotor torque test for one gearbox.
Smooth operation, vibration, noise and temperature rise check on all equipment.
Note:
1) Shop tests shall be conducted with soften Quality Water.
2) Bidder shall furnish details of proposed test procedures including test lay out, type and
level of accuracy of instruments, sample calculation etc.
3) Tests shall be done in accordance with latest edition of Hydraulic Institute Standard, USA.
4) Tested Pump parameters shall be within following tolerances.
At design head: + 10% of design capacity
At design capacity : + 5% of design head (Under 152.4 meter)
+ 3% of design head (for 152.4 meter and above)
Results must show no minus tolerance with regard to flow and head.
No minus tolerance on efficiency or positive tolerance on power input at motor terminals shall
be allowed.
SECTION-VI
PART-B
E - 6
TURBINE HALL EOT CRANES
QUALITY ASSURANCE
E-6
TURBINE HALL EOT
CRANE
PAGE
1 OF 1
CLAUSE NO.
SECTION-VI
PART-B
1.00.00 TURBINE HALL EOT CRANES
1.01.00 HOOKS :
1.01.01 All Tests including proof load test as per relevant IS shall be carried out.
1.01.02 MPI / DPT shall be done after proof load test.
1.02.00 STEEL CASTINGS :
1.02.01 DPT on machined surface shall be carried out.
1.03.00 GIRDERS, END CARRIAGE, CRAB, GEAR-BOX AND ROPE DRUM
1.03.01 The plates of thickness 25mm and above shall be ultrasonically tested.
1.03.02 NDT requirements on weldments shall be as follows
(a) Butt welds in tension:- 100% RT & 100% DPT
(b) Butt welds in compression:- 10% RT & 100% DPT
(c) Butt weld in rope drum:- 100% RT & 100% DPT
(d) Fillet welds:- random 10% DPT
1.04.00 Forgings (Wheel, Gears, Pinions, Axles, Hooks & Hook Trunion)
1.04.01 All forgings greater than or equal to 50mm dia. or thickness shall be subjected to
Ultrasonic Testing
1.04.02 DPT/MPI shall be done after hardfacing and machining
1.05.00 Wire Rope shall be tested as per relevant standard
1.06.00 Reduction Gears shall be tested for reduction ratio, backlash & contact pattern. Gear
Box shall be subjected to No load run test to check for oil leakage, temp. rise, noise
and vibration
1.07.00 The cranes shall be completely assembled at shop for final testing. All tests for
dimension, deflection, load, overload, hoisting motion, cross travel etc. as per IS-3177
shall be carried out at shop
1.08.00 All Electric Hoist shall be tested as per IS-3938 and Chain Pulley Blocks shall be
tested as per IS-3832.
SECTION-VI
PART-B
E - 7
CLAUSE NO.
QUALITY ASSURANCE

STAGE II (2X660 MW)
SECTION-VI
PART-B
E-7
EQUIPMENT COOLING
WATER SYSTEM
PAGE
1 OF 1

TEST / CHECKS

ITEM / COMPONENTS
M
a
t
e
r
i
a
l

T
e
s
t

W
P
S
/
P
Q
R
/
W
e
l
d
e
r

Q
u
a
l
i
f
i
c
a
t
i
o
n

D
P
T
/
M
P
I

A
s
s
e
m
b
l
y

F
i
t

U
p

V
i
s
u
a
l

&

D
i
m
e
n
s
i
o
n
a
l

C
h
e
c
k

U
T

R
T

H
y
d
r
a
u
l
i
c

/

W
a
t
e
r

F
i
l
l

B
a
l
a
n
c
i
n
g

T
y
p
e

T
e
s
t

P
e
r
f
o
r
m
a
n
c
e

T
e
s
t

O
t
h
e
r

T
e
s
t

A PLATE TYPE HEAT
EXCHANGER
Y Y
3
Y Y Y
A.1 Heat Transfer Plates Y
1
Y
2
Y Y
5a
Y
7

A.2 Gaskets Y Y
A.3 Cover Plates
(Front & Rear)
Y
1
Y Y
5a

A.4 Tie Rods Y
1
Y
4
Y
5b

B
HORIZONTAL / VERTICAL
CENTRIFUGAL PUMP
Y Y Y
10

B.1 Casing Y
1
Y
4
Y Y
B.2 Impeller Y
1
Y
4
Y Y
9

B.3 Shaft Y
1
Y Y Y
5b
Y
9

B.4 Fabricated Components Y
1
Y Y
3
Y Y Y
5a
Y
6
Y
8

NOTES
1 One per heat / HT batch
2 Pressing operation of HT plates shall be carried out in single operation. DP Test shall be conducted for 10% of
the lot of HT plates. However, in case of any defect, entire lot shall be tested and only defect free plates shall be
accepted.
3 100% DP Test shall be conducted on butt welds and 10% DPT on fillet weld after final run.
4 100% DPT shall be carried out on machined surfaces.
5a UT shall be done on plates with thickness 25 mm or above.
5b UT shall be done on shaft / tie rod with diameter 50 mm or above.
6 RT shall be conducted on butt joints having plate thickness above 10 mm. Quantum of RT shall be based on
pressure rating.
7 Each Plate after pressing shall be subject to either of the following tests, as per Manufacturer Practice
a) Light Box Test b) Vacuum Test c) Air Chamber Test
8 All pressure retaining parts shall be hydrostatically tested at 200% of pump rated head or 150% of shut off
head, whichever is higher, for at least 30 minutes. No leakage is allowed.
9 Static and Dynamic Balancing shall be carried out on complete rotor assembly.
10 All pumps shall be tested at rated speed, for head, flow capacity, efficiency and power consumption for the entire
operating range i.e. from shut off head to maximum flow. A minimum of 7 readings shall be taken to plot the
curve, with one reading at design flow. Testing standard shall be HIS (Hydraulic Institute Standard) of USA.
Performance test shall be carried out with contract motor, wherever Liquidated Damages are to be ascertained
based on performance test at shop.
11 For Piping & Valves, refer LP Piping System.

SECTION-VI
PART-B
E - 8
CLAUSE NO.
QUALITY ASSURANCE

STAGE II (2X660 MW)
SECTION-VI
PART-B

E-8
CPU
PAGE
1 OF 2

CONENSATE POLISHING PLANT

Tests/Check

Items /
Components

M
a
t
e
r
i
a
l

T
e
s
t

W
P
S
/
P
Q
R
/
W
e
l
d
e
r

Q
u
a
l
i
f
i
c
a
t
i
o
n

D
P
T
/
M
P
I

A
s
s
e
m
b
l
y

F
i
t

u
p

D
i
m
e
n
s
i
o
n

R
T

H
y
d
r
a
u
l
i
c

/

W
a
t
e
r

F
i
l
l

P
n
e
u
m
a
t
i
c

T
e
s
t

F
u
n
c
t
i
o
n
a
l
/
o
p
e
r
a
t
i
o
n
a
l

T
e
s
t

B
l
e
e
d
i
n
g

r
e
s
i
s
t
a
n
c
e

t
e
s
t
s

A
d
h
e
s
i
o
n
/

S
p
a
r
k

T
e
s
t

P
e
r
f
o
r
m
a
n
c
e

T
e
s
t

O
t
h
e
r

T
e
s
t

A
l
l

T
e
s
t

a
s

p
e
r

r
e
l
e
v
a
n
t

S
t
d
/

A
p
p
d

D
a
t
a

S
h
e
e
t
s

D
y
n
a
m
i
c

B
a
l
a
n
c
i
n
g

R
e
m
a
r
k
s

CPU Service
Vessel
Y
a
Y Y Y Y Y Y
3

Y
1

Acid
Alkali/Chemical
Storage Tanks/
Vessels (LP)
Y
a
Y Y Y Y Y
4

Y
Resins/Activated
Carbon & Internals
of CPU
Y
a
Y Y
Rubber Lining of
Vessels/ Tanks/
Pipes etc
Y
a
Y Y
2
Y Y
Dosing
Pumps/Metering
Pumps
Y
a
Y Y
5
Y
Diaphragm Valves Y
a
Y Y
6

Y
6
Y
7

Butterfly Valves
(Low Pressure)
Y Y
6

Y Y
8

1. Body (Cast) Y
a
Y
b

2. Disc (Cast) Y
a
Y
b

3. Shaft Y
a
Y Y
c

High Pressure Ball
Valves & Butterfly
Valves
Y
a
Y Y
Horizontal
Centrifugal Pumps
Y Y Y
5
Y
1. Casing Y
a
Y
b
Y
2. Impeller Y
a
Y
b
Y
3. Shaft Y
a
Y Y
c
Y
Rotary Blowers Y Y Y Y
1. Casing Y
a
Y
b
Y
2. Rotor Y
a
Y Y Y
CLAUSE NO.
QUALITY ASSURANCE

STAGE II (2X660 MW)
SECTION-VI
PART-B

E-8
CPU
PAGE
2 OF 2

Notes:
1. Heat Treatment shall be done as per ASME code.
2. Bleeding Resistance tests shall be done by keeping the sample in 33% HCl, 48% NaOH
and DM Water for 72 Hrs.
3. Hydro Test shall be conducted, before Rubber lining.
4. As per code requirements.
5. As per HIS, USA.
6. Hydro test of body before Rubber lining. Seat Leakage test for Actuator operated valves
shall be done by closing the Valves with J ob Actuator.
7. Tests on Rubber parts such as Diaphragms shall be done per batch of Rubber mix, such
as Tensile, Hardness, Adhesion, Spark Test, Bleed Resistance test and Flex test. Life
Cycle test for Diaphragms for 50000 cycles etc shall also be done.
8. Hydro Test of Body, Seat & Disc Strength shall be carried out in accordance with latest
edition of AWWA C-504 Standard. Proof of Design Test in accordance with latest edition
of AWWA C-504 Standard shall also be carried out, if not carried out earlier. Seat
Leakage test for Actuator operated valves shall be done by closing the Valves with J ob
Actuator. Seat leakage test shall be carried out in both directions.
a) One per Heat/Heat Treatment batch/Lot
b) On machined surfaces only.
c) UT shall be done for shafts with Dia 50 mm or above.
9. For all other Misc. items, refer Table on LP piping.

SECTION-VI
PART-B
E - 9
CLAUSE NO.
QUALITY ASSURANCE

STAGE II (2X660 MW)
SECTION-VI
PART-B
E-9
LPP

PAGE
1 OF 2

LOW PRESSURE PIPING :

Tests/Check

Items /
Components
M
a
t
e
r
i
a
l

T
e
s
t

D
P
T
/
M
P
I

U
l
t
r
a
s
o
n
i
c

T
e
s
t

W
P
S
/

W
Q
S
/
P
Q
R

B
a
l
a
n
c
i
n
g

H
y
d
r
a
u
l
i
c

/

W
a
t
e
r

F
i
l
l

T
e
s
t

P
n
e
u
m
a
t
i
c

T
e
s
t

A
s
s
e
m
b
l
y

F
i
t

u
p

D
i
m
e
n
s
i
o
n
s

F
u
n
c
t
i
o
n
a
l
/
o
p
e
r
a
t
i
o
n
a
l

T
e
s
t

P
e
r
f
o
r
m
a
n
c
e

T
e
s
t

O
t
h
e
r

T
e
s
t
s

A
l
l

T
e
s
t
s

a
s

p
e
r

r
e
l
e
v
a
n
t

S
t
d

A
d
h
e
s
i
o
n
/
S
p
a
r
k

T
t
R
E
M
A
R
K
S

1. Pipes & Fittings and
Metered Bends

Y
a

Y
b

Y

Y

2. Diaphragm Valves

Y
a

Y
5

Y

Y
6

3. Butterfly Valves(Low
Pressure)

3.a) Casted Butterfly Valves
(i)Body (Cast)

Y
a
Y
b
Y Y Y Y Y
7

(ii)Disc (Cast)

Y
a
Y
b

(iii)Shaft

Y
a
Y Y
c

3.b) Fabricated Butterfly
Valves

RE
F.
NO
TE
14
4. Gate/ Globe/Swing Check
Valves

Y
a

Y
b

Y
c

Y
5

Y

Y

Y
8

5. Dual Plate Check Valves

Y
a

Y
b

Y
c

Y

Y

Y

Y
4

6. Rolled & Welded Pipes

Y
a

Y
3

Y

Y
1

Y

7. Coating & Wrapping of
Pipes
Y
2

Y
2

8. Tanks & Vessels Y
a
Y
b
Y Y
9. Strainers Y
a
Y
b
Y Y
11

10. Rubber Expansion J oints

Y
a

Y
12

Y

Y
13

11. Rubber Lining of Pipes
`
Y
a

Y
b

Y

Y

Y

Y
9

Y

12. Hangers & Supports
`
Y
a

Y

13. Fastners

Y
a

Y
b

Y

14. Site Welding

Y
1

Y

Y

CLAUSE NO.
QUALITY ASSURANCE

STAGE II (2X660 MW)
SECTION-VI
PART-B
E-9
LPP

PAGE
2 OF 2

Notes:

1. Weld J oints not subjected to hydraulic test shall be subjected to 100% RT.
2. Spark Test, Adhesion Test and Material Test for 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 Employers
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.
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. 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.
(c)
For shaft/spindles >or =50 mm

SECTION-VI
PART-B
E - 10
NOT USED
SECTION-VI
PART-B
E - 11
QUALITY ASSURANCE
E-11
HYDROGEN
GENERATION
PLANT
PAGE
1 OF 1
CLAUSE NO.
SECTION-VI
PART-B
HYDROGEN GENERATION PLANT-TESTS
TESTS/CHECK
ITEM / COMPONENTS
M
a
t
e
r
i
a
l

T
e
s
t
W
P
S
/
P
Q
R
/
W
e
l
d
e
r

Q
u
a
l
i
f
i
c
a
t
i
o
n
D
P
T
/
M
P
I
U
l
t
r
a
s
o
n
i
c

t
e
s
t
R
T
P
n
e
u
m
a
t
i
c

t
e
s
t
H
y
d
r
a
u
l
i
c
/
W
a
t
e
r

F
i
l
l

t
e
s
t
s
A
s
s
e
m
b
l
y
/
f
i
t

u
p
D
i
m
e
n
s
i
o
n
F
u
n
c
t
i
o
n
a
l
/
o
p
e
r
a
t
i
o
n
a
l

t
e
s
t
s
P
e
r
f
o
r
m
a
n
c
e

t
e
s
t
s
O
t
h
e
r

t
e
s
t
s
R
e
m
a
r
k
s
H2 PLANT
A. COMPRESSOR Y Y Y
1) Casing Y
3
2) Crank shaft/
connecting rod Y
3
Y Y Y
3) Piston/Diaphragm Y
3
Y
B. DRYING PLANT Y
1) Raw material
identification Y
3
Y
1
Y
2
C. HYDROGEN GENERATOR Y Y Y
D. CELL MODULE Y Y Y
E. GAS HOLDER Y
3
Y
1. Fillet welds/nozzles welds and knuckle portion of dished ends and all butt welds.
2. 100% butt welds and 100% for Tee joints and dished ends welds.
3. One per heat /HT batch.
Notes.
1. Quantum of checks shall be 100% unless otherwise specified.
SECTION-VI
PART-B
E - 12
SERVICE ELEVATORS
QUALITY ASSURANCE
E-12
SERVICE
ELEVATORS
CLAUSE NO.
SECTION-VI
PART-B
PAGE
1 OF 1
PASSENGER / SERVICE ELEVATORS & LIFTS
TESTS/CHECK
ITEM
Shaft/Rack/Gears Y Y Y Y
Geared Machine Y
Welding Y Y
Complete Lifts/Elevators Y Y Y1 Y2 Y
Electrical & Instrumentation Y3
Items
Notes:
Y1 - At Site
Y2 - Load and Overload test at site.
Y3 - Refer relevant portion of Technical Specification for testing requirements on
electrical & instrumentation items.
M
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SECTION-VI
PART-B
E - 13
POWER CYCLE PIPING
QUALITY ASSURANCE
E-13
POWER CYCLE
PIPING
PAGE
1 OF 3
CLAUSE NO.
SECTION-VI
PART-B
POWER CYCLE PIPING
1.00.00 H.P. PIPING FOR TURBINE AND AUX.
1.01.00 Piping & Fittings :
mandatory and supplementary checks of material specification.
(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.
(1) 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.
QUALITY ASSURANCE
E-13
POWER CYCLE
PIPING
PAGE
2 OF 3
CLAUSE NO.
SECTION-VI
PART-B
(2) 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.
(3) 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 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.
(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.
1.02.00 Hangers & Supports:
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 and shall meet the requirements of NTPC data sheet.
1.03.00 Thermal Insulation & Lagging, Cladding:
1.03.01 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 and shall meet the requirements of
NTPC data sheet. Wire mesh of diameter 0.71mm(min.) as per data sheet shall only
be used.
QUALITY ASSURANCE
E-13
POWER CYCLE
PIPING
PAGE
3 OF 3
CLAUSE NO.
SECTION-VI
PART-B
1.03.02 Lagging &Cladding:
Aluminium sheeting confirming to ASTM B-203-1060 temper H14 from reputed
manufacturer meeting the requirements of NTPC data sheet.
1.04.00 Valves:
(a) Pressure retaining parts of valves shall be subjected to (min.) NDT as per
Table1.
(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
(1) Smooth operation
(2) Valve travel, closing and opening time.
(3) 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.
TABLE-1
Valve size ANSI Class ANSI Class ANSI Class ANSI Class
NB in mm upto 300 above 300 above 600 900 & above
upto 600 below 900 & below 4500
Less than 50 Visual Visual Visual MPI
50 & above but Visual Visual MPI MPI & RT
below 100 (on 10% of valves
on 100% area)
100 & above but Visual MPI MPI & RT (on 10% MPI & RT (on
less than 300 of valves on change 100% area)
of section & weld ends)
300 and above MPI MPI MPI & RT (on change MPI, RT on
of sections & weld ends) 100% area)
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.
SECTION-VI
PART-B
E - 14
QUALITY ASSURANCE
E-14
OTHER CRANES
AND HOISTS
CLAUSE NO.
SECTION-VI
PART-B
PAGE
1 OF 1
1.00.00 OTHER CRANES & HOIST
1.01.00 HOOKS :
1.01.01 All Tests including proof load test as per relevant IS shall be carried out.
1.01.02 MPI / DPT shall be done after proof load test.
1.02.00 STEEL CASTINGS :
1.02.01 DPT on machined surface shall be carried out.
1.03.00 GIRDERS, END CARRIAGE, CRAB, GEAR-BOX AND ROPE DRUM
1.03.01 The plates of thickness 25mm and above shall be ultrasonically tested.
1.03.02 NDT requirements on weldments shall be as follows
(a) Butt welds in tension:- 100% RT & 100% DPT
(b) Butt welds in compression:- 10% RT & 100% DPT
(c) Butt weld in rope drum:- 100% RT & 100% DPT
(d) Fillet welds:- random 10% DPT
1.04.00 Forgings (Wheel,Gears, Pinions,Axles,Hooks & Hook Trunion)
1.04.01 All forgings greater than or equal to 50mm dia. or thickness shall be subjected to
Ultrasonic Testing
1.04.02 DPT/MPI shall be done after hardfacing and machining
1.05.00 Wire Rope shall be tested as per relevant standard
1.06.00 Reduction Gears shall be tested for reduction ratio, backlash & contact pattern. Gear
Box shall be subjected to No load run test to check for oil leakage, temp. rise, noise
and vibration
1.07.00 The cranes shall be completely assembled at shop for final testing. All tests for
dimension, deflection, load, overload, hoisting motion, cross travel etc. as per IS-3177
shall be carried out at shop.
1.08.00 All Electric Hoist shall be tested as per IS-3938 and Chain Pulley Blocks shall be
tested as per IS-3832.
SECTION-VI
PART-B
E - 15
GENERATOR & AUXILIARIES
CLAUSE NO.
QUALITY ASSURANCE

STAGE II (2X660 MW)
SECTION-VI
PART-B
E-15
GENERATOR &
AUXILIARIES
PAGE
1 OF 10

Generators & Auxiliaries
PROCESS CHECK FOR STATIC PARTS GENERATOR / EXCITOR

TESTS

ITEM/
COMPONENTS
/PROCESS

V
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Sheet and Fabrication
-END shield
Y Y Y Y Y Y1 Y1 Y Y

-Stator casing Y Y Y Y Y Y1 Y1 Y Y

-Bushing boxes Y Y Y Y Y Y1 Y1 Y Y

-Terminal plates Y Y Y Y Y Y1 Y1 Y

-Manhole and covers Y Y Y Y Y Y1 Y1 Y

-Trunniuns Y Y Y Y Y Y Y

Core bar Y Y Y

Press ring Y Y Y Y

Core bolt (insulated) Y Y Y Y Y

Gaskets Y Y

Bearing and Hydrogen
Seals
Y Y Y Y2

Terminal Bushing
Y
RTD/ Thermocouple
Y
Additional checks for
-Non magnetic
Components
Y

-Non magnetic
Components welding
Y

Y-Test applicable, Y1-For Hydrogen cooled machine, Y2-UT on Babbitt for bearing,
Note:
1. This is an indicative list of tests / checks. The manufacturer is to furnish a
detailed Quality Plan indicating the practice and procedure along with relevant
supporting documents.
2. All generators shall be assembled at works and shall be tested to verify/ensure
design and workman ship in accordance with IEC-34, VDE 0530, IEEE 115,
IEEE 43. The manufacturer shall submit detailed test procedure which clearly
specify test set up, instruments to be used, acceptance norms (wherever
applicable) recording of different parameter, interval of recording, precautions
etc.
3. Cooler, control panel and other auxiliaries (as applicable) to be suitably tested as
per tests covered in the specification.
4. Test requirements of primary water system, seal oil system and Hydrogen
cooling system shall be as per tests specified for similar items under respective
tables covered in this section.

CLAUSE NO.
QUALITY ASSURANCE

STAGE II (2X660 MW)
SECTION-VI
PART-B
E-15
GENERATOR &
AUXILIARIES
PAGE
2 OF 10

PROCESS CHECK FOR CORE GENERATOR/EXCITOR

TESTS

ITEM/
COMPONENTS
/PROCESS
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Y Y Y Y Y
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core Laminations
Y Y
Check for varnish Y
Ventilation Stamping
Y
Core assembly
Y

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CLAUSE NO.
QUALITY ASSURANCE

STAGE II (2X660 MW)
SECTION-VI
PART-B
E-15
GENERATOR &
AUXILIARIES
PAGE
3 OF 10

PROCESS CHECK for CONDUCTOR (GENERATOR / EXCITOR)STATOR CONDUCTOR AND WINDING

TESTS

ITEM/
COMPONENTS
/PROCESS

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Insulation material
Y Y Y Y Y

Manufacturing
Winding bar &
phase bar
Y Y Y
Y
Y1 Y Y1 Y
Winding laying
Y Y Y

Y Y
Water Supply
Hoses
Y Y Y Y

Y
Winding support
ring
Y Y Y

Connection
between bars
Y
wound stator Y
1

Y - Test Applicable Y1 - For hollow conductor.

CLAUSE NO.
QUALITY ASSURANCE

STAGE II (2X660 MW)
SECTION-VI
PART-B
E-15
GENERATOR &
AUXILIARIES
PAGE
4 OF 10

PROCESS CHECK FOR CONDUCTOR (GENERATOR / EXCITOR)
STATOR CONDUCTOR AND WINDING

TESTS

ITEM/
COMPONENTS
/ PROCESS

T
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d
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t

a
r
r
a
n
g
e
m
e
n
t

Winding copper and
connecting bus bars

Insulated conductor Y
Insulation material
Manufacturing Winding
bar & phase bar
Y Y Y Y1 Y
Winding laying Y
Water Supply Hoses Y Y Y
Connection between
bars
Y
wound stator Y Y Y

Y - Test Applicable
Y1- Applicable for hollow conductor

CLAUSE NO.
QUALITY ASSURANCE

STAGE II (2X660 MW)
SECTION-VI
PART-B
E-15
GENERATOR &
AUXILIARIES
PAGE
5 OF 10

PROCESS CHECK FOR ROTOR AND ASSEMBLY
GENERATOR/EXCITOR

TESTS

ITEM/
COMPONENTS
/PROCESS

R
e
p
.

s
a
m
p
l
e

t
e
n
s
i
l
e

s
t
r
e
s
s

R
e
p
.

s
a
m
p
l
e

0
.
2

l
i
m
i
t

R
e
p
.

s
a
m
p
l
e

e
l
o
n
g
a
t
i
o
n

H
a
r
d
n
e
s
s

o
n

S
a
m
p
l
e

I
m
p
a
c
t

&

s
t
r
e
s
s

r
u
p
t
u
r
e

p
r
o
p
.

c
h
e
c
k

o
n

s
a
m
p
l
e

R
e
p
.

s
a
m
p
l
e

C
h
e
m
.

p
r
o
p
.

N
D
T
T
,

F
A
T
T

(
a
s

a
p
p
l
i
c
a
b
l
e
)

P
r
o
c
e
s
s

c
h
e
c
k

i
n
c
l
u
d
i
n
g

h
e
a
t

t
r
e
a
t
m
e
n
t

(
a
s

a
p
p
l
i
c
a
b
l
e
)

U
l
t
r
a
s
o
n
i
c

t
e
s
t
/
R
T

(
a
t

s
u
p
p
l
i
e
r
s

w
o
r
k
s

a
n
d

a
f
t
e
r

p
r
e
l
i
m
i
n
a
r
y

m
a
c
h
i
n
i
n
g
)

S
u
l
p
h
u
r

P
r
i
n
t
s

C
h
e
c
k

F
l
u
x

c
a
r
r
y
i
n
g

c
a
p
a
c
i
t
y

/

M
a
g
n
e
t
i
c

p
r
o
p
.

B
o
r
o
s
c
o
p
i
c

E
x
a
m
i
n
a
t
i
o
n

Rotor forging & slip ring
shaft depending on
provenness
Y Y Y Y Y Y Y Y Y Y Y Y
Rotor end retaining ring
, locking ring &
Slip ring forgings,
diode wheel

Y Y Y Y Y Y Y
Rotor winding copper
rotor wedges,
damper Wedges,
CC-bolts & D-leads

Y Y Y Y Y
Rotor slot boxes/
insulating material
Y
Coil manufacture
Rotor winding Y
Winding connection studs
& assembly

Complete rotor Y
Test on completed rotor at
various speed up to rated
speed

Test on completed rotor
before & after overspeed

Fan hubs/blades Y Y Y
GENERATOR assembly
Diode wheel Assembly
Permanent magnet Y Y
EXCITER assembly

Y- Test Applicable

CLAUSE NO.
QUALITY ASSURANCE

STAGE II (2X660 MW)
SECTION-VI
PART-B
E-15
GENERATOR &
AUXILIARIES
PAGE
6 OF 10

GENERATOR/EXCITOR

TESTS

ITEM/
COMPONENTS
/PROCESS

M
P
I
/
D
P
/
N
D
T

t
e
s
t

V
i
s
u
a
l
/
D
i
m
e
n
s
i
o
n
/
C
l
e
a
n
l
i
n
e
s

A
d
h
e
s
i
o
n
,

t
h
i
c
k
n
e
s
s

o
f

C
o
a
t

o
n

s
i
l
v
e
r

p
l
a
t
i
n
g
,

i
f

a
p
p
l
i
c
a
b
l
e

E
l
e
c
t
r
i
c
a
l

c
o
n
d
u
c
t
i
v
i
t
y

a
n
d

O
x
y
g
e
n

c
o
n
t
e
n
t

M
e
c
h
.

t
e
s
t

o
n

s
a
m
p
l
e

E
l
e
c
t
r
i
c
a
l

t
e
s
t

R
e
s
i
s
t
a
n
c
e

m
e
a
s
u
r
e
m
e
n
t

P
u
r
g
e

t
e
s
t

o
n

v
e
n
t
s

H
e
l
i
u
m

l
e
a
k

t
e
s
t

f
o
r

H
y
d
r
o
g
e
n

c
o
o
l
e
d

M
/
C

I
n
t
e
r

t
u
r
n

t
e
s
t

D
i
e
l
e
c
t
r
i
c

t
e
s
t

shaft
Y Y

Rotor end retaining ring &
cover, locking ring &
Slip ring forgings,
diode wheel
Y Y

Rotor winding copper,
rotor wedges,
damper Wedges,
CC-bolts & D-leads
Y Y Y
Y
Rotor slot boxes/
insulating material

Y Y
Coil manufacture
Y

Rotor winding
Y Y
Y Y Y Y
& assembly
Y
Y Y Y
Complete rotor

Y Y
speed

Y Y Y1
Y
Y Y
Fan hubs/blades
Y Y

GENERATOR assembly
Y

Diode wheel Assembly
Y

Permanent magnet
Y
Y
EXCITOR assembly
Y

Y-Test Applicable

CLAUSE NO.
QUALITY ASSURANCE

STAGE II (2X660 MW)
SECTION-VI
PART-B
E-15
GENERATOR &
AUXILIARIES
PAGE
7 OF 10

GENERATOR/EXCITOR

TESTS

ITEM/
COMPONENTS
/PROCESS

I
n
s
u
l
a
t
i
o
n

R
e
s
i
s
t
a
n
c
e

P
I

R
a
d
i
a
l

r
u
n

o
u
t
/
a
l
i
g
n
m
e
n
t

I
m
p
e
d
a
n
c
e

m
e
a
s
u
r
e
m
e
n
t
/

R
S
O

(
r
e
p
e
t
i
t
i
v
e

s
u
r
g
e

o
s
c
i
l
l
o
g
r
a
p
h
)

D
y
n
a
m
i
c

b
a
l
a
n
c
i
n
g

I
S
O

5
3
9
3
,

5
4
0
6
,

2
3
7
2
,

1
9
4
0

i
n
c
l
u
d
i
n
g

A
i
r

r
u
n

t
e
s
t

O
v
e
r

s
p
e
e
d

t
e
s
t

(
1
2
0
%
)

f
o
r

2

m
i
n
u
t
e

A
x
i
a
l

r
u
n

o
u
t

M
e
t
a
l
l
o
g
r
a
p
h
y

e
x
a
m
i
n
a
t
i
o
n

T
o
r
q
u
e

o
n

j
o
i
n
t

b
o
l
t
s

F
i
t
t
i
n
g

a
n
d

l
o
c
k
i
n
g

o
f

B
a
l
a
n
c
i
n
g

w
e
i
g
h
t
s

B
r
a
z
e
r

a
n
d

b
r
a
z
i
n
g

p
r
o
c
e
d
u
r
e

shaft

Y
Rotor end retaining ring &
cover, locking ring &
Slip ring forgings,
diode wheel

CC-bolts

Y
Rotor slot boxes/
insulating material

Coil manufacture

Y
Rotor winding

Y
& assembly
Y

Complete rotor
Y Y Y
Y Y
Y
speed

Y

Y Y Y

Fan hubs/blades

Y
GENERATOR assembly Y Y Y

Y Y Y Y
Diode wheel Assembly Y

Y Y Y
Permanent magnet

EXCITOR assembly Y

Y Y

Y-Test applicable

CLAUSE NO.
QUALITY ASSURANCE

STAGE II (2X660 MW)
SECTION-VI
PART-B
E-15
GENERATOR &
AUXILIARIES
PAGE
8 OF 10

ADDITIONAL CHECK FOR EXCITOR

TESTS

ITEM/
COMPONENTS
/PROCESS

A
s

p
e
r

I
E
C
-
1
4
6

A
s

p
e
r

I
E
C
-
7
6

P
o
l
e

p
a
r
a
l
l
e
l
i
s
m

&

p
o
l
a
r
i
t
y

M
e
c
h
.

c
h
e
m
.

&

M
a
g
n
e
t
i
c

p
r
o
p
.

F
u
n
c
t
i
o
n
a
l

c
h
e
c
k

I
n
s
u
l
a
t
i
o
n

r
e
s
i
s
t
a
n
c
e

I
E
E
E
/
A
N
S
I
-
C
3
7
.
1
8

I
S
-
8
0
8
4

A
s

p
e
r

s
p
e
c
i
f
i
c
a
t
i
o
n

D
i
m
e
n
s
i
o
n
a
l

a
n
d

v
i
s
u
a
l

Fuse diode & filter
Circuit
Y
Y
Aux.Transformer
(if applicable)
Y

PMG & Exciter
stator
Y Y Y

Bandaging wire
Y

Exciter field
Breaker
Field discharge
resistor
Y

Bearing, exciter
armature
field, axis coil RTD
Y

Excitation
Transformer
Y

Thyristors
Y

Field breaker
Y

Bus duct AC/DC

Y

Voltage Regulator

Y

Y - Test applicable

CLAUSE NO.
QUALITY ASSURANCE

STAGE II (2X660 MW)
SECTION-VI
PART-B
E-15
GENERATOR &
AUXILIARIES
PAGE
9 OF 10

FINAL ACCEPTANCE TEST GENERATOR / EXCITOR

TESTS

ITEM/
COMPONENTS
/PROCESS

G
a
s

t
i
g
h
t
n
e
s
s

f
o
r

H
y
d
r
o
g
e
n

c
o
o
l
e
d

M
/
C

R
e
s
i
s
t
a
n
c
e

m
e
a
s
u
r
e
m
e
n
t

R
o
t
o
r

i
m
p
e
d
a
n
c
e

a
t

v
a
r
i
o
u
s

s
p
e
e
d
s

H
e
a
t

r
u
n

t
e
s
t

F
u
n
c
t
i
o
n

c
h
e
c
k

V
o
l
t
a
g
e

r
e
g
u
l
a
t
i
o
n

O
C
C

S
C
C

R
e
c
o
r
d

A
u
x
.

p
a
r
a
m
e
t
e
r
s

S
t
e
a
d
y

s
t
a
t
e

r
e
a
c
t
a
n
c
e
s

E
f
f
i
c
i
e
n
c
y

B
y

s
e
p
a
r
a
t
i
o
n

o
f

l
o
s
s
e
s

Works running on generator
Y Y Y Y Y Y Y Y Y
Without Excitation, Open
Circuit & Short Circuit
with rated voltage &
current for Generator
Y
Works test on brush
less exciter
Y Y Y
PMG works test
Y Y Y
Full load for PMG &
convertor assembly
Y
Convertor assembly
Y
Static excitation system
Y Y

TESTS

ITEM/
COMPONENTS
/PROCESS

I
n
s
u
l
a
t
i
o
n

r
e
s
i
s
t
a
n
c
e

P
o
l
a
r
i
s
a
t
i
o
n

i
n
d
e
x

P
h
a
s
e

s
e
q
.

v
o
l
t
a
g
e
b
a
l
a
n
c
e

S
h
a
f
t

v
o
l
t
a
g
e

&

c
u
r
r
e
n
t

H
.
V
.

t
e
s
t

(
e
x
c
e
p
t

e
l
e
c
t
r
o
n
i
c

c
i
r
c
u
i
t
)

R
T
D
,

B
T
D

C
h
e
c
k

C
a
p
a
c
i
t
a
n
c
e

m
e
a
s
u
r
e
m
e
n
t

T
a
n

d
e
l
t
a
,

d
e
l
t
a

t
a
n

d
e
l
t
a

R
o
t
o
r

j
o
u
r
n
a
l

B
e
a
r
i
n
g

o
i
l

c
a
t
c
h
e
r

Works running
on generator
Y Y Y Y Y Y Y Y
On total wdg / phases at interval
0.2 Un for Generator
Y Y
Condition after dismantling Y Y
Works test on brush
less exciter
Y Y
PMG works test Y Y Y
Convertor assembly Y Y
Static excitation system Y Y

Y - Test Applicable

CLAUSE NO.
QUALITY ASSURANCE

STAGE II (2X660 MW)
SECTION-VI
PART-B
E-15
GENERATOR &
AUXILIARIES
PAGE
10 OF 10

FINAL ACCEPTANCE TEST GENERATOR/EXCITOR

TESTS

ITEM/
COMPONENTS
/PROCESS

S
e
a
l

r
i
n
g
s
,

l
i
n
e
r
s

W
i
n
d
i
n
g

O
v
e
r
h
a
n
g

V
i
b
r
a
t
i
o
n

m
e
a
s
u
r
e
m
e
n
t

N
o

l
o
a
d

L
o
a
d

c
h
a
r
a
c
t
e
r
i
s
t
i
c
s

C
h
a
r
a
c
t
e
r
i
s
t
i
c
s

o
f

s
e
a
r
c
h

c
o
i
l
,
q
u
a
d
,

a
x
i
s

A
s

p
e
r

a
p
p
l
i
c
a
b
l
e

s
t
a
n
d
a
r
d

V
i
s
u
a
l

&

d
i
m
e
n
s
i
o
n

P
a
r
t
i
a
l

d
i
s
c
h
a
r
g
e

Works running
on generator
Y
Y Y
Without EXC, OC & SC
with rated voltage &
current for Generator

On total wdg / phases at
interval 0.2 Un for Generator

Condition after dismantling
Y Y

Works test on brush
less exciter
Y Y Y Y
Y
PMG works test
Y Y

Full load for PMG &
convertor assembly

Convertor assembly

Static excitation system
Y

Y - Test Applicable

SECTION-VI
PART-B
E - 16
MOTORS

STAGE II (2X600 MW)
SECTION VI
PART-B
E-16
MOTORS
PAGE 1 OF 1

INDUCTION MOTOR & SYNCHRONOUS MACHINE
TESTS/CHECKS

TEMS/COMPONENTS

V
i
s
u
a
l

D
i
m
e
n
s
i
o
n
a
l

M
a
k
e
/
T
y
p
e
/
R
a
t
i
n
g
/
T
C
/
G
e
n
e
r
a
l

P
h
y
s
i
c
a
l

I
n
s
p
e
c
t
i
o
n

M
e
c
h
/
C
h
e
m
.

P
r
o
p
e
r
t
i
e
s

N
D
T

/
D
P
/
M
P
I
/
U
T

M
e
t
a
l
l
o
g
r
a
p
h
y

E
l
e
c
t
r
i
c
a
l

C
h
a
r
a
c
t
e
r
i
s
t
i
c
s

W
e
l
d
i
n
g
/
B
r
a
z
i
n
g
(
W
P
S
/
P
Q
R
)

H
e
a
t

T
r
e
a
t
m
e
n
t

M
a
g
n
e
t
i
c

C
h
a
r
a
c
t
e
r
i
s
t
i
c
s

H
y
d
r
u
a
l
i
c
/
L
e
a
k
/
P
r
e
s
s
u
r
e

T
e
s
t

T
h
e
r
m
a
l

C
h
a
r
a
c
t
e
r
i
s
t
i
c
s

R
u
n

o
u
t

D
y
n
a
m
i
c

B
a
l
a
n
c
i
n
g

A
l
l

t
e
s
t
s

a
s

p
e
r

I
S
-
3
2
5
/
I
S
-
4
7
2
2

/

9
2
8
3

V
i
b
r
a
t
i
o
n

O
v
e
r

s
p
e
e
d

T
a
n

d
e
l
t
a
,

s
h
a
f
t

v
o
l
t
a
g
e

&

p
o
l
a
r
i
s
a
t
i
o
n

i
n
d
e
x

t
e
s
t

Plates for stator frame, end shield, spider
etc.
Y Y Y Y Y
Shaft Y Y Y Y Y Y Y
Magnetic Material Y Y Y Y Y Y Y Y
Rotor Copper/Aluminium Y Y Y Y Y Y Y
Stator copper Y Y Y Y Y Y Y
SC Ring Y Y Y Y Y Y Y Y Y
Insulating Material Y Y Y Y Y
Tubes for Cooler Y Y Y Y Y Y Y
Sleeve Bearing Y Y Y Y Y Y Y
Stator/Rotor, Exciter Coils Y Y Y Y Y
Castings, stator frame, terminal box and
bearing housing etc.
Y Y Y Y Y Y
Fabrication & machining of stator, rotor,
terminal box
Y Y Y Y
Wound stator Y Y Y Y
Wound Exciter Y Y Y Y
Rotor complete Y Y Y Y Y
Exciter, Stator, Rotor, Terminal Box
assembly
Y Y Y
Accessories, RTD, BTD,CT, Brushes,
Diodes,Space heater, antifriction bearing,
cable glands, lugs, gaskets etc.
Y Y Y
Motor (IS 325 / 4722/ 9283) Y Y Y Y Y Y Y1
Note: 1. This is an indicative list of tests/checks. The manufacture is to furnish a detailed Quality Plan indicating the practices & Procedure followed along with
relevant supporting documents during QP finalization. However, No QP for LT motor up to 50KW.
2. Makes of all major bought out items will be subject to NTPC approval.
Y1 =for HT Motor / Machines only.

SECTION-VI
PART-B
E - 17
LT SWITCHGEAR & BUS DUCT
CLAUSE NO.
QUALITY ASSURANCE

STAGE II (2X660 MW)

SECTION-VI
PART-B

E-17
LT SWITCHGEAR & BUS
DUCT
PAGE
1 OF 3

LT SWITCHGEAR
(MCC, PCC, ACDB, DCDB, FUSE BOARDS, LOCAL PUSH BUTTON STATION, LOCAL MOTOR
STARTERS)
ATTRI BUTES /
CHARACTERI S-
TI CS

ITEMS/
COMPONENTS/ SUB
SYSTEM ASSEMBLIY
M
a
k
e
,

M
o
d
e
l
,

T
y
p
e
,

R
a
t
i
n
g

&

T
C

D
i
m
e
n
s
i
o
n
s

&

F
i
n
i
s
h

E
l
e
c
t
r
i
c
a
l

p
r
o
p
e
r
t
i
e
s

M
e
c
h
a
n
i
c
a
l

P
r
o
p
e
r
t
i
e
s

C
h
e
m
i
c
a
l

p
r
o
p
e
r
t
i
e
s

F
u
n
c
t
i
o
n
a
l

&

O
p
e
r
a
t
i
o
n
a
l

F
e
a
t
u
r
e
s

a
s

p
e
r

N
T
P
C

S
p
e
c
.

I
t
e
m

t
o

c
o
n
f
o
r
m

t
o

r
e
l
e
v
a
n
t

S
t
a
n
d
a
r
d
s

P
r
e
t
r
e
a
t
m
e
n
t

a
s

p
e
r

I
S

6
0
0
5

P
a
i
n
t

S
h
a
d
e
,

A
d
h
e
s
i
o
n
,

T
h
i
c
k
n
e
s
s

&

F
i
n
i
s
h
F
u
n
c
t
i
o
n
a
l

C
h
e
c
k
s

M
i
l
l
i
-
v
o
l
t

d
r
o
p

T
e
s
t

I
R

H
V

I
R

T
e
s
t

D
e
g
r
e
e

o
f

P
r
o
t
e
c
t
i
o
n

R
o
u
t
i
n
e

t
e
s
t

a
s

p
e
r

N
T
P
C

s
p
e
c

A
l
l

R
o
u
t
i
n
e

t
e
s
t
s

a
s

p
e
r

N
T
P
C

s
p
e
c
.

&

I
S

Sheet Steel (IS : 513) Y Y Y Y Y
Aluminum Bus bar
Material
(IS : 5082)
Y Y Y Y Y Y
Copper Bus bar
Material
(IS : 613)
Y Y Y Y Y Y
Support Insulator Y Y Y Y Y
Air Circuit Breaker (IS:
13947)
Y Y Y Y Y Y Y
Energy Meters (IS :
13010, 13779 )
Y Y Y Y Y Y
Power & Aux.
Contactors
(IS : 13947)
Y Y Y Y Y
Protection & Aux.
Relays
(IS : 3231)
Y Y Y Y Y Y
Control & Selector
Switches
IS : 13947)
Y Y Y Y Y
CTs & PTs (IS 2705 /
3156)
Y Y Y Y
MCCB (IS : 13947) Y Y Y Y
Indicating Meters (IS :
1248)
Y Y Y Y Y Y
Indicating Lamps (IS :
13947)
Y Y Y Y Y
Air Break Switches
(IS : 13947)
Y Y Y Y Y
Control Terminal Blocks Y Y Y Y

CLAUSE NO.
QUALITY ASSURANCE

STAGE II (2X660 MW)

SECTION-VI
PART-B

E-17
LT SWITCHGEAR & BUS
DUCT
PAGE
2 OF 3

LT SWITCHGEAR
(MCC, PCC, ACDB, DCDB, FUSE BOARDS, LOCAL PUSH BUTTON STATION, LOCAL
MOTOR STARTERS)
ATTRI BUTES /
CHARACTERI
S-TI CS

ITEMS/
COMPONENTS/
SUB SYSTEM
ASSEMBLIY
M
a
k
e
,

M
o
d
e
l
,

T
y
p
e
,

R
a
t
i
n
g

&

T
C

D
i
m
e
n
s
i
o
n
s

&

F
i
n
i
s
h

E
l
e
c
t
r
i
c
a
l

p
r
o
p
e
r
t
i
e
s

M
e
c
h
a
n
i
c
a
l

P
r
o
p
e
r
t
i
e
s

C
h
e
m
i
c
a
l

p
r
o
p
e
r
t
i
e
s

F
u
n
c
t
i
o
n
a
l

&

O
p
e
r
a
t
i
o
n
a
l

F
e
a
t
u
r
e
s

a
s

p
e
r

N
T
P
C

S
p
e
c
.

I
t
e
m

t
o

c
o
n
f
o
r
m

t
o

r
e
l
e
v
a
n
t

S
t
a
n
d
a
r
d
s

P
r
e
t
r
e
a
t
m
e
n
t

a
s

p
e
r

I
S

6
0
0
5

P
a
i
n
t

S
h
a
d
e
,

A
d
h
e
s
i
o
n
,

T
h
i
c
k
n
e
s
s

&

F
i
n
i
s
h

F
u
n
c
t
i
o
n
a
l

C
h
e
c
k
s

M
i
l
l
i
-
v
o
l
t

d
r
o
p

T
e
s
t

I
R

H
V

I
R

T
e
s
t

D
e
g
r
e
e

o
f

P
r
o
t
e
c
t
i
o
n

R
o
u
t
i
n
e

t
e
s
t

a
s

p
e
r

N
T
P
C

s
p
e
c

A
l
l

R
o
u
t
i
n
e

t
e
s
t
s

a
s

p
e
r

N
T
P
C

s
p
e
c
.

&

I
S

Fuse (IS 13703) Y Y Y Y
Control
Transformer (IS :
12021)
Y Y Y Y Y Y
Push Buttons (IS :
4794)
Y Y Y Y Y
Transducer (IEC :
60688)
Y Y Y Y Y Y
MCB IS : 8828) Y Y Y Y Y
Breaker Handling
Trolley
Y Y Y Y Y Y
Synthetic Rubber
Gasket (IS : 11149)
Y Y Y Y Y
LT SWITCHGEAR
(IS : 8623 )
Y Y Y Y Y Y Y Y Y Y Y
Notes:

1. This is an indicative list of tests / checks. The manufacturer is to furnish a detailed Quality Plan
indicating the practice and procedure along with relevant supporting documents.
2. Makes of all major Bought Out Items will be subject to NTPC approval.

CLAUSE NO.
QUALITY ASSURANCE

STAGE II (2X660 MW)

SECTION-VI
PART-B

E-17
LT SWITCHGEAR & BUS
DUCT
PAGE
3 OF 3

LT BUSDUCT
ATTRIBUTES ,
CHARACTERISTICS

ITEM, COMPONENTS,
SUB SYSTEM ASSEMBLY

D
i
m
e
n
s
i
o
n

&

S
u
r
f
a
c
e

F
i
n
i
s
h

M
a
k
e
,

T
y
p
e
,

R
a
t
i
n
g

&

T
C

E
l
e
c
t
r
i
c
a
l

P
r
o
p
e
r
t
i
e
s

M
e
c
h
a
n
i
c
a
l

P
r
o
p
e
r
t
i
e
s

C
h
e
m
i
c
a
l

P
r
o
p
e
r
t
i
e
s

I
t
e
m

t
o

c
o
n
f
o
r
m

t
o

r
e
l
e
v
a
n
t

I
S

W
P
S

A
p
p
r
o
v
a
l
,

W
e
l
d
e
r

Q
u
a
l
i
f
i
c
a
t
i
o
n

W
e
l
d

Q
u
a
l
i
t
y

C
h
e
c
k

(

D
P

t
e
s
t

&

x
-
r
a
y

T
e
s
t
)

P
a
i
n
t

S
h
a
d
e
,

T
h
i
c
k
n
e
s
s
,

A
d
h
e
s
i
o
n

&

F
i
n
i
s
h

T
i
g
h
t
n
e
s
s

b
y

T
o
r
q
u
e

m
e
a
s
u
r
e
m
e
n
t

E
l
e
c
t
r
i
c
a
l

C
l
e
a
r
a
n
c
e
s

G
a
l
v
a
n
i
z
i
n
g

T
e
s
t

a
s

p
e
r

I
S

2
6
2
9
/

2
6
3
3
/

4
7
5
9

I
R

H
V

I
R

T
e
s
t

P
h
a
s
e

S
e
q
u
e
n
c
e

C
h
e
c
k

D
e
g
r
e
e

o
f

P
r
o
t
e
c
t
i
o
n

r
o
u
t
i
n
e

t
e
s
t

a
s

p
e
r

N
T
P
C

s
p
e
c
.

Aluminum Sheets / Plates /
Strips / Flexibles / tubes
(IS : 5082 / 737)
Y Y Y Y Y Y Y
CRCA Flats / ISMC (IS
2062)
Y Y Y Y Y
Neoprene / Synthetic
Rubber Gaskets (IS 11149 /
3400)
Y Y Y Y
Rubber Bellows (IS : 3400) Y Y Y Y
Support Insulator Y Y Y Y
Galvanized Structure & GI
Earthing Flat
(IS : 2629 / 2633 / 4749 )
Y Y Y Y
Space Heater & Thermostat Y Y Y
LT Busduct (IS : 8623
PART 2)
Notes:

indicating the practice and
procedure along with relevant supporting documents.

SECTION-VI
PART-B
E - 18
LT POWER CABLES
CLAUSE NO.
QUALITY ASSURANCE

STAGE II (2X660 MW)
SECTION-VI
PART-B
E-18
L.T. POWER CABLES
PAGE
1 OF 3

L.T. POWER CABLES
(1.1 KV PVC & XLPE CABLES)

Attributes /
Characteristics

Item / Components /
Sub System Assembl y

M
a
k
e
,

R
a
t
i
n
g
,

T
y
p
e

&

T
C

D
i
m
e
n
s
i
o
n
/
s
u
r
f
a
c
e

f
i
n
i
s
h

M
e
c
h
a
n
i
c
a
l

P
r
o
p
e
r
t
i
e
s

C
h
e
m
i
c
a
l

C
o
m
p
o
s
i
t
i
o
n

E
l
e
c
t
r
i
c
a
l

P
r
o
p
e
r
t
i
e
s

S
p
a
r
k

T
e
s
t

H
o
t

s
e
t

t
e
s
t

(
X
L
P
E
)

L
a
y

l
e
n
g
t
h

/

S
e
q
u
e
n
c
e

A
r
m
o
u
r

c
o
v
e
r
a
g
e
,

C
r
o
s
s

o
v
e
r
,

l
o
o
s
e
n
e
s
s
,

G
a
p

b
e
t
w
e
e
n

t
w
o

a
r
m
o
u
r

w
i
r
e
/
s
t
r
i
p

S
e
q
u
e
n
t
i
a
l

m
a
r
k
i
n
g
/
s
u
r
f
a
c
e

f
i
n
i
s
h

/
c
a
b
l
e

l
e
n
g
t
h

T
e
n
s
i
l
e

s
t
r
e
n
g
t
h
,

e
l
o
n
g
a
t
i
o
n

b
e
f
o
r
e

&

a
f
t
e
r

a
g
e
i
n
g

o
f

i
n
s
u
l
a
t
i
o
n

&

o
u
t
e
r

s
h
e
a
t
h

T
h
e
r
m
a
l

S
t
a
b
i
l
i
t
y

o
f

i
n
s
u
l
a
t
i
o
n

a
n
d

o
u
t
e
r

s
h
e
a
t
h

*

A
n
t
i

t
e
r
n
i
t
e

t
r
e
a
t
m
e
n
t

o
n

w
o
o
d
e
n

d
r
u
m
s

C
o
n
s
t
r
u
c
t
i
o
n
a
l

/

r
e
q
u
i
r
e
m
e
n
t

a
s

p
e
r

N
T
P
C

S
p
e
c
.

R
o
u
t
i
n
e

a
n
d

a
c
c
e
p
t
a
n
c
e

t
e
s
t

a
s

p
e
r

R
e
l
e
v
a
n
t

S
t
a
n
d
a
r
d

a
n
d

N
T
P
C

s
p
e
c
i
f
i
c
a
t
i
o
n

F
R
L
S

T
e
s
t

Aluminum (IS-8130) Y Y Y Y Y
PVC Compound (IS-5831) Y Y Y Y
XLPE Compound(IS-7098 Part-
I)
Y Y Y Y Y
FRLS PVC Compound(IS-5831)
ASTM-D-2843/ ASTM-D-2863
IEC-754 Part-I
Y Y Y
Armour wire/strip (IS-3975) Y Y Y
Insulated Core Y Y Y Y
Laid up core Y Y
PVC Inner sheath Y
Armouring Y Y
Outer sheath Y Y Y Y Y
Finish cable (IS-1554 & 7098
Part-1)
ASTM-D-2843/ IS 10810 (Part- -
58)
IEC-754 Part-I
Swedish Chimney SS 4241475
for (F3 category)
Flammability test IEC-332 Part
3 Cat-B
Y Y Y Y Y Y Y

Y Y
Wooden drum (IS-10418) / Steel
drum
Y Y
Note: This is an indicative list of test/checks. The manufacturer is to furnish a detailed quality plan indicating the practice and
procedure along with relevant supporting documents.

2. Not applicable for XLPE insulation

CLAUSE NO.
QUALITY ASSURANCE

STAGE II (2X660 MW)
SECTION-VI
PART-B
E-18
L.T. POWER CABLES
PAGE
2 OF 3

ROUTINE TESTS
Routine tests shall be carried out on each drum of finished cables for all
types & sizes.
Following shall constitute routine tests:
1) Conductor Resistance test
2) High voltage test at room temperature

ACCEPTANCE TESTS
Following Acceptance tests shall be carried out for each type and size
of the cables on the cable drums selected at random as per sampling
plan mentioned in IS: 1554 Part 1 & IS 7098 Part-I
A) For Conductor
1) Annealing test For copper conductor only
2) Tensile test For aluminium conductor only
3) Wrapping test For aluminium conductor only
4) Resistance test
B) For Armour Wires / Formed Wires (If applicable)
1) Measurement of Dimensions
2) Tensile Tests
3) Elongation Test
4) Torsion Test For Round wires only
5) Wrapping Test
6) Resistance Test
7) Mass of Zinc coating test For G S wires / Formed wires
only
CLAUSE NO.
QUALITY ASSURANCE

STAGE II (2X660 MW)
SECTION-VI
PART-B
E-18
L.T. POWER CABLES
PAGE
3 OF 3

8) Uniformity of Zinc coating For G S wires / Formed wires
only
9) Adhesion test For G S wires / Formed wires
only
10) Freedom from defects
C) For PVC / XLPE insulation & PVC Sheath
1) Test for thickness
2) Hot set test For XLPE insulation only
3) Tensile strength & Elongation before ageing
D) For completed cables
1) Insulation resistance test (Volume resistivity method)
E) Following tests shall be carried out and only one sample shall be taken
from each offered lot of all sizes for these tests:-
1) Tensile strength & elongation after ageing on PVC / XLPE insulation and
PVC outer sheath
2) Thermal stability test on PVC insulation and outer sheath
3) Oxygen index test on outer sheath
4) Smoke density rating test on outer sheath as per ASTM D 2843
5) Acid gas generation test on outer sheath as per IEC 754 (Part 1)
6) Flammability test as per IEC-332 - Part- 3 (Category- B) on completed
cable
7) Fire resistance test as per SS 4241475 (F3 Category) on completed cable
F) Following tests shall be carried on one length of each size of offered
lot:
1) Surface finish, length measurement, sequence of cores, armour coverage,
Gap between two consecutive armour wires / formed wires

SECTION-VI
PART-B
E - 19
LT CONTROL CABLES
CLAUSE NO.
QUALITY ASSURANCE

STAGE II (2X660 MW)
SECTION-VI
PART-B
E-19
L.T. CONTROL CABLES
PAGE
1 OF 3

L.T. CONTROL CABLES
(1.1 KV PVC CABLES)
Attributes /

Characteristics

Item / Components /
Sub System
Assembly

M
a
k
e
,

T
y
p
e
,

R
a
t
i
n
g
,

T
.
C

D
i
m
e
n
s
i
o
n
/
s
u
r
f
a
c
e

f
i
n
i
s
h

M
e
c
h
a
n
i
c
a
l

P
r
o
p
e
r
t
i
e
s

C
h
e
m
i
c
a
l

C
o
m
p
o
s
i
t
i
o
n

E
l
e
c
t
r
i
c
a
l

P
r
o
p
e
r
t
i
e
s

S
p
a
r
k

T
e
s
t

L
a
y

l
e
n
g
t
h
/
S
e
q
u
e
n
c
e

A
r
m
o
u
r

c
o
v
e
r
a
g
e
,

c
r
o
s
s

o
v
e
r
,

l
o
o
s
e
n
e
s
s
,

g
a
p

b
e
t
w
e
e
n

t
w
o

a
r
m
o
u
r

w
i
r
e

S
e
q
u
e
n
t
i
a
l

m
a
r
k
i
n
g
/
s
u
r
f
a
c
e

f
i
n
i
s
h
/
c
a
b
l
e

l
e
n
g
t
h

T
e
n
s
i
l
e

s
t
r
e
n
g
t
h
,

e
l
o
n
g
a
t
i
o
n

b
e
f
o
r
e

&

a
f
t
e
r

a
g
e
i
n
g

o
f

i
n
s
u
l
a
t
i
o
n

&
o
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t
e
r

s
h
e
a
t
h

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r
m
a
l

s
t
a
b
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y

o
f

i
n
s
u
l
a
t
i
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n

a
n
d

o
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t
e
r

s
h
e
a
t
h

A
n
t
i

t
e
r
m
i
t
e

t
r
e
a
t
m
e
n
t

o
n

w
o
o
d
e
n

d
r
u
m
s

C
o
n
s
t
r
u
c
t
i
o
n
a
l

f
e
a
t
u
r
e

a
s

p
e
r

N
T
P
C

S
p
e
c
R
o
u
t
i
n
e

&

A
c
c
e
p
t
a
n
c
e

t
e
s
t

a
s

p
e
r

r
e
l
e
v
a
n
t

s
t
a
n
d
a
r
d

&

p
a
g
e

2

&

3

o
f

t
h
i
s

t
a
b
l
e
F
R
L
S

T
e
s
t

Copper Conductor
(IS-8130)
Y Y Y Y Y
PVC Compound (IS-
5831)
Y Y Y Y
FRLS PVC Compound
IS-5831
ASTM-D-2843/ IS
10810 (Part-58 )
IEC-754 Part-1
Y Y Y Y
Armour wire/strip (IS-
3975)
Y Y Y
Insulated Core Y Y Y Y
Laid up core Y Y
PVC Inner sheath Y
Armouring Y Y
Outer sheath Y Y Y Y Y
Finish cable (IS-1554-
1)
ASTM-D-2843/ IS
10810 (Part-58)
IEC-754 Part-1
Swedish Chimney: SEN
SS 424-1475 (F3
category)
Flammability test IEC-
332 Part-3 Cat-B
Y Y Y Y Y Y Y Y Y
Wooden drum (IS :
10418) / Steel drum
Y Y
1.Note : This is an indicative list of test/checks. The manufacturer is to furnish a detailed quality plan
indicating the Practice and procedure along with relevant supporting documents.

CLAUSE NO.
QUALITY ASSURANCE

STAGE II (2X660 MW)
SECTION-VI
PART-B
E-19
L.T. CONTROL CABLES
PAGE
2 OF 3

CONTROL CABLE
ROUTINE TESTS
Routine tests shall be carried out on each drum of finished cables for all
types & sizes.
Following shall constitute routine tests:
1) Conductor Resistance test
ACCEPTANCE TESTS
Following Acceptance tests shall be carried out for each type and size
of the cables on the cable drums selected at random as per sampling
plan mentioned in IS: 1554 Part 1
A) For Conductor
1) Annealing test For copper conductor only
2) Resistance test
B) For Armour Wires / Formed Wires ( If applicable )
1) Measurement of Dimensions
2) Tensile Tests
3) Elongation Test
4) Torsion Test For Round wires only
5) Wrapping Test
6) Resistance Test
7) Mass of Zinc coating test For G S wires / Formed wires only
8) Uniformity of Zinc coating For G S wires / Formed wires only
9) Adhesion test For G S wires / Formed wires only
10) Freedom from defects

CLAUSE NO.
QUALITY ASSURANCE

STAGE II (2X660 MW)
SECTION-VI
PART-B
E-19
L.T. CONTROL CABLES
PAGE
3 OF 3

C) For PVC insulation & PVC Sheath
1) Test for thickness
2) Tensile strength & Elongation before ageing
D) For completed cables
1) Insulation resistance test ( Volume resistivity method )
E) Following tests shall be carried out and only one sample shall be taken
from each offered lot of all sizes for these tests:-
1) Tensile strength & elongation after ageing on PVC insulation and PVC
outer sheath
2) Thermal stability test on PVC insulation and outer sheath
3) Oxygen index test on outer sheath
4) Smoke density rating test on outer sheath as per ASTM D 2843
5) Acid gas generation test on outer sheath as per IEC 754 (Part 1)
6) Flammability test as per IEC-332 - Part- 3 ( Category- B ) on completed
cable
7) Fire resistance test as per SS 4241475 (F3 Category ) on completed cable
F) Following tests shall be carried on one length of each size of offered
lot:
1) Surface finish, length measurement, sequence of cores, armour coverage,
Gap between two consecutive armour wires / formed wires

SECTION-VI
PART-B
E - 20
CABLING, EARTHING, LIGHTNING
PROTECTION
CLAUSE NO.
QUALITY ASSURANCE

STAGE II (2X660 MW)
SECTION-VI
PART-B
E-20
CABLING, EARTHING
LIGHTNING
PROTECTION
PAGE
1 OF 1

CABLING, EARTHING, LIGHTNING PROTECTION
ATTRIBUTES /
CHARACTERISTICS

ITEMS/COMPONENTS /
SUB SYSTEMS

D
i
m
e
n
s
i
o
n

P
a
i
n
t

s
h
a
d
e
,

p
a
i
n
t

t
h
i
c
k
n
e
s
s
,

a
d
h
e
s
i
o
n

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e
-
t
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a
t
m
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n
t

o
f

s
h
e
e
t

I
P

p
r
o
t
e
c
t
i
o
n

P
r
o
o
f

l
o
a
d
*

S
u
r
f
a
c
e

f
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n
i
s
h

D
e
f
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c
t
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n

t
e
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t
*

H
V

&

I
R

G
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l
v
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n
i
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e

T
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t

(
I
f

A
p
p
l
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c
a
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e
)

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n
c
t
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a
l

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t

o
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i
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m
s
/
B
i
l
l

o
f

m
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t
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t

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t
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d
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d

&

s
p
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c
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f
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t
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n

A
c
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p
t
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t
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a
s

p
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v
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t

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t
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d
a
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d

&

s
p
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c
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f
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c
a
t
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n

C
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n
s
t
r
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c
t
i
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n
a
l

f
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t
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e

a
s

p
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r

N
T
P
C

S
i
f
i
t
i
Cable glands(BS-6121) Y Y
Cable lug(IS-8309) Y Y
Lighting wire(IS-694) Y Y
Flexible conduits Y Y Y
Conduits(Galvanized &
Epoxy) IS-9537 & IS-
2629,2633 ,6745
Y Y Y Y Y
RCC Hume Pipe (IS-458) Y
Cable straight through joint
(VDE-0278)
Y Y Y
Cable Trays, & supports
system & accessories IS-
513, 2629,2633,6745
Trefoil clamp Y Y
GI flats for earthing &
lighting protection (IS 2062,
2629, 6745,2633)
Y Y Y Y Y
GI wire (IS-280) Y Y
Fire Sealing System (BS
476)
Y Y Y

.Note:1.This is an indicative list of tests /checks. The manufacturer is to furnish a detailed Quality
Plan indicating the practice and procedure along with relevant supporting documents.
2. Make of all items will be subject to NTPC approval.

SECTION-VI
PART-B
E - 21
LIGHTING
CLAUSE NO.
QUALITY ASSURANCE

STAGE II (2X660 MW)
SECTION-VI
PART-B
E-21
LIGHTING
PAGE
1 OF 1

LIGHTING

Item Components
Sub System
Assembly

Attributes
Characteristics

M
a
k
e
,

T
y
p
e

,

R
a
t
i
n
g
/

T
C

D
i
m
e
n
s
i
o
n

P
r
e
-
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r
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a
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n
t

o
f

s
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t
s

P
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t

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h
a
d
e

T
h
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c
k
n
e
s
s

A
d
h
e
s
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o
n

&

F
i
n
i
s
h

T
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s
t

f
o
r

G
a
l
v
a
n
i
z
a
t
i
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n

I
P

T
e
s
t

B
o
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g
h
t

O
u
t

I
t
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m
s
/

B
i
l
l

o
f

M
a
t
e
r
i
a
l

H
V

&

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R

F
u
n
c
t
i
o
n
a
l

C
h
e
c
k

a
s

p
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r

s
p
e
c
.

C
o
n
s
t
r
u
c
t
i
o
n
a
l

F
e
a
t
u
r
e

a
s

p
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r

N
T
P
C

s
p
e
c
.

R
o
u
t
i
n
e

T
e
s
t

a
s

p
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l
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v
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t

s
t
d

a
n
d

s
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c

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p
t
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c
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T
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s
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a
s

p
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l
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v
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t

s
t
d

a
n
d

s
p
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c

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t
e
m

t
o

c
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n
f
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m

t
o

r
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l
e
v
a
n
t

s
t
a
n
d
a
r
d

Luminaries (IS-10322
Part-5 Sec.1; IS- 2206)
Y Y Y Y

Y
Electronic Ballast Y
Y
Y Y
Lighting Wire (IS-694) Y
Y

Pole (IS-2713) Y Y Y
Y
Y
Lamps (IS-9800, IS-9974) Y Y Y
Switch Box/ J unction
Box/Receptacles/ Local
Push Button, Lighting
Panel / flame proof type
(IS-513, 2629, 2633,
4759, 6745, 2148)
Cable Gland (BS-6121) Y Y Y

Cable Lug (IS-8309) Y Y Y

Flexible Conduit Y
Y

Lighting Transformer (IS-
1117, 11333)
Y Y Y
Epoxy & Galvanised
Conduit (IS-9537, 2629,
2633, 4759, 6745)
Y Y
Y
Y
Notes:
indicating the practice and procedure along with relevant supporting documents.
2. Make of all major Bought Out Items will be subject to NTPC approval.

SECTION-VI
PART-B
E - 22
PASSENGER / SERVICE ELEVATORS
AND LIFTS
CLAUSE NO.
QUALITY ASSURANCE

STAGE III (2X660 MW)
SECTION-VI
PART-B
E-22
ELEVATORS
PAGE
1 OF 1

ELECTRICAL PORTION OF PASSENGER /
SERVICE ELEVATORS AND LIFTS

Items
Description

G
e
n
e
r
a
l

p
h
y
s
i
c
a
l

I
n
s
p
e
c
t
i
o
n

/

D
i
m
e
n
s
i
o
n
s

F
u
n
c
t
i
o
n
a
l
/

O
p
e
r
a
t
i
o
n
a
l

T
e
s
t

B
u
r
n

i
n

T
e
s
t

o
n

o
n

e
l
e
c
t
r
o
n
i
c

c
a
r
d
s

P
r
e
-
t
r
e
a
t
m
e
n
t

i
n

s
e
v
e
n

t
a
n
k

f
o
r

s
h
e
e
t

s
t
e
e
l

,

P
a
i
n
t
i
n
g

P
a
i
n

s
h
a
d
e
,

t
h
i
c
k
n
e
s
s

&

a
d
h
e
s
i
o
n

A
l
l

R
o
u
t
i
n
e

t
e
s
t
s

a
s

p
e
r

r
e
l
e
v
a
n
t

s
t
a
n
d
a
r
d

Electrical Motor IS 325 / IS 4722

Y Y Y
PLC (IEC 1131) Y Y Y Y
VVVF Panel Y Y Y Y Y Y

Note :
1) This is an indicative list of tests/checks. The manufacture is to furnish a
detailed Quality Plan indicating the practices & Procedure followed
alongwith relevant supporting documents during QP finalisation.

2) Make of all major Bought Out Items will be subject to NTPC approval.

SECTION-VI
PART-B
E - 23
MONITORING & INFORMATION SYSTEM
(DDCMIS)
CLAUSE NO.

QUALITY ASSURANCE

STAGE-II (2X660 MW)
SECTION-VI
PART-B
E-23
DDCMIS
PAGE
1 OF 10

1.00.00 REQUIREMENTS OF AUTHORISATION-TO-SHIP-TEST (ATST) FOR DDCMIS
1.01.00 (a) Authorization-to-ship-test (ATST) or Factory Acceptance Test (FAT) shall
include all required tests to fully demonstrate to Employers satisfaction that
each equipment/sub-system/system as well as software modules furnished
as per this specification as well as DDCMIS as a whole, fully meets the
functional, parametric and other requirements of this specification and
Employers approved drawings/documents under all operating regimes. The
parametric requirements shall be as per DDCMIS specifications. All tests
pertaining to Control System shall be applicable to SG-C&I, TG-C&I and
BOP-C&I also (wherever applicable).
(b) Contractor to note that ATST / FAT procedure given below in subsequent
clauses are only indicative in order to help the Contractor in understanding
the requirements and help him in submitting a detailed procedure based on
these guidelines meeting all the specification requirements. These
requirements are in addition to those stipulated against DDCMIS integrated
testing.
(c) The results of the following activities shall be made available to the
Employers representative before start of ATST / FAT.
(i) Implementation check of various applications including those based
on NTPC input, as per clause no 9.03.04, Part-C, GTR..
(d) Generally, the ATST / FAT shall be carried out with the equipment
earmarked for the particular project and unit. However, for the following item,
the testing can be carried out with similar / equivalent dummy equipment
fulfilling the following condition, subject to Employers approval.
SN ITEM CONDITION
1 LVS Testing of LVS functionalities can be done by using
monitors connected to the LVS Workstations.
Despatch of LVS can be allowed like a cat-III item, but
only after successful testing of functionalities as
indicated above.
2 LVS WS / OWS LVS WS / OWS for the first unit to be tested on the
target machines. In case the testing carries over to
next unit, dummy equipment may be used. Despatch
of LVS WS / OWS of subsequent units can be allowed
like a cat-III item, but only after successful testing of
first unit as indicated above.
3 MASTER CLOCK Can be directly despatched if alternate test set-up for
time synchronisation can be arranged.

CLAUSE NO.

QUALITY ASSURANCE

STAGE-II (2X660 MW)
SECTION-VI
PART-B
E-23
DDCMIS
PAGE
2 OF 10

4 NETWORK
COMPONENT
To be done with target machines only for first unit. In
case the testing carries over to next unit, dummy
equipment may be used. Despatch of network
components of subsequent units / station can be
allowed like a cat-III item, but only after successful
testing of functionalities as indicated above.
5 VARIOUS BUS
SYSTEM
CABLES
For FAT, the target Main system bus shall be used. In
case the testing carries over to next unit, dummy
equipment may be used.
1.01.01 The Authorisation-To-Ship-Test (ATST) 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:
(a) Pre power on checks / Power
failure auto-restart tests

(b) Power on check
(c) Hardware tests
(d) Functional tests To be done only for the first unit (in
case of a multi-unit project). Only
if, under any unavoidable situation,
some exception remains,
functional / parametric tests for
only those shall be done in
subsequent unit
(e) Parametric test ---- do ----
1.01.02 Pre power on checks
These tests shall include but not be limited to the following:
(a.) Visual Checks:
These tests will include checking of individual cubicles, peripherals, etc. for
damages; proper inspection of cubicles, internal cabling, tuning, door
arrangements, louvers, fans etc.
(b.) Hardware verification:
These tests will include verification of location of each card and module in
Control System, MMIPIS, master clock systems, etc. Verification of no. of
modules as per the approved BOM and corresponding layout drgs. on sub
system basis. Verification of spare capacity in the cubicle for installation of
new modules.
CLAUSE NO.

QUALITY ASSURANCE

STAGE-II (2X660 MW)
SECTION-VI
PART-B
E-23
DDCMIS
PAGE
3 OF 10

(c.) Verification of system technical documentation as per approved list.
(d.) Verification of degree of protection of various cabinets as per specifica-
tion.
1.01.03 Power on check / Power failure auto-restart tests
To observe the start up and automatic loading initialization of software when system
is energised. Verification of availability of all system functions automatically after
restoration of power after power failure to DDCMIS. Verification of restoration of all
data which was stored in the system at the time of power loss.
1.01.04 Hardware tests
These tests shall include but not be limited to the following tests:
(a.) Verification of healthiness of all modules e.g., I/O modules, controller
modules, processors, peripherals, etc.
(b.) System configuration:
(1.) Verification of system configuration with reference to approved
configuration diagrams including verification of controller
configuration, group/ sub-group segregation; grouping of controllers
both for CLCS & OLCS , communication controller, I/O redundancy,
verification of multiple measurement scheme, MMIPIS configuration,
etc.
(2.) Verification of features of complete DDCMIS like on line removal of
I/O and controller modules, etc. in line with specification
requirements.
(3.) Verification of spare capacity w.r.t. spare wired-in space in
cabinets/ cubicles, terminal blocks, peripherals, etc. in line with spec.
requirements as stipulated under scope of work.
(c.) Simulation of inputs:
To verify conversion calculations, scan rates, operators functions,
corrections of calculations. For simulation of inputs for I/O modules, this
test will be carried out for 10% of each type of modules or min. 1 no. of
each type, whichever is more.
(d.) Accuracy test:
Accuracy for analog inputs/output shall be demonstrated for each type of
analog input/output. The No. of samples shall be decided during detailed
engineering.
(e.) Demonstration of the manual and auto switchover from master to standby
system bus, controllers, I/Os, processors etc.
CLAUSE NO.

QUALITY ASSURANCE

STAGE-II (2X660 MW)
SECTION-VI
PART-B
E-23
DDCMIS
PAGE
4 OF 10

(f.) Diagnostics Tests:
Complete on-line diagnostic tests on MMIPIS, individual peripherals,
Control System, programmer stations, etc.
1.01.05 Functional Tests
The following tests shall be carried out on Contractors DDCMIS.
(a.) Functional tests of CLCS:
(1.) Verification of proper signal acquisition, conditioning and
distribution.
(2.) Verification of proper realisation of controller functions like bumpless
transfer from auto to manual and vice versa (as stated above),
functional checking of bias circuit (wherever provided), etc.
(3.) Verification of response of control system by simulating changes in
the system inputs by using mathematical modelling of the process for
control loops like CCS, fuel flow control, air flow control, furnace draft
control, feed water control, SH/RH temperature control, etc., in line
with the approved ATST procedure
(4.) Sample verification of availability of all automatic CLCS functions
without HMIPIS.
(5.) Sample verification of availability of all CLCS functions within one
Functional Group without System Bus.
(b.) Functional tests of OLCS:
(1.) Verification of proper signal acquisition, conditioning and
distribution.
(2.) Verification of proper realisation of logic functions, sequence control
functions, running of complete start up program sequence in all
modes of operation, shut down program, etc.
(3.) Verification of logic computation in controller by simulating inputs.
(4.) Sample verification of availability of all automatic OLCS functions
without HMIPIS.
(5.) Sample verification of availability of all OLCS functions within one
Functional Group without System Bus.
(c.) Functional tests for MMIPIS
(1.) Verification of all types of displays, logs including their formats,
bar graphs, X-Y plots etc. availability of all operator functions.
CLAUSE NO.

QUALITY ASSURANCE

STAGE-II (2X660 MW)
SECTION-VI
PART-B
E-23
DDCMIS
PAGE
5 OF 10

(2.) Verification of event generation and handling capabilities of
MMIPIS processors by simulating various types of events/data and
observing associated event sequence display and alarm signalling
boxes.
(3.) Calculations:
All calculations shall be tested on sample basis to demonstrate that
these are in accordance with the specification and Employers
inputs as applicable. The Contractor shall prepare all tests cases for
calculations for proper verification for the features required for each
type of computations.
(4.) Checking historical storage and retrieval functions including long
term storage.
(5.) Testing of initialization and loading of configuration data,etc.
(6.) Verification of all programmers stations functions for MMIPIS and
Control System, as well as for documentation facility as specified.
(7.) For SER function, verification of resolution of SOE inputs, time
synchronisation with master clock, data base modification, SOE
report, printout, off-line & on line diagnostic features etc. For this
purpose a test-simulator to generate sequences of 1 ms resolution for
100 points distributed in different panels shall be made available
during testing.
(8.) Testing of each peripheral viz., monitors CRTs, printers, optical disks,
hard disk drive, floppy drive, etc.
(9.) Testing of power supply system to DDCMIS, tolerance of DDCMIS
w.r.t. voltage & frequency limits as specified, performance of DDCMIS
with power supply break as specified .(One sample of each type)
(10.) Verification of switchover of main processor/controller to stand by
processor/controller.
(11.) Testing of time synchronisation function of system time of DDCMIS
(Control System, HMIPIS & Systems on LAN). In case it is not
possible to bring the master clock procured under this package, then
signal generator with stable source, capable of generating all required
type of synchronizing signal to be arranged by Contractor.
(12.) Testing of the Station LAN shall be carried out with unit-1 testing. It
will cover one unit DDCMIS and at least 2 other DDCMIS systems, as
well as two client PCs and one third party PLC (either actual or
simulated to be organised by Employer).

CLAUSE NO.

QUALITY ASSURANCE

STAGE-II (2X660 MW)
SECTION-VI
PART-B
E-23
DDCMIS
PAGE
6 OF 10

1.01.06 Parametric tests
Following tests shall be carried out to test Contractors DDCMIS w.r.t.
specification requirements.
(a.) For control system (CLCS+OLCS): (on two most heavily loaded Functional
group)
(1.) CPU loading
(2.) Cycle time/controller reaction time.
(3.) Memory spare capacity
(b.) For MMIPIS
(1.) CPU loading
(2.) Spare duty cycle
(3.) Spare memory capacity
(c.) Spare duty cycle for system bus
(d.) Various display response time
(e.) System accuracy
(f.) Demonstration of system reliability
(g.) Display update time on OWS LVS
Verification of availability of all system functions automatically after restoration of
power after power failure to DDCMIS. Verification of restoration of all data which
was stored in the system at the time of power loss.
1.01.07 The Contractor shall submit a detailed ATST procedure for Employers approval
during detailed engineering stage based on the above guidelines. The ATST pro-
cedure to be submitted by the Contractor shall be detailed and exhaustive enough
such that Employer is satisfied that all the DDCMIS System specification
requirements and features are being tested andthe system meets these
requirements. The test results obtained shall be properly documented by the
Contractor and furnished in the Employer approved format as decided during
detailed engg. And submitted in the requisite no. of copies with all annexures
irrespective of the fact that Employers representative was present during the tests.
1.01.08 The following minimum criteria shall be followed during all tests:

CLAUSE NO.

QUALITY ASSURANCE

STAGE-II (2X660 MW)
SECTION-VI
PART-B
E-23
DDCMIS
PAGE
7 OF 10

1.02.00 Integrated Test Set-Up
For integrated testing of the total DDCMIS system, the Contractor shall employ a
test set-up, which will be capable of generating I/O signals in a requisite manner. It is
preferable to adopt soft signal simulating device to avoid / minimise the cumbersome
process of physical connection of I/Os through potentiometers, switches, Lamps/
LEDs etc. The exact configuration/ set-up shall be as finalised during detailed
engineering
1.02.01 The Contractor is to submit Authorisation-To-Ship-Test (ATST) procedure as a part
of Draft QA Programme fully meeting the intent and requirements of above and
other applicable clauses of this specification. Since, the exact definition & extent /
parameters of ATST can be finalised only when the engineering of DDCMIS has
been finalised to a great extent, it is required that the detailed draft ATST procedure
be submitted by the Contractor at a later date as intimated by the Employer during
engineering stage for Employers comment and finalisation. Contractor shall
incorporate all modifications, additions/ deletions to the ATST procedure as
indicated by the Employer. The ATST shall be conducted as per Employer approved
procedure for ATST which will be included in the approved QA Programme. The
Employer reserves the right to ask the Contractor to conduct any other test also
during the ATST which may be required to fully satisfy the Employer regarding full
compliance with specification requirements. Contractor shall conduct all such tests
also within the quoted lumpsum price for this contract.
1.02.02 The results of all ATS Tests shall be properly documented by the Contractor and
submitted to Employer in requisite number of copies with all annexures.
1.02.03 Following the tests, if in the opinion of the Employer, the system has not been
adequately manufactured, programmed, tested or debugged the Contractor shall
make good all deficiencies including system parametric specifications of display
response time, processor duty cycle, SOE resolution, etc., and re-run the test to fully
satisfy the Employer regarding full compliance with specification requirements and
requisite quality standards.
1.02.04 The system shall not be shipped without approval of Employer in writing.
1.02.05 Upon successful completion of Authorisation-To-Ship Test, the Employer will provide
the Contractor with a written authorisation for shipment of the system equipment to
the project site.
1.02.06 All final documentation as per requirement of this specification shall be available at
the time of Authorisation-To-Ship-Test and this shall be dispatched alongwith the
equipment in required number of copies.
1.02.07 Contractor shall note that no payments towards dispatch of equipment and
subsequent activities shall be due and payable to the Contractor till the Contractor is
able to successfully demonstrate to Employers satisfaction that the DDCMIS and
parts thereof fully meet the Authorisiation-To-Ship Test requirements.
CLAUSE NO.

QUALITY ASSURANCE

STAGE-II (2X660 MW)
SECTION-VI
PART-B
E-23
DDCMIS
PAGE
8 OF 10

DISTRIBUTED DIGITAL CONTROL MONITORING & INFORMATION SYSTEM
(DDCMIS)
TESTS

ITEMS
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DDCMIS
Integrated
System
Y Y Y Y Y Y Y
DDCMIS
CUBICLES
Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y
MMI

Y Y Y Y Y Y Y Y Y Y Y Y Y Y
Master Clock

Programmer
Station
Y Y Y Y
Peripherals

Y Y
Sequence of
Event
Y Y Y
R-Routine Test A- Acceptance Test Y Test applicable
Note: 1) Detailed procedure of Environmental Stress Screening test shall be as per
Quality Assurance Programme in General Technical Conditions.

2) This is an indicative list of tests/checks. The manufacturer is to furnish a
detailed quality plan indicating the Practices and Procedure adopted
alongwith relevant supporting documents.

CLAUSE NO.

QUALITY ASSURANCE

STAGE-II (2X660 MW)
SECTION-VI
PART-B
E-23
DDCMIS
PAGE
9 OF 10

(DDCMIS)
TESTS

ITEMS

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DDCMIS

Integrated
System
Y Y Y Y Y Y
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CUBICLES
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MMI

Master Clock

Y Y Y Y Y
Programmer
Station
Y Y Y
Peripherals

Y Y Y
Large video
screen
Y Y Y Y Y Y
Note: 1) Detailed procedure of Environmental Stress Screening test shall be as
per Quality Assurance Programme in General Technical Conditions.

detailed quality plan indicating the Practices and Procedure adopted

CLAUSE NO.

QUALITY ASSURANCE

STAGE-II (2X660 MW)
SECTION-VI
PART-B
E-23
DDCMIS
PAGE
10 OF 10

(DDCMIS)
TESTS

ITEMS

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System
Y Y Y Y Y Y Y Y Y Y Y Y Y Y
CLCS & OLCS

Y Y Y Y Y Y Y Y
MMI

Master Clock

Y Y
Programmer
Station
Y Y
Note: 1) Detailed procedure of Environmental Stress Screening test shall be as
per Quality Assurance Programme in General Technical Conditions.

2) This is an indicative list of tests/checks. The manufacturer is to furnish
a detailed quality plan indicating the Practices and Procedure adopted

SECTION-VI
PART-B
E - 24
MAIN EQUIPMENT RELATED CONTROL
AND INSTRUMENTATION SYSTEM
QUALITY ASSURANCE
E-24
MAIN EQP
INST SYS
PAGE
1 OF 1
CLAUSE NO.
SECTION-VI
PART-B
MAIN EQUIPMENT RELATED CONTROL AND
TG RELATED SPECIFIC INSTRUMENTATION & CONTROL
TESTS
ITEMS
TURBO SUPERVISORY/VIBRATION
MONITORING SYSTEM
Proximeter Y Y
Accelerometer Y Y
LVDT Y
Monitor Y Y*
Overal system Y Y Y Y Y
R-Routine Test A- Acceptance Test Y - Test applicable
Note: 1) Detailed procedure of Enviromental Stress Screening test shall be as per Quality
Assurance Programme in General Technical Conditions
2) This is an indicative list of tests/checks. The manufacturer is to furnish a detailed
quality plan indicating the Practices and Procedure adopted along with relevant
* applicable for monitor electronics.
L
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(
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SECTION-VI
PART-B
E - 25
(PRIMARY AND SECONDARY)
QUALITY ASSURANCE
E-25
MEAS. INST.
PAGE
1 OF 2
CLAUSE NO.
SECTION-VI
PART-B
MEASURING INSTRUMENTS (PRIMARY AND SECONDARY)
TESTS
ITEMS
1. PR Gauge (IS-3624) Y Y Y Y Y
2. Temp. Gauge (BS-5235) Y Y Y Y Y
3. Pr./D.P.Switch(BS-6134) Y Y Y Y Y Y
4. Electronic Transmitter(IEC-770) Y Y Y Y Y Y
5. Temp. Switch Y Y Y Y Y Y
6. Recorder(IS-9319/ANSI C-39.4) Y Y Y Y Y Y
7. Vertical indicators Y Y Y Y Y
8. Digital Indicators Y Y Y Y Y
9. Integrators Y Y Y Y
10. Electrical Metering Instrument
(IS-1248) Y Y Y Y Y Y
11. Transducer (IEC-688) Y Y Y Y Y Y
12. Thermocouples (ANSI-MC-96.1) Y Y Y Y Y Y
13. RTD (IEC-751) Y Y Y Y Y Y
14. Thermowell Y Y Y Y Y
Note: 1) Detailed procedure of Environmental Stress screening test shall be as per Quality
quality plan indicating the Practices and Procedure adopted alongwith relevant
D
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QUALITY ASSURANCE
E-25
MEAS. INST.
PAGE
2 OF 2
CLAUSE NO.
SECTION-VI
PART-B
TESTS
ITEMS
15. Cold junction compensation Y Y Y Y Y
box
16. Orifice plate (BS-1042) Y Y Y Y* Y Y** Y** Y Y** Y
17. Flow nozzle (BS-1042) Y Y Y Y* Y Y Y Y Y Y
18. Impact head type element Y Y Y Y Y
19. Level transmitter/float type Y Y Y Y Y Y Y Y
switch
20. Flue Gas analyser Y Y Y Y
21. Dust emission monitors Y Y Y Y
* Calibration to be carried out on
one flow element of each type
and size if calibration carried
out as type test same shall not
be repeated.
** If applicable
Note: 1) Detailed procedure of Environmental Stress screening test shall be as per Quality
D
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(
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SECTION-VI
PART-B
E - 26
POWER SUPPLY SYSTEM
QUALITY ASSURANCE
E-26
POWER SUPPLY
PAGE
1 OF 2
CLAUSE NO.
SECTION-VI
PART-B
ELECTRIC POWER SUPPLY SYSTEM
ATTRIBUTRES/
CHARACTERISTICS
ITEMS/COMPONENTS
SUB-ASSEMBLY
BATTARY CHARGER
Rectifier Transformer (IS:2026) Y Y Y Y
Electronic Components Y Y
including Potentiometer
(Vernier Type)
PCB & Electronic Cards Y Y
19" standard racks for Y Y
electronic cards
Control & Selector Switches Y Y Y
(IS : 6875)
Indicating Meters (IS : 1248 ) Y Y Y
Indicating Lamps (IS: 13947) Y Y Y
Air Break Switches / Fuses Y Y Y
(IS : 13947 / 13703)
Control Terminal Blocks Y Y
(IS :13947)
Control Transformer Y Y Y
(IS : 12021)
Push Buttons (IS : 4794) Y Y Y
MCB (IS : 8828) Y Y Y
PVC insulated Copper control Y Y
wires (IS : 694)
Sheet Steel (IS : 513) Y Y Y Y
Synthetic Rubber Gaskets Y Y Y
Annunciator Y Y Y
Battery Charger Y Y Y Y Y Y Y Y Y
Not es: 1. Detailed procedure of Enviromental Stress Screening test shall be as per Quality Assurance
Programme in General Technical Conditions
2. This is an indicative list of tests / checks. The manufacturer is to furnish a detailed Quality
Plan indicating the Practice and procedure along with relevant supporting documents.
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.
QUALITY ASSURANCE
E-26
POWER SUPPLY
PAGE
2 OF 2
CLAUSE NO.
SECTION-VI
PART-B
POWER SUPPLY SYSTEM
TESTS
ITEMS
UPS/CONVERTER
(IEC-146 PT-4) Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y
VOLTAGE STABILISER Y Y Y Y Y Y Y Y
LEAD ACID BATTERY
(TUBLAR)-IS-1651 Y
LEAD ACID BATTERY
(PLANTE)-IS-1652 Y
NICKEL CADMIUM BATTERY
(IS-10918/IEC-623) Y
* Transfer time and Over shoot /under shoot during load & system transfer shall be recorded.
Quality Assurance Programme in General Technical Conditions
V
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(
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&
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SECTION-VI
PART-B
E - 27
PROCESS CONNECTION AND PIPING
QUALITY ASSURANCE
E-27
PCP
PAGE
1 OF 1
CLAUSE NO.
SECTION-VI
PART-B
P
R
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S

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V i s u a l
G A , B O M , L a y o u t o f c o m p o n e n t
& c o n s t r u c t i o n f e a t u r e
D i m e n s i o n
P a i n t S h a d e / t h i c k n e s s
F l a t t e n i n g , f l a r i n g , h y d r o t e s t , h a r d n e s s
c h e c k a s p e r A S T M s t a n d a r d ( A )
C o m p o n e n t R a t i n g s
W i r i n g
M a k e , M o d e l , T y p e , R a t i n g
I R & H V
R e v i e w o f T C f o r
i n s t r u m e n t / d e v i c e s ( R )
A c c e s s a b i l i t y o f T B s / D e v i c e s
I l l u m i n a t i o n , g r o u n d i n g
T u b i n g
L e a k / H y d r o t e s t ( A )
C h e m i c a l / p h y s i c a l p r o p e r t i e s o f m a t e r i a l ( A )
P r o o f p r e s s u r e t e s t , D i s m a n t l i n g & r e a s s e m b l y
t e s t , H y d r u l i c i m p u l s e a n d v i b r a t i o n t e s t ( R )
T e s t s a s p e r s t a n d a r d s & s p e c i f i c a t i o n
SECTION-VI
PART-B
E - 28
INSTRUMENTATION CABLES
CLAUSE NO.
QUALITY ASSURANCE

STAGE II (2X660 MW)
SECTION-VI
PART-B
E-28
INSTRUMENTATION
CABLES
PAGE
1 OF 1

INSTRUMENTATION CABLE
TESTS

ITEMS

C
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1. Instrument cable
twisted and shielded

Conductor(IS-8130) Y Y Y
Insulation(VDE-207) Y Y Y Y Y Y
Pairing/Twisting Y Y Y
Shielding Y Y Y
Drain wire Y Y Y Y Y
Inner Sheath Y Y Y Y Y Y
Outer Sheath Y Y Y Y Y Y
Over all cable Y Y Y Y Y Y Y Y Y
Cable Drums(IS-
10418)
Y Y
Note : High Temp. cables shall be subjected to tests as per VDE-207(Part-6) Compensating
cables shall be checked for Thermal EMF/Endurance test as per IS 8784.
Note : This is an indicative list of tests/checks. The manufacture is to furnish a detailed Quality
Plan indicating his practice & Procedure along with relevant supporting documents during QP
finalization for all items.
Note : - Routine Test A - Acceptance Test Y - Test Applicable
Note : Sampling Plan for Acceptance test shall be as per IS 8784 (As applicable)
* FRLS Tests: Oxygen / Temp Index ( ASTM D-2863), Smoke Density Rating ( ASTM D
2843), HCL Emission ( IEC-754-1)
** Characterisitic Impedence, Attenuation, Mutual Capacitance, Cross Talk ( As applicable)
+ Sample size will be One No. of each size/type per lot.
++Sample size will be One No. sample for complete lot offered irrespective of size/type.

SECTION-VI
PART-B
E - 29
CONTROL VALVES
QUALITY ASSURANCE
E-29
CONTROL VALVES
AND ACTUATORS
PAGE
1 OF 1
CLAUSE NO.
SECTION-VI
PART-B
CONTROL VALVES AND ACTUATORS
CONTROL VALVE ACTUATORS AND ACCESSOIRES
TESTS
ITEMS
CONTROL VALVE AND
ACTUATOR
Overall Y Y Y Y Y Y Y Y Y
Body Y Y Y Y Y Y Y
Bonnet Y Y Y Y
Trim Y Y Y*
Pneumatic actuator Y Y Y
R- Routine Test A - Acceptance Test Y - Test Applicable
Y* - UT on spindle dia >= 40 mm.
Note : 1) Detailed procedure of Environmental Stress Screening test shall be as per
Quality Assurance Programme General Technical Conditions
2) This is an indicative list of tests/checks. The manufacture is to furnish a detailed
Quality Plan indicating his practice & Procedure along with relevant supporting
documents during QP finalisation for all item.
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SECTION-VI
PART-B
E - 30
ELECTRIC ACTUATORS
QUALITY ASSURANCE
E-30
ELECTRIC
ACTUATOR
PAGE
1 OF 1
CLAUSE NO.
SECTION-VI
PART-B
ELECTRICAL ACTUATORS WITH INTEGRAL STARTER
TEST/ATTRIBUTES
CHARACTERISTICS
ITEM/COPONENT/
SUB SYSTEM
ASSEMBLY/TESTING
ELECTRICAL ACTUATOR
WITH INTEGRAL
STARTER(IS-9334)
Motor Y Y Y Y Y
Final Testing Y Y Y Y Y Y Y Y Y Y Y Y Y
Note: 1) Detailed procedure of Environmental Stress Screeing test shall be as per Quality
quality plan indicating the practices and procedure adopted along with relevant
- Routine Test (A) - Acceptance Test Y - Test applicable
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SECTION-VI
PART-B
E - 31
AUXILIARY PLANT CONTROL
QUALITY ASSURANCE
E-31
AUX. PLANT
CTRL
PAGE
1 OF 3
CLAUSE NO.
SECTION-VI
PART-B
C
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V i s u a l
G A , B O M , L a y O u t o f c o m p o n e n t s
D i m e n s i o n s
P a i n t S h a d e / T h i c k n e s s / A d h e s i o n
A l i g n m e n t o f S e c t i o n
C o m p o n e n t R a t i n g / M a k e / T y p e
W i r i n g
I R & H V
R e v i e w o f T C f o r i n s t r u m e n t s / D e v i c e s / R e c o r d e r s ,
I n d i c a t o r s / M o s a i c I t e m s / T r a n s d u c e r s
A c c e s s i b i l i t y o f T B S / D e v i c e s
I l l u m i n a t i o n
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T e s t a s p e r I E C 1 1 3 1 *
T e s t a s p e r S t d & ( A )
QUALITY ASSURANCE
E-31
AUX. PLANT
CTRL
PAGE
2 OF 3
CLAUSE NO.
SECTION-VI
PART-B
ATTRIBUTES/
CHARACTERISTICS
ITEMS/COMPONENTS/
SUB-ASSEMBLY
BATTARY CHARGER
Rectifier Transformer
(IS:2026) Y Y Y Y
Electronic Components
including Potentiometer
(Vernier Type) Y Y
PCB & Electronic Cards Y Y
19" standard racks for
electronic cards Y Y
Control & Selector Switches
(IS : 6875) Y Y Y
Indicating Meters (IS : 1248 ) Y Y Y
Indicating Lamps (IS: 13947) Y Y Y
Air Break Switches / Fuses
(IS : 13947 / 13703 ) Y Y Y
Control Terminal Blocks
(IS :13947) Y Y
Control Transformer
(IS : 12021) Y Y Y
Push Buttons (IS:4794) Y Y Y
MCB (IS : 8828) Y Y Y
PVC insulated Copper
control wires (IS : 694 ) Y Y
Sheet Steel ( IS : 513 ) Y Y Y Y
Synthetic Rubber Gaskets Y Y Y
Annunciator Y Y Y
Battery Charger Y Y Y Y Y Y Y Y Y
Notes: 1. Detailed procedure of Environmental Stress Screening test shall be as per
2. This is an indicative list of tests / checks. The manufacturer is to furnish a
detailed Quality Plan indicating the Practice and procedure along with relevant
M
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.
QUALITY ASSURANCE
E-31
AUX. PLANT
CTRL
PAGE
3 OF 3
CLAUSE NO.
SECTION-VI
PART-B
POWER SUPPLY SYSTEM
TEST
ITEMS
UPS/CONVERTER
(IEC-146 PT-4) Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y
VOLTAGE STABILISER Y Y Y Y Y Y Y Y
LEAD ACID BATTERY
(TUBLAR)-IS-1651 Y
LEAD ACID BATTERY
(PLANTE)-IS-1652 Y
NICKEL CADMIUM
BATTERY
(IS-10918/IEC-623) Y
* Transfer time and Over shoot /under shoot during load & system transfer shall be
recorded.
detailed quality plan indicating the Practices and Procedure adopted alongwith
relevant supporting documents.
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(
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SECTION-VI
PART-B
PRE-COMMISSIONING AND
COMMISSIONING

CLAUSE NO.


STAGE II (2X660 MW)

SECTION-VI

PART-B
PRE-COMMISSIONING
AND COMMISSIONING
PAGE 1 OF 22

PRE-COMMISSIONING ACTIVITIES, COMMISSIONING OF FACILITIES AND INITIAL
OPERATIONS
1.00.00 GENERAL
1.01.00 The pre-commissioning and commissioning activities including Guarantee tests, checks and
initial operations of the equipment furnished and installed by the Contractor shall be the
responsibility of the Contractor as detailed in relevant clauses in Technical Specification. The
Contractor shall provide, in addition, test instruments, calibrating devices, etc. and labour
required for successful performance of these operations. If it is anticipated that the above
test may prolong for a long time, the Contractor's workmen required for the above test shall
always be present at Site during such operations.
1.02.00 It shall be the responsibility of the Contractor to provide all necessary temporary
instrumentation and other measuring devices required during start-up and initial operation of
the equipment systems which are installed by him. The Contractor shall also be responsible
for flushing & initial filling of all oils & lubricants required for the equipment furnished and
installed by him so as to make such equipment ready for operation. The Contractor shall be
responsible for supplying such flushing oil and other lubricants unless otherwise specified
elsewhere in these specifications & documents.
1.03.00 The Contractor upon completion of installation of equipments and systems, shall conduct
precommissioning and commissioning activities, to make the facilities ready for sustained
safe, reliable and efficient operation. All precommissioning/ commissioning activities
considered essential for such readiness of the facilities including those mutually agreed and
included in the Contractors quality assurance programme as well as those indicated in
clauses elsewhere in the technical specifications shall be performed by the Contractor.
2.00.00 TESTING / COMMISSIONING SCHEDULE
The Contractor shall submit to the Employer, his testing/ commissioning schedules for
various equipments/ systems covered under the contract, for approval, at least 18 months
before the actual commissioning of the equipment/ systems.
The testing/ commissioning schedule is required to be of a standard format in order to
maintain consistency of presentation, content and reporting. The list of documents and
commissioning checks to be submitted and their content details shall be agreed upon during
preaward discussions.
The list of model commissioning documents viz. standard checklists, testing/ commissioning
schedules, commissioning tests and checks and the details regarding contents of testing/
commissioning schedule are indicated in this chapter. These schedules are indicative only.
(i) Testing Schedules & Commissioning Schedules.
(ii) Standard Checklist of Items.
(iii) Commissioning Test and checks
(iv) Brief write-up on Contents of Testing Schedule.
Procedures/ Schedule shall be approved by the Employer.

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3.00.00 PRECOMMISSIONING & COMMISSIONING ACTIVITIES
3.01.00 General
The pre-commissioning activities including some of the important checks & tests for certain
major equipment/ systems (as a minimum) are described below, although it is the
Contractor's responsibility to draw up a detailed sequential & systematic list of checks / tests
and various activities / procedures connected with pre-commissioning of the complete
facilities with all systems, sub-systems and equipment supplied and installed by him and get
the same approved by the Employer.
3.02.00 DEMONSTRATION DURING COMMISSIONING
The following test shall be demonstrated during commissioning. Bidder has to furnish the
procedure and get the approval of employer.
3.02.01 Start-up, Loading, Unloading and Shutdown Capabilities (For Turbine Generator)
(i) Unit Start Up
Start-up time (upto full load), and loading capabilities for the Turbine Generator
together for cold start conditions (greater than 36 hours shutdown), warm start
conditions (between 8 and 36 hours shutdown) and hot start conditions (less than 8
hours shutdown) as indicated by the Contractor in the offer and accepted by the
EMPLOYER shall be demonstrated, ensuring that the various turbine operational
parameters like vibration, absolute and differential expansion, eccentricity and
steam-metal temperature mismatch etc. are within design limits.
(ii) Sudden Total Loss of External Load
On occasions, the steam turbine generator unit may experience sudden total loss of
all external load. Under these conditions, the steam turbine generator unit shall not
trip for reasons attributable to the contractor but shall continue to be in operation
under the control of its speed governor to supply power for the plant auxiliary load
with HP-LP bypass in operation while staying within the agreed limits of steam to
metal temperature mismatch, exhaust hood temperature, absolute and differential
expansion, vibration and eccentricity. The same shall be demonstrated. Further, the
provisions of Part-B, Section-VI, shall also be complied with.
(iii) Steam Metal Temperature Mismatch Limitation
The steam-metal temperature differential for cold, warm and hot start up , loading /
unloading and shutdown conditions shall be within the permissible limits indicated by
the Bidder in the offer and accepted by the Employer.
3.02.02 Turbine Generator Set Capability
The steam turbine generator unit shall be capable of delivering at generator terminals the
output as indicated by the BIDDER in the heat balances submitted alongwith his bid, under
the following conditions.
(a) Maximum continuous output at generator terminals corresponding to both strings of
HP heaters out of operation, under rated steam conditions, at a condenser pressure
of 77 mm of Hg (Abs) and 3% make up.
NOTE: While conducting the tests of (a) above the condenser pressure measurement shall
be done at 300mm above the top row of condenser tubes.

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3.02.03 Turbine Auxiliaries
(i) H.P./L.P. Bypass Capabilities
The HP & LP Bypass system should satisfy the following functional requirements
under automatic interlock action. It should come into operation automatically under
the following conditions :
(a) Generator circuit breaker opening.
(b) HP - IP stop valves closing due to turbine tripping.
(c) Sudden reduction in demand to house load.
Under all these conditions, while passing the required steam flows as per the
relevant heat balances, the condenser should be able to swallow the entire steam
without increasing the exhaust hood temperature and condenser pressure beyond
the maximum permissible value indicated by the BIDDER in his offer and accepted
by the EMPLOYER. The same shall be demonstrated.
(ii) Steam Condensing Plant for main turbine
(a) Temperature of condensate, at outlet of condenser, shall not be less than
saturation temperature corresponding to the condenser pressure at all loads.
(b) Oxygen content in condensate, at hotwell outlet, shall not exceed 0.015 CC
per litre over the entire load range and shall be determined according to
calorimetric Indigo - Carmine method.
(c) Air leakage in the condenser under full load condition shall not exceed more
than 50% of design value taken for sizing the condenser air evacuation
system.
(d) When one half of the condenser is isolated, condenser shall be capable of
taking at least 60% T.G. load under EMCR conditions.
(e) The capacity of each vacuum pump in free dry air under standard conditions
at a condenser pressure of 25.4 mm Hg (abs) and sub cooled to 4.17 deg.C
below the temperature corresponding to absolute suction pressure shall not
be less than 30 SCFM. Correction curves for establishing the capacity at site
conditions shall also be furnished.
(f) The air and vapour mixture from air cooling zone of condenser shall be 4.17
deg.C below the saturation temperature corresponding to 25.4 mm Hg (abs)
suction pressure. Correction curves for establishing the same at site

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(iii) Steam Condensing Plant for drive turbine condenser (if envisaged)
(a) Temperature of condensate, at outlet of condenser, shall not be less than
saturation temperature corresponding to the condenser pressure at all loads.
(b) Air leakage in the condenser under full load condition shall not exceed more
than 50% of design value taken for sizing the condenser air evacuation
system.
(c) The capacity of each vacuum pump in free dry air under standard conditions
at a condenser pressure of 25.4 mm Hg (abs) and sub cooled to 4.17 deg.C
below the temperature corresponding to absolute suction pressure shall be
demonstrated. Correction curves for establishing the capacity at site
(d) The air and vapour mixture from air cooling zone of condenser shall be 4.17
deg.C below the saturation temperature corresponding to 25.4 mm Hg (abs)
suction pressure. Correction curves for establishing the same at site
(iv) Feed water heaters & Deaerator
(a) TTD's and DCA's of feed water heaters in line with 660 MW heat rate
guarantee heat balance shall be demonstrated.
(b) Difference between saturation temperature of steam entering the deaerator
and temperature of feed water leaving deaerator.
(v) Condensate Extraction Pumps
(a) Each CEP set shall be capable of delivering flow & total dynamic head
corresponding to runout point as specified.
(b) The vibration, noise level and parallel operation of any two of the three
pumps shall be demonstrated.
(vi) Drip Pumps (if envisaged)
(a) Each drip pump shall be capable of delivering flow & total dynamic head
corresponding to design point as specified.
(b) The vibration and noise level shall be demonstrated.
(vii) Boiler feed pumps
(a) Each boiler feed pump set shall be capable to deliver flow and total dynamic
head corresponding to runout point as specified elsewhere.

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(b) The vibration, noise level and parallel operation of any two of the three
pumps shall be demonstrated as per specification requirements.
(c) Cold start up / hot start up of the unit using TDBFP with motive steam from
auxiliary steam header.
3.02.04 Balance Pumps, Blowers, Fans, Compressors and rotating equipment.
a) The vibration, noise level and parallel operation, wherever applicable, of the pumps,
blowers, fans, compressors and rotating equipment shall be demonstrated.
b) Pumps, blowers, fans, compressors and rotating equipment shall be capable of
delivering flow and head corresponding to design point as specified.
3.02.05 Pre-commissioning & Commissioning acti vities requiring approval of the employer:
(a) Hydraulic Test for STG integral piping, heat exchangers, condenser tubes &
condenser, equipment cooling water system pipes and associated equipment etc.
shall be done. The hydraulic test of other piping system as per statutory requirement
and specified elsewhere shall also be carried out. All equipment needed for the tests
shall be furnished by the Contractor.
(b) Oil flushing of lube oil system, control & jacking oil system, etc. for turbines shall be
done. Entire flushing oil requirement & refilling with fresh oil and other consumables
along with flushing equipment shall be met by the Contractor.
(c) High Pressure/Low Pressure (HP/LP) bypass tests, vacuum tightness test as per
approved procedures shall be done by the Contractor after arranging & lining up of
all the necessary equipment by him.
(d) Steam blowing & chemical cleaning, as applicable of integral piping of the turbo-
generator, Low pressure piping, Power cycle piping & other piping in the scope of the
Contractor shall be done by the Contractor.
(e) Steam blowing & chemical cleaning, as applicable of integral piping of CEP sets &
other piping in the scope of the Contractor shall be done by the Contractor.
(f) All tests and activities pertaining to the CEP and its drive as per manufacturer's
recommendations and as given in the chapter and covered in the specification.
(g) Steam blowing & chemical cleaning, as applicable of integral piping of Drip Pump
sets & other piping (if applicable) in the scope of the Contractor shall be done by the
Contractor.
(h) All tests and activities pertaining to the Drip Pump and its drive (if applicable) as per
manufacturers recommendations and as given in the chapter and covered in the
specification.

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PART-B
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AND COMMISSIONING
PAGE 6 OF 22

(i) Hydraulic Test for heat exchangers and associated equipment etc. shall be done.
The hydraulic test of other piping system as per statutory requirement and specified
elsewhere shall also be carried out. All equipment needed for the tests shall be
furnished by the Contractor.
(j) Steam blowing & chemical cleaning, as applicable of integral piping of the Heaters &
other components in the scope of the Contractor shall be done by the Contractor.
(k) All tests and activities pertaining to the Heater as per manufacturer's
(l) Hydraulic test for equipments and associated system shall be done. The hydraulic
test of other piping systems as per statutory requirement and specified elsewhere
shall also be carried out. All equipment needed for test shall be furnished by the
contractor.
(m) Oil flushing of lube oil system, control & jacking oil system, for BFP sets shall be
done. Entire flushing oil requirement & refilling with fresh oil and other consumables
alongwith flushing equipment shall be met by the Contractor.
(n) Steam blowing & chemical cleaning, as applicable of integral piping of BFP sets &
other piping in the scope of the Contractor shall be done by the Contractor.
(o) All tests and activities pertaining to the BFP and its drive as per manufacturer's
(p) Hydraulic Test for all low and high pressure piping, equipment cooling water system
pipes and associated equipment etc. shall be done as per statutory requirement and
specified elsewhere shall be carried out. All equipment needed for the tests shall be
furnished by the Contractor.
(q) All tests and activities pertaining to the Generator and Excitation as per
manufacturer's recommendations and covered in the specification.
(r) All tests and activities pertaining to the Generator Auxiliaries viz Primary water
system, Seal oil system, Gas system etc., as per manufacturer's recommendations
and covered in the specification.
(q) Any other pre-commissioning checks/ tests and activities as described below and
also those mutually agreed between the Contractor & the Employer shall be
undertaken by

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PART-B
PRE-COMMISSIONING
AND COMMISSIONING
PAGE 7 OF 22

CONTROL & INSTRUMENTATION SYSTEM REQUIREMENTS
3.02.06 For STG integral controls the following requirement shall be demonstrated.
3.02.07 The offered control system shall meet the requirement of initial pressure at turbine inlet as
per the requirement of IEC-45-1 or equivalent as defined under mechanical sections of the
specification. In order to realize the stipulated process requirement of TG systems, that will
be realized by interaction with employer procured control system, Bidder will provide all
required data and necessary interfaces so that Integrated Plant operation and control can be
seamlessly realized by the employer.
3.02.08 Further the Contractor DDCMIS and Employers BOP C&I part of DDCMIS shall be properly
integrated to achieve total plant operation. All required interfacing requirements shall be
provided by the Contractor for enabling this integration of the total plant C&I and achieving
the performance requirements. Tests in this regard shall be carried out at site by the
Employer to verify the integrated performance of the total plant C&I. In case during these
tests or otherwise it is observed that the behaviour/response of Contractor's system (drives
actuators/valves etc.) is not satisfactory/acts as a limitation/restriction in achieving the
permissible limits, the Contractor shall carry out all required modifications, rectification etc. in
his systems without any price repercussions whatsoever so that the permissible limits can be
achieved. Contractor shall depute his experts for associating in the above tests and also for
carrying out the necessary modifications, rectification etc. in Contractor's equipment and
Control systems.
3.02.09 In case the Contractor feels that some specific requirements are to be met by the BOP C&I
contractors, then the same has to be clearly brought out in the offer. (For example the loop
reaction time is specified as 500 millisec. in BOP C&I specification).
3.02.10 Contractor shall meet system performance and parametric requirement follows -
3.02.11 On the bidders supplied DDCMIS system, the following parametric tests shall also be
conducted under worst case loading conditions (details of worst case loading shall be as
agreed during detailed engineering.)
(i) For control system
- CPU loading, Cycle time/controller reaction time
(ii) For MMIPIS
- CPU loading, spare duty cycle, Memory Spare Capacity (if applicable as per
standard practice of bidder)
(iii) Spare duty cycle for system bus (if applicable as per standard practice of bidder)

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AND COMMISSIONING
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(iv) Various display response time
(v) System accuracy
(vi) Display update time
3.02.12 For the parametric test, the following requirements shall be met
(i) Processor Spare Duty Cycle (Free Time)
- Under worst case loading of MMIPIS and system bus each MMIPIS
processor shall have 40% free time when measured over any two second
period and 50% free time when measured over any one minute period. (if
applicable as per standard practice of bidder)
- Under worst case loading conditions of control system, control system
processor shall have 20% free time when measured over any one minute
period.
- The Bidder shall furnish all necessary data to fully satisfy the Employer that
the processor spare duty cycle figures quoted by the Bidder are realistic and
based on configuration and computation capability of the offered system and
these shall be actually achieved in the fully implemented system as
commissioned at project site.
System Bus Spare Duty Cycle (Free Time) (ii)
The system bus shall have min. 50% free time during the worst case loading
conditions of control system, MMIPIS and the system Bus, measured over any 2
seconds interval. (if applicable as per standard practice of bidder)
(iii) Response Time
(a) Display:
The time from mouse click or last button pressed to the commencement of the
requested display under the worst case loading conditions shall not be worse than
the following:
All control related displays 2 sec

Point Details Display(single point) 1-2 secs

Bar chart display (20 points, current data) 2-3 secs.

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Operator guide/plant start-up guide message display
(full screen of alphanumeric information and a
maximum of ten numbers of dynamic data items)
1-2 secs.

Plant mimic display of fair complexity with a minimum
of 120 numbers of dynamic data items e.g., values,
macros, line segment, etc.
2-3 secs.

Group review display (current values of twenty points) 2-3 secs.

X-Y plot display (2 X-Y- plots and a single display
requiring both historical as well as current data)
3-4 secs.

X-T plot display (Trend of 6 analog points and a single
display requiring both historical as well as current
data)
3-4 secs.

Plant Summary display (e.g., bad point summary, limit
check removed point summary. Assume the whole
data base search is required and the summary display
contains ten points only).
3-4 secs.
(b) Command:
The response time for screen update, after the execution of the control command,
from the time the command is issued (for example command to start a motor to the
time the screen is updated) shall be within two seconds (excluding the drive
actuation time).
(iv) System Accuracy Requirements
The overall system accuracy from signal input terminals to output presentation on
display and printers shall meet process requirement as agreed during detailed
engineering.
(v) Display Updated Rates
All displays shall be updated at least every two seconds.

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3.03.00 LIST OF TEST / ACTIVITIES TO BE PERFORMED ON TG & AUXILIARY
(BUT NOT LIMITED TO THE FOLLOWING)
A) TESTING SCHEDULES
1. TURBINE ON BARRING GEAR
2. BEARING AND J ACKING OIL INITIAL CIRCULATION
3. HP BYPASS SYSTEM
4. LP BYPASS SYSTEM
5. GOVERNOR OIL CONTROL SYSTEM
6. VACUUM RAISING PLANT
7. CONDENSER & COLTCS SYSTEM
8. CENTRAL OIL PURIFICATION PLANT
9. HYDRAULIC TEST PROCEUDRE FOR
A) LUB OIL SYSTEM
B) CONTROL OIL & J ACKING OIL SYSTEM
C) GENERATOR SEAL OIL SYSTEM
D) GENERATOR STATOR WATER SYSTEM
E) GENERATOR GAS SYSTEM (Alternatively, pneumatic test with
suitable leak detection method shall also be acceptable subject to
owners approval)
F) HEATERS
10. OIL FLUSHING OF LUB OIL SYSTEM
11. OIL FLUSHING OF CONTROL & J ACKING OIL SYSTEM
12. OIL FLUSHING OF GENERATOR SEAL OIL SYSTEM
13. ALKALI FLUSHING FOR CONDENSATE SYSTEM
14. HP/ LP BYPASS SYSTEM
15. CONDENSER FLOOD TEST
16. CONDENSER VACUUM TIGHTNESS TEST
17. STEAM BLOWING OF GLAND SEAL PIPE LINES, AUX. STEAM PIPELINE

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18. CEP
19. Drip Pump (if applicable)
20. HEATER
21. DEAERATOR
22. BFP
23. BEARING AND J ACKING OIL INITIAL CIRCULATION
24. GOVERNOR OIL CONTROL SYSTEM
25. HYDRAULIC TEST PROCEDURE FOR
A) LUB OIL SYSTEM
B) CONTROL OIL & J ACKING OIL SYSTEM
C) WATER SYSTEM
D) HEAT EXCHANGERS
26. OIL FLUSHING OF LUB OIL SYSTEM
27. OIL FLUSHING OF CONTROL & J ACKING OIL SYSTEM
28. STEAM BLOWING OF GLAND SEAL PIPE LINES, AUX. STEAM PIPELINE
29 HT MOTORS
B) COMMISSIONING SCHEDULE
1. Turbine Gland sealing system for Main Turbine
2. HP-LP Bypass system
3. Turbine Initial Run up for Main Turbine
4. Lube Oil / Governing Oil System for Main Turbine
5. LP HEATERS
6. HP HEATERS
7. DEAERATOR STEAM OPERATION
8. Turbine Gland sealing system for BFP turbine
9. Turbine Initial Run up for BFP turbine
10. Lube Oil / Governing Oil System for BFP turbine

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11. Generator and excitation system
12. Generator seal oil system
13. Generator stator water system
14. Generator gas system
C) COMMISSIONING TESTS/CHECKS
1. Test running of all pumps
2. Condenser vacuum test, feed water heater operational tests for establishing
correct cascaded flow, heater water levels etc. & checking of all parameters
as per approved heat balance diagrams.
3. Test for HP/LP bypass valves operation & their control system.
4. Test for operation of governing control system for turbines.
5. Standard commissioning tests and procedures as per Contractor's practice
for steam turbine generator and other equipment / auxiliaries within the
Contractor's scope of work.
6. Checks on operation of all individual control loops in the turbine generator
control system.
7. Checks on correct functioning of the Turbine Protection System (TPS),
Turbine Supervisory Control System (TSCS) for main turbine, Automatic
Turbine Run-up System (ATRS), Automatic Testing of Turbine (ATT).
for CEP and other equipment / auxiliaries within the Contractor's scope of
work.
9. Checks on operation of all individual control loops in the CEP control system.
10. Standard commissioning tests and procedures as per Contractors practice
for Drip Pump (if applicable) and other equipment / auxiliaries within the
Contractors scope of work.
11. Checks on operation of all individual control loops in the Drip Pump control
(if applicable) system.
12. Feed Water Heater operational test for establishing correct cascaded flow,
heater water levels and checking of all parameters as per approved heat
balance diagram
for heaters and deaerator and other equipment / auxiliaries within the
Contractor's scope of work.

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14. Checks on operation of all individual control loops in the heater and
deaerator control system.
15. Test for operation of governing control system for BFP turbines.
for BFP and other equipment / auxiliaries within the Contractor's scope of
work.
17. Checks on operation of all individual control loops in the BFP control system.
18. Checks on correct functioning of the BFP Turbine for Turbine Protection
System (TPS), Turbine Supervisory Control System (TSCS) for main turbine,
Automatic Turbine Run-up System (ATRS), Automatic Testing of Turbine
(ATT).
19. Calibration tests of orifice, flow nozzles, instruments and control equipment
to the extent included in these specifications.
20. Checks on operation of all rotating equipments to ascertain level of noise
and vibration
21. Checks on operation of all static equipments to ascertain level of noise and
vibration
22. Standard commissioning tests and procedures as per manufacturers
practice for Generator, Excitation and its auxiliaries within the Contractors
scope of work.
3.04.00 Chemical Cleaning of Pressure Parts
Complete chemical cleaning procedure, the scheme and layout including parameters of the
pumps, size of tanks, materials of construction, the rate of consumption and total
requirements of steam and water for such cleaning process shall meet the approval of the
Employer.
The Contractor shall furnish all labour, materials such as the required chemicals and other
consumables, all equipment such as acid transfer and acid circulating pumps complete with
drive motors, acid storage and acid mixing tanks, all temporary piping, valves and specialities
and local instruments for pressure, temperature and flow measurements and any other items
needed to carry out the process. All equipment required for chemical cleaning shall be
supplied by the contractor.
The Employer will arrange to supply Raw water and Demineralised water required for the
cleaning operations at the Terminal Point's as indicated elsewhere, in the specification.
The Contractor shall take care to dispose off the used chemicals and the effluents from the
cleaning operations, after neutralisation, meeting all the statutory regulations and in a
manner acceptable to the Project Manager and which would comply with the norms of the

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State Pollution Control Board. This include construction of suitable neutralization pit,
channels, disposal equipments etc.
The Contractor shall specifically make all necessary arrangements for prevention of any fire
accidents, explosions etc. during the performance of the chemical cleaning operations.
The Contractor shall ensure that during the cleaning process the procedure adopted shall be
such as to consume minimum demineralized water.
All equipment needed for such preservation including the nitrogen cylinders, interconnecting
piping and any regulating equipment for N2 cap and other preservatives shall be provided by
the Contractor and the same shall also become the property of the Employer after completion
of the chemical cleaning.
The Contractor shall provide adequate safety and protective equipment for all his employees
and ensure that they are worn at all times of danger. Specialised treatment equipment (such
as required for first aid when using hydrofluoric acid) must be provided at the place of
handling acid. An acid cleaning report and log of each cleaning must be provided by the
Contractor to the Employer, immediately after the cleaning operation.
3.05.00 Steam Blowing
Steam blowing of various pipelines shall be carried out by the Contractor as per
requirements/scope of work of this specification. In addition if any other piping, not
specifically mentioned in the scope of the Contractor and is also required to be steam blown,
the Contractor shall also to perform steam blowing of these additional piping during steam
blowing operation.
The Contractor shall give recommended procedures, method of blowing and scheme for
steam blowing indicating clearly additional system, if any, to be cleaned by steam blowing
and furnish data/ write-up/ layouts/ drawings to that effect to the Employer for the Employer's
approval.
The Contractor shall furnish his recommendations regarding use of various test equipments
and instruments and termination/acceptance criteria for steam blowing, which in any case
shall meet the steam turbine-generator requirements.
The systems which should be ready and operational before steam blowing and are in the
scope of the Contractor shall be made ready/operational by the Contractor by the scheduled
date for starting of steam blowing.
For equipments/components installed on high pressure boiler external piping, such as
various thermowells, flow meter, control valves, HP/LP Bypass valves etc., the Contractor
shall comply with guidelines to be followed during steam blowing, with respect to removal /
blanking / replacement of such items their internals etc. by spool pieces as given by the
respective manufacturer/sub-contractor.

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Supply of all such spools (as above) and/or blanks, temporary piping and supports etc. as
required, cutting / welding / edge preparation and rewelding required for blanking, temporary
piping connection and/or for replacements by spool pieces shall be the responsibility of the
Contractor. After steam blowing removal of spool pieces & temporary piping and
reinstallation of various components, shall also be the responsibility of the Contractor.
The Contractor shall ensure successful and timely completion of steam blowing of all
systems and will render all help/services as required including:
(i) Services of test/operating personnel/supervisors.
(ii) Extending all cooperation during erection, pre-commissioning of plant and equipment
to be made ready and operational before starting steam blowing.
(iii) Extending all cooperation for interface engineering of equipments/components of
temporary system required for steam blowing operation.
(iv) Contractor's engineers shall be available for all coordination meetings arranged by
the Employer for finalising the details of temporary system for steam blowing.
3.06.00 Balance of Plant equipment & systems
All pre-commissioning tests & activities as indicated above and elsewhere in the technical
specification shall be performed by the Contractor.
3.07.00 Commissioning of Facilities
3.07.01 General
Upon completion of precommissioning activities/test the Contractor shall initiate
commissioning of facilities. During commissioning the Contractor shall carryout system
checking and reliability trials on various parts of the facilities.
Contractor shall carry out these checks/tests at site to prove to the Employer that each
equipment of the supply complies with requirements stipulated and is installed in accordance
with requirements specified. Before the plant is put into initial operation the Contractor shall
be required to conduct test to demonstrate to the Employer that each item of the plant is
capable of correctly performing the functions for which it was specified and its performance,
parameters etc. are as per the specified/approved values. These tests may be conducted
concurrently with those required under commissioning sequence.
The Contractor shall finalise the protocol of check lists, after erection of the system and
equipment, as per International Codes/Standard with the Employer.
The Contractor shall furnish requisite no. of copies of procedures and list of start up,
precommissioning, commissioning and initial operation tests for Employer's approval.

CLAUSE NO.


STAGE II (2X660 MW)

SECTION-VI

PART-B
PRE-COMMISSIONING
AND COMMISSIONING
PAGE 16 OF 22

The Contractor shall also demonstrate the performance of all C&I equipment, the tests on
main equipment or prior to that as the case may be.
Other tests shall be conducted, if required by the Employer, to establish that the plant
equipments are in accordance with requirements of the specifications.
4.00.00 Initial Operation
Upon completion of system checking/tests as per clause 4.01.00 and 4.02.00 above and as a
part of commissioning of facilities, complete plant/facilities shall be put on initial operation for
a period of thirty (30) days or 720 hours as stipulated in General Technical Requirements.
5.00.00 The Contractor shall conduct all the commissioning tests and undertake commissioning
activities pertaining to all other auxiliaries and equipments including all Electrical & C&I
equipment/systems not specifically brought out above but are within the scope of work and
facilities being supplied & installed by the Contractor and follow the guidelines indicated
above or elsewhere in these technical specifications (Section-VI).
6.00.00 COMMISSIONING SPARES
6.01.00 It will be the responsibility of the Contractor to provide all commissioning spares including
consumable spares required for initial operation till the Completion of Facilities. The
Contractor shall furnish a list of all commission-ing spares within 60 days from the date of
Notification of Award and such list shall be reviewed by the Employer and mutually agreed to.
However. such review and agreement will not absolve the Contractor of his responsibilities
to supply all commissioning spares so that initial operation do not suffer for want of
commissioning spares. All commissioning spares shall be deemed to be included in the
scope of the Contract at no extra cost to the Employer.
6.02.00 These spare will be received and stored by the Contractor atleast 3 months prior to the
schedule date of commencement of initial operation of the respective equipment and utilised
as and when required. The unutilised spares and replaced parts, if any, at the end of
successful completion of guarantee tests shall be the property of the Contractor and he will
be allowed to take these parts back at his own cost with the permission of Employer.

CLAUSE NO.


STAGE II (2X660 MW)

SECTION-VI

PART-B
PRE-COMMISSIONING
AND COMMISSIONING
PAGE 17 OF 22

7.00.00 STANDARD CHECKLIST
7.01.00 MECHANICAL
7.01.01 COMMISSIONING/ TESTING ESSENTIAL PRE-REQUISITE
A) VALVES
1. MANUALLY OPERATED VALVE
2. ELECTRICALLY OPERATED VALVE
3. PNEUMATICALLY ACTUATED VALVE
4. HYDRAULICALLY ACTUATED VALVE
5. SAFETY VALVE
6. ELECTROMATIC RELIEF VALVE
7. STEAM TRAP
8. BUTTERFLY VALVE (ELECTRICALLY OPERATED)
9. BUTTERFLY VALVE (MANUALLY OPERATED)
10. BUTTERFLY VALVE (FOUR WAY - ELECTRICAL)
11. NON-RETURN VALVE (INCLUDING HYDRAULIC/PNEUMATIC QCNRVS)
12. THREE WAY CONTROL VALVE
13. RELIEF VALVE
14. DIFFERENTIAL PRESSURE REGULATING VALVE
15. FLOAT OPERATED VALVES
B) TANKS AND PRESSURE VESSELS
1. TANKS (METAL) UPTO 20 M
3
2. TANKS (LARGE STORAGE)
3. PRESSURE VESSEL (BELOW 17 BARS)
4. AIR RECEIVER
5. PRESSURE VESSEL - ACCESS DOOR
C) PUMPS
1. PUMP - LOW PRESSURE CENTRIFUGAL
(MOTOR DRIVEN)

CLAUSE NO.


STAGE II (2X660 MW)

SECTION-VI

PART-B
PRE-COMMISSIONING
AND COMMISSIONING
PAGE 18 OF 22

2. PUMP - UPTO 350 HP (260 KW)
3. PUMP - SUMP INSTALLATION
4. GEAR PUMP/ SCREW PUMP
D) PIPE WORK SYSTEM
1. STEAM SERVICES
2. WATER SERVICES
3. OIL/ FIRE RESISTANT FLUID SYSTEM
4. AIR SERVICES (COMPRESSOR)
5. HIGH PRESSURE SERVICES
6. CONSTANT LOAD SUPPORT
7. SPRING SUPPORTS
8. PF COAL
9. HANGERS AND OTHER SUPPORTS
E) STRAINER AND FILTER
1. STRAINER/ FILTER BASKET TYPE
2. STRAINER ROTARY (LOW PRESSURE)
3. FILTER & STRAINERS CENTRIFUGAL SEPARATORS
4. FILTER & STRAINER Y-TYPE
5. FILTER & STRAINER (PLATE TYPE)
6. PURIFIER
7. FILTER - COMPRESSED AIR LINE
F) HEAT EXCHANGER
1. HEAT EXCHANGER (GENERAL)
2. HEAT EXCHANGER - OIL/ WATER
3. ROTARY AIR HEATER
G) FANS & COMPRESSORS
1. FANS - NON-PRESSURE LUBRICATED
2. FANS - AXIAL FLOW PRESSURE LUBRICATED
3. COMPRESSORS GENERAL

CLAUSE NO.


STAGE II (2X660 MW)

SECTION-VI

PART-B
PRE-COMMISSIONING
AND COMMISSIONING
PAGE 19 OF 22

H) DAMPERS & GATES
1. MANUALLY OPERATED DAMPER
2. PNEUMATICALLY OPERATED DAMPER
3. ELECTRICALLY OPERATED DAMPER
4. MANUALLY OPERATED GATES
5. PNEUMATICALLY OPERATED GATE
6. ELECTRICALLY OPERATED GATE
I) CRANES AND ELEVATORS
1. AUXILIARY OVERHEAD CRANE
2. TRAVEL SUPPORT STRUCTURE FOR CRANE
3. LONG TRAVEL & CROSS TRAVERSE MOTION OF CRANE
4. MAIN AUX. HOIST MOTION (CRANE)
5. CRANE, ELECTRIC HOIST
J) POWER TRANSMISSION
1. POWER TRANSMISSION GEAR BOX
2. BEARINGS
3. FLUID COUPLINGS
7.02.00 ELECTRICAL
1. D.C. MOTOR
2. HV SQUIRREL CAGE INDUCTION MOTOR
3. 415 V SQUIRREL CAGE INDUCTION MOTOR
4. MOTOR OPERATED ACTUATORS
5. LT SWITCHGEARS/MCC
(I.) STANDARD CHECLISTS FOR ALL TYPES OF RELAYS USED IN
SWITCHGEARS PROTECTION SYSTEM
(II.) PT CARRIAGE AND CUBICLES
(III.) CABLE/BUS DUCT/BUS BARS
(IV.) CONTRACTOR MODULE

CLAUSE NO.


STAGE II (2X660 MW)

SECTION-VI

PART-B
PRE-COMMISSIONING
AND COMMISSIONING
PAGE 20 OF 22

(V.) SWITCH FUSE MODULE
(VI.) MASTER PANEL OF LUBE OIL PANEL
(VII.) FEEDER PANEL OF LUBE OIL PANEL
(VIII.) SPACE HEATER AND CABLE MODULE
(IX.) HT CIRCUIT BREAKER
(X.) 415 V CIRCUIT BREAKER
6. POWER CABLE
7. AUXILIARY CABLE
8. D.C. CABLE
9. EXPLOSION PROOF ELECTRICAL EQUIPMENT
10. J UNCTION BOX
11. CONTROL TRANSFORMER MODULE
12. BRUSH GEAR ASSEMBLY
13. AUX. CONTROL AND RELAY PANEL DESK
14. INDICATING INSTRUMENT
15. RECORDING INSTRUMENT
16. INTEGRATING INSTRUMENT
7.03.00 CONTROL & INSTRUMENTATION
1. CONDUCTIVITY ANALYSING EQUIPMENT INCLUDING TEST PROCEDURES
2. PH ANALYSER INCLUDING TEST PROCEDURE
3. SILICA ANALYSER
4. LEVEL SWITCH (FLOAT ACTUATED)
5. LEVEL SWITCH (ELECTRODE TYPE)
6. LEVEL SWITCH DISPLACED ACTUATED)
7. TRANSMITTER (FLOAT OPERATED PNEUMATIC OUTPUT) INCLUDING
TESTING PROCEDURE
8. LEVEL INDICATOR (FLOAT/PULLEY TYPE)
9. LOCAL TEMPERATURE INDICATORS INCLUDING TEST PROCEDURE

CLAUSE NO.


STAGE II (2X660 MW)

SECTION-VI

PART-B
PRE-COMMISSIONING
AND COMMISSIONING
PAGE 21 OF 22

10. RESISTANCE THERMOMETER ELEMENT INCLUDING TEST PROCEDURE
11. THERMOCOUPLE ELEMENT AND CONNECTING CABLE
12. THERMOCOUPLE AND RESISTANCE THERMOMETER CONVERTOR/
TRANSMITTER INCLUDING TEST PROCEDURES.
13. TEMPERATURE SWITCH/THERMOSTAT INCLUDING TEST PROCEDURES
14. COLD J UNCTION BOXES
15. ZENER BARRIER
16. O2 ANALYSER
17 O2 IN HYDROGEN INCLUDING TEST PROCEDURES
18. PRESSURE AND VACUUM GAUGE
19. PRESSURE AND VACUUM SWITCH INCLUDING TEST PROCEDURE
20. DIFFERENTIAL PRESSURE TRANSMITTER INCLUDING TEST PROCEDURE
21. DIFFERENTIAL PRESSURE SWITCH INCLUDING TEST PROCEDURE.
22. FLOW INDICATOR (VARIABLE AREA)
23. ORIFICE PLATE
24 TURBINE FLOW TRANSMITTER
(A.) FLOW SWITCH
(B.) WEIR
(C.) NOZZLE
(D.) FLOW INDICATOR (PNEUMATIC INPUT) INCLUDING TEST
PROCEDURE
(E.) FLOW INTEGRATOR (PNEUMATIC INPUT) INCLUDING TEST
PROCEDURE
(F.) FLOW INDICATOR (FLOAT OPERATED) INCLUDING TEST PROCEDURE
(G.) VENTURI (FLUID)
(H.) FLOW SWITCH (MAGNETIC TYPE)
(I.) AVERAGING INLET
(J .) LIMIT SWITCHES
(K.) TURBINE SUPERVISORY MEASURING SYSTEM

CLAUSE NO.


STAGE II (2X660 MW)

SECTION-VI

PART-B
PRE-COMMISSIONING
AND COMMISSIONING
PAGE 22 OF 22

(L.) POSITION MEASUREMENT AND INDICATION INCLUDING TEST
PROCEDURES
(M.) TACHOMETER
(N.) VIBRATION MEASUREMENT
(O.) DIGITAL INDICATOR
(P.) MOVING COIL INDICATOR INCLUDING TEST PROCEDURE
(Q.) RECORDER INCLUDING TEST PROCEDURE
(R.) FLAME SCANNER
(S.) ELECTRICAL AUTO MANUAL CONTROL STATION
(T.) PUSH BUTTON MODULE
(U.) ALARM ANNUNCIATOR EQUIPMENT INCLUDING TEST PROCEDURE
(V.) TEST PROCEDURE FOR ELECTRONIC MODULES OF DDCMIS
(W.) THERMO CONTROL VALVE
(X.) TEST PROCEDURE FOR ADJ USTMENT OF MODULATING
CONTROLLER - PID TERMS
(Y.) TEST PROCEDURE INDICATING CONTROLLER-ELECTRICAL INPUT
AND PNEUMATIC OUTPUT
Note: The items which are not part of this specification may be considered as not
applicable.

STAGE-II (2X660 MW)
P PP PPAR AR AR AR ART - C T - C T - C T - C T - C
SECTION - VI
FOR
STAGE-II (2X660 MW)
P PP PPAR AR AR AR ART - C T - C T - C T - C T - C
SECTION - VI
FOR
SECTION-VI
TABLE OF CONTENTS
A Project Synopsis
A A-1 Provenness
A Essential Data
A A-2 General
A A-7 (NOT USED)
A D-1 Civil Works
A Spares
MECHANICAL
B A-2 Layout
SECTION-VI
B A-7 (NOT USED)
ELECTRICAL
B B-2 Motors
B B-7 Lighting
(DDCMIS)
SECTION-VI
CIVIL
B D-1 Civil Works
B E-10 (NOT USED)
B E-16 Motors
SECTION-VI
B E-20 Cabling
B E-21 Lighting
E TENDER DRAWING
F NOT USED
SECTION-VI
PART-C
PART - C
GENERAL TECHNICAL REQUIREMENTS
SECTION-VI
PART-C
PART - C
CONTENTS
------------------------------------------------------------------------------------------------------------------------------
Clause No. Description Page No.
------------------------------------------------------------------------------------------------------------------------------
1.00.00 Introduction 1
2.00.00 Brand Name 1
3.00.00 Base Offer & Alternate Proposals 1
4.00.00 Completeness of Facilities 1
5.00.00 Rules, Regulations, Codes & Standards 2
6.00.00 Equipment Functional Guarantee 5
7.00.00 Design of Facilities / Maintenance
& Availability Considerations 5
8.00.00 Documents, Data and Drawings to
be Furnished by Contractor 6
9.00.00 Quality Assurance Programme 23
10.00.00 Pre-commissioning and Commissioning Facilities 34
11.00.00 Guarantee Tests 37
12.00.00 Taking Over 38
13.00.00 Training of Employer's Personnel 38
14.00.00 Safety Aspects During Construction and Erection 40
15.00.00 Noise Level 40
16.00.00 Packaging and Transportation 40
17.00.00 Electrical Enclosure 41
18.00.00 Instrumentation and Control 41
SECTION-VI
PART-C
------------------------------------------------------------------------------------------------------------------------------
------------------------------------------------------------------------------------------------------------------------------
19.00.00 Electrical Noise Control 42
20.00.00 Instrument Air System 42
21.00.00 Tapping Points for Measurements 42
22.00.00 Electronic Module/Component Details (Not Used) 43
Annexure - I 44
Annexure - II 47
Annexure - III 60
Annexure - IV 61
Annexure - V 62
CLAUSE NO. GENERAL TECHNICAL REQUIREMENTS
GENERAL TECHNICAL
REQUIREMENTS
PAGE
1 OF 64
SECTION-VI
PART-C
STAGE-II (2X660 MW)
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 Employer 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 Contractor may have standardized on the use of certain components,
materials, processes or procedures different than those specified herein.
Alternate proposals offering similar equipment based on the manufacturer's
standard practice may also be considered, provided the base offer is in line
with technical specifications and such proposals meet the specified design
standards and performance requirement and are acceptable to the Employer.
Sufficient amount of information for justifying such proposals shall be furnished
to Employer alongwith the bid to enable the Employer 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 equipments furnished by the Contractor shall be complete in every respect,
with all mountings, fittings, fixtures and standard accessories normally provided
with such equipment and/or those needed for erection, completion and safe
GENERAL TECHNICAL
REQUIREMENTS
PAGE
2 OF 64
SECTION-VI
PART-C
STAGE-II (2X660 MW)
operation & maintenance of the equipment and for the safety of the operating
personnel, as required by applicable codes, though they may not have been
specifically detailed in the respective specifications, unless included in the list
of exclusions.
All same standard components/ parts of same equipment provided, shall be
interchangeable with one another.
4.03.00 For the C&I systems, the Contractor shall be required to provide regular
information about future upgrades and migration paths to the Employer.
5.00.00 RULES, REGULATIONS, 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, NTPC rules / codes of practices as well as of the locality where they
will be installed, including the following:
(a.) Indian electricity act
(b.) Indian electricity rules
(c.) Indian Explosives Act
(d.) Indian Factories Act and State Factories Act
(e) Indian Boiler Regulations (IBR)
(f.) Regulations of the Central Pollution Control Board, India
(g.) Regulations of the Ministry of Environment & Forest (MoEF),
Government of India
(h) Pollution Control Regulations of Department of Environment, Government
of India
(i.) State Pollution Control Board.
(j.) Rules for Electrical installation by Tariff Advisory Committee (TAC).
GENERAL TECHNICAL
REQUIREMENTS
PAGE
3 OF 64
SECTION-VI
PART-C
STAGE-II (2X660 MW)
(k.) Building and other construction workers (Regulation of Employment and
Conditions of services) Act, 1996
(l.) Building and other construction workers (Regulation of Employment and
Conditions of services) Central Rules, 1998
(m.) Explosive Rules, 1983
(n.) Petroleum Act, 1984
(o.) Petroleum Rules, 1976,
(p.) Gas Cylinder Rules, 1981
(q.) Static and Mobile Pressure Vessels (Unified) Rules, 1981
(r.) Workmen's Compensation Act, 1923
(s.) Workmen's Compensation Rules, 1924
(t.) NTPC Safety Rules for Construction and Erection
(u.) NTPC Safety Policy
(v.) Any other statutory codes / standards / regulations, as may be
applicable.
5.02.00 Unless covered otherwise 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) Bureau of Indian Standards (BIS)
(b.) J apanese Industrial Standards (J IS)
(c.) American National Standards Institute (ANSI)
(d.) American Society of Testing and Materials (ASTM)
(e.) American Society of Mechanical Engineers (ASME)
(f.) American Petroleum Institute (API)
GENERAL TECHNICAL
REQUIREMENTS
PAGE
4 OF 64
SECTION-VI
PART-C
STAGE-II (2X660 MW)
(g.) Standards of the Hydraulic Institute, U.S.A.
(h.) International Organisation for Standardization (ISO)
(i.) Tubular Exchanger Manufacturer's Association (TEMA)
(j.) American Welding Society (AWS)
(k.) National Electrical Manufacturers Association (NEMA)
(l.) National Fire Protection Association (NFPA)
(m.) International Electro-Technical Commission (IEC)/European Norm (EN)
(n.) Expansion J oint Manufacturers Association (EJ MA)
(o.) Heat Exchange Institute (HEI)
5.03.00 Other International/ National standards such as DIN, VDI, BS, GOST etc. shall
also be accepted for only material codes and manufacturing standards, subject
to the Employer's approval, for which the Bidder shall furnish, adequate
information to justify that these standards are equivalent or superior to the
standards 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 equipments such as Steam Turbine and
Generator, National /International standards such as J IS, 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. 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, and structural works
shall be provided by the Contractor to the Employer within two calendar
months from the date of the Notification of Award.
GENERAL TECHNICAL
REQUIREMENTS
PAGE
5 OF 64
SECTION-VI
PART-C
STAGE-II (2X660 MW)
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 Employer
shall have the option to incorporate the changed requirements or to retain the
original standard. It shall be the responsibility of the Contractor to bring to the
notice of the Employer such changes and advise Employer of the resulting
effect.
6.00.00 EQUIPMENT FUNCTIONAL GUARANTEE
6.01.00 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.
6.02.00 Liquidated damages for shortfall in meeting functional guarantee(s) during the
performance and guarantee tests shall be assessed and recovered from the
Contractor as specified elsewhere in this specification.
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 Contractor shall be responsible for the selection and design of appropriate
equipments to provide the best co-ordinated 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.
GENERAL TECHNICAL
REQUIREMENTS
PAGE
6 OF 64
SECTION-VI
PART-C
STAGE-II (2X660 MW)
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 turbine and equipments, inspection of
the steam path and the minor and major overhauls shall be specified in terms
of running hours, clearly defining the spare parts and manhour requirement for
each stage.
Lifting devices i.e. hoists and chain pulley jacks, etc. shall be provided by the
contractor for handling of any equipment or any of its part having weight in
excess of 500 Kgs during erection and maintenance activities.
Lifting devices like lifting tackles, slings, etc. to be connected to hook of the
hoist / crane shall be provided by the contractor for lifting the equipment and
accessories covered under the specification.
8.00.00 DOCUMENTS, DATA AND DRAWINGS TO BE FURNISHED BY
CONTRACTOR
8.01.00 Bidders may note that this is a contract inclusive of the scope as indicated
elsewhere in the specification. Each of the plant and equipment shall be fully
integrated, engineered and designed to perform in accordance with the
technical specification. All engineering and technical services required ensuring
a completely engineered plant shall be provided in respect of mechanical,
electrical, control & instrumentation, civil & structural works as per the scope.
Each main and auxiliary equipment/item of the plant including instruments shall
be assigned a unique tag number. The assignment of tag numbers shall be
in accordance with KKS system. In all drawings/documents/data sheet etc.
KKS tag number of the equipment/item/instrument etc. shall be indicated.
The Contractor shall furnish engineering data/drgs. in accordance with the
schedule of information as specified in Technical Specification and data sheet.
8.02.00 The number of copies/prints/CD-ROMs/manuals to be furnished for various
types of documents is given in Annexure-I
8.03.00 The documentation that shall be provided by the Contractor is indicated in the
various sections of specification. This documentation shall include but not be
limited to the following :
(a.) BASIC ENGINEERING DOCUMENTATION
Prior to commencement of the detailed engineering work, the Contractor
GENERAL TECHNICAL
REQUIREMENTS
PAGE
7 OF 64
SECTION-VI
PART-C
STAGE-II (2X660 MW)
shall furnish a Plant Definition Manual within 12 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/ equipments/ structures/ equipment foundations
alongwith 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
equipments / system covered under the scope.
viii. General Layout plan of the power station incorporating all
facilities in Contractor's as well as those in the Employer's
scope. This drawing shall also be furnished in the form of CD-
ROMs to the Employer for engineering of areas not included in
Contractor's scope.
ix. Basic layouts and cross sections of the TG building (various
floor elevations), and other areas included in the scope of the
Contractor.
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
Employer.
GENERAL TECHNICAL
REQUIREMENTS
PAGE
8 OF 64
SECTION-VI
PART-C
STAGE-II (2X660 MW)
(b) DETAILED ENGINEERING DOCUMENTS
i. General layout plan of the station.
ii. Layouts, general arrangements, elevations and cross-sections
drawings for all the equipment and facilities of the plant.
iii. Flow diagrams, Process & Instrumentation Diagrams alongwith
write-up and system description.
iv. Start-up curves for turbine, for various start-ups, viz. cold, warm
and hot start-up.
v. Piping isometric, composite layout and fabrication drawings.
vi. Piping engineering diagrams, pipe and fittings schedules, valve
schedules, hanger and support schedules, insulation schedules.
vii. Technical data sheets for all bought out and manufactured
items. Contractor shall use the NTPC specifications as a base
for placement of orders on their sub-vendors.
viii. 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.
ix. Transient, hydraulic and thermal stress analysis of piping and
system wherever applicable & input and output data alongwith
stress analysis isometrics showing nodes.
x. Thermal cycle information (heat balance diagrams, 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
Employer's facilities giving details of location, terminal pressure,
temperature, fluid handled & end connection details, forces,
moments etc.
GENERAL TECHNICAL
REQUIREMENTS
PAGE
9 OF 64
SECTION-VI
PART-C
STAGE-II (2X660 MW)
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.
xxii. Detailed DDCMIS system manuals
xxiii. Detailed flow chart for digital control system.
xxiv. Mimic diagram layout, Assignment for other application engg.
xxv. Civil & Structural works drawings and documents for all
structures, facilities, foundations, underground and overground
works and super-structural works as included in the scope of
the Bidder.
xxvi. Model study reports wherever applicable.
xxvii. Functional & guarantee test procedures and test reports.
xxviii. Documentation in respect of Quality Assurance System as listed
out elsewhere in this specification.
GENERAL TECHNICAL
REQUIREMENTS
PAGE
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xxix. Documentation in respect of commissioning as listed out
elsewhere in this specification.
xxx. The Contractor 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 Contractor shall make first submission of instruction manual for all the
equipments covered under the Contract as per agreed Engineering Information
schedule. 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 Employer 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 Employer. The Instruction Manuals shall comprise of the following.
(a.) 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 equipments like cranes, dozers, etc.
f) Bill of Materials
g) Procedure for erection.
h) General safety procedures to followed during erection/installation.
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i) Procedure for initial checking after erection.
j) Procedure for testing and acceptance norms.
k) Procedure / Check list for pre-commissioning activities.
l) Procedure / Check list for commissioning of the system.
m) Safety precautions to be followed in electrical supply distribution
during erection
(b.) 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 Employer 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 Employer.
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 Employer 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
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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 mal operation 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 Employer indicating lubrication
method for each type/category of bearing.
8.03.02 PLANT HANDBOOK
The Contractor shall submit to the Employer a preliminary plant hand book
preferably in A-4 size sheets which shall contain the design and performance
data of various plants, equipments and systems covering the complete project
including
1. Design and performance data.
2. Process & Instrumentation diagrams.
3. Single line diagrams.
4. Sequence & Protection Interlock Schemes.
5. Alarm and trip values.
6. Performance Curves.
7. General layout plan and layout of main plant building and auxiliary
buildings
8. Important Do's & Don't's
The plant handbook shall be submitted within twelve (12) months from the
date of award of contract. After the incorporation of Employer's comments, the
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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 Contractor shall submit a Project Completion Report at the time of
handing over the plant.
8.03.04 DRAWINGS
(a.) All the plant layouts shall be made in computerised 3D modelling
system. The Employer reserves the right to review the 3D model at
different stages during the progress of engineering. The layout drawings
submitted for Employer's review shall be fully dimensioned and
extracted from 3D model after interference check.
(b.) All documents submitted by the Contractor for Employer's review shall
be in electronic form (soft copies) along with the desired number of
hard copies as per Annexure-I. The soft copies shall be uploaded by
the vendors in c-folder, a web based system of NTPC ERP, for which
a username and password will be alloted to the new vendor by NTPC.
Similarly, the vendor can download the drawings / documents, approved
/ commented by NTPC , through above site.
The soft copies of identified drawings / documents shall be in pdf
format, whereas the attachements / reply to the submitted document(s)
can be in .doc, .xls, .pdf, .dwg or .std formats.
(c.) Final copies of the approved drawings alongwith requisite number of
hard copies shall be submitted as per Annexure-I.
(d.) NOT USED.
(e.) All documents/text information shall be in latest version of MS Office
and MS Excel as applicable.
(f.) All drawings submitted by the Contractor including those submitted at
the time of bid shall be in sufficient detail indicating the type, size,
arrangement, weight of each component for packing and shipment, the
external connection, fixing arrangement required, the dimensions required
for installation and interconnections with other equipments and materials,
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clearance and spaces required between various portions of equipment
and any other information specifically requested in the drawing
schedules.
(g.) Each drawing submitted by the Contractor (including those of
subvendors) shall bear a title block at the right hand bottom corner
with clear mention of the name of the Employer, the system
designation, the specifications title, the specification number, the name
of the Project, drawing number and revisions. If standard catalogue
pages are submitted the applicable items shall be indicated therein. All
titles, notings, markings and writings on the drawing shall be in English.
All the dimensions should be in metric units.
(h.) The drawings submitted by the Contractor (or their subvendors) shall
bear Employer's drawing number in addition to contractor's (their sub-
vendor's) own drawing number. Employer's drawing numbering system
shall be made available to the successful bidder so as to enable him
to assign Employer's drawing numbers to the drawings to be submitted
by him during the course of execution of the Contract.
(i.) The Contractor shall also furnish a "Master Drawing List" which shall be
finalized during post bid discussions and shall be duly integrated with
approved PERT network. Master Drawing List shall be a comprehensive
list of all drawings/ documents/ calculations envisaged to be furnished
by him during the detailed engineering to the Employer. Such list
should clearly indicate the purpose of submission of these drawings i.e.
"FOR APPROVAL" or "FOR INFORMATION ONLY".
(j.) Similarly, all the drawings/ documents submitted by the Contractor during
detailed engineering stage shall be marked "FOR APPROVAL" or "FOR
INFORMATION" prior to submission.
Further, space shall be identified on each drawing for approval stamp
and electronic signature.
(k.) The furnishing of detailed engineering data and drawings by the
Contractor shall be in accordance with the time schedule for the
project. The review of these documents/ data/ drawings by the
Employer will cover only general conformance of the data/ drawings/
documents to the specifications and contract, interfaces with the
equipments provided by others and external connections & dimensions
which might affect plant layout. The review by the Employer should
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not be construed to be a thorough review of all dimensions, quantities
and details of the equipments, materials, any devices or items indicated
or the accuracy of the information submitted. The review and/ or
approval by the Employer / Project Manager shall not relieve the
Contractor of any of his responsibilities and liabilities under this contract.
(l.) After the approval of the drawings, further work by the Contractor shall
be in strict accordance with these approved drawings and no deviation
shall be permitted without the written approval of the Employer.
(m.) All manufacturing, fabrication and execution of work in connection with
the equipment / system, prior to the approval of the drawings, shall be
at the Contractor's risk. The Contractor is expected not to make any
changes in the design of the equipment /system, once they are
approved by the Employer. However, if some changes are necessitated
in the design of the equipment/system at a later date, the Contractor
may do so, but such changes shall promptly be brought to the notice
of the Employer indicating the reasons for the change and get the
revised drawing approved again in strict conformance to the provisions
of the Technical Specification.
(n.) Drawings shall include all installations and detailed piping layout
drawings. Layout drawings for all piping of 65 mm and larger diameter
shall be submitted for review/ approval of Employer prior to erection.
Small diameter pipes shall however be routed as per site conditions in
consultation with site authority / representative of Employer based on
requirements of such piping indicated in approved / finalized Flow
Scheme / Process & Instrumentation Diagrams and/or the requirements
cropping up for draining & venting of larger diameter piping or otherwise
after their erection as per actual physical condition for the entire scope
of work of this package.
(o.) Assessing & anticipating the requirement and supply of all piping and
equipment shall be done by the contractor well in advance so as not
to hinder the progress of piping & equipment erection, subsequent
system charging and its effective draining & venting arrangement as
per site suitability.
(p.) As Built Drawings
After final acceptance of individual equipment / system by the
Employer, the Contractor will update all original drawings and
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documents for the equipment / system to "as built" conditions and
number of coppies as per Annexure-I.
(q.) Drawings must be checked by the Contractor in terms of its
completeness, data adequacy and relevance with respect to Engineering
schedule prior to submission to the Employer. In case drawings are
found to be submitted without proper endorsement for checking by the
Contractor, the same shall not be reviewed and returned to the
Contractor for re-submission. The contractor shall make a visit to site
to see the existing facilities and understand the layout completely and
collect all necessary data / drawings at site which are needed as an
input to the engineering. The contractor shall do the complete
engineering including interfacing and integration of all his equipment,
systems & facilities within his scope of work as well as interface
engineering & integration of systems, facilities, equipment & works
under Employer's scope and submit all necessary drawings/
documents for the same.
(r.) The Contractor shall submit adequate prints of drawing / data /
document for Employer's review and approval. The Employer shall
review the drawings and return soft copy to the Contractor 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 Contractor to submit/rectify and
resubmit in time shall not be accepted as a reason for delay in the
contract schedule.
(s.) All engineering data submitted by the Contractor after final process
including review and approval by the Project Manager/ Employer 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
Project Manager in writing.
8.04.00 ENGINEERING INFORMATION SUBMISSION SCHEDULE
During post bid discussions a Detailed Engineering Information Submission
Schedule / Master Drawing List duly integrated with approved PERT network
shall be tied up with the Employer. 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 /
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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 Employer
before proceeding further, and
(b.) Information that would be submitted for Employer's information only.
The Master Drawing List (MDL) shall be updated periodically and submitted to
the Employer, highlighting the changes made in the MDL.
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 The Contractor shall submit every month an Engineering progress and
Exception 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 Employer within four
(4) weeks of the award of the contract, which shall then be discussed and
finalised with the Employer.
8.06.00 TECHNICAL CO-ORDINATION MEETING
8.06.01 The Contractor shall be called upon to organise and attend monthly Design/
Technical Co-ordination Meetings (TCMs) with the Employer/Employer's
representatives and other Contractors of the Employer during the period of
contract. The Contractor shall attend such meetings at his own cost at NEW
DELHI / NOIDA or at mutually agreed venue as and when required and fully
co-operate with such persons and agencies involved during the discussions.
8.06.02 The Contractor should note that Time is the essence of the contract. In order
to expedite the early completion of engineering activities, the Contractor shall
submit all drawings as per the agreed Engineering Information Submission
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Schedule.The drawings submitted by the Contractor will be reviewed by the
Employer as far as practicable within three (3) weeks from the date of receipt
of the drawing .The comments of the Employer shall then be discussed
across the table during the above Technical Co-ordination Meeting (s) wherein
best efforts shall be made by both sides to ensure the approval of the
drawing.
8.06.03 The Contractor shall ensure availability of the concerned experts / consultants/
personnel who are empowered to take necessary decisions during these
meetings. The Contractor shall be equipped with necessary tools and facilities
so that the drawings/documents can be resubmitted after incorporating
necessary changes and approved during the meeting itself.
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 Contractor to incorporate Employer's
comments and resubmit the same during the TCM shall be considered as
a default and in no case shall entitle the Contractor to alter the Contract
completion date.
8.07.00 DESIGN IMPROVEMENTS
The Employer or the Contractor may propose changes in the specification of
the equipment or quality thereof and if the parties agree upon any such
changes the specification shall be modified accordingly.
If any such agreed upon change is such that it affects the price and schedule
of completion, the parties shall agree in writing as to the extent of any
changing the price and/or schedule of completion before the Contractor
proceeds with the change. Following such agreement, the provision thereof,
shall be deemed to have been amended accordingly.
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 Employer. 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.
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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.
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 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 Employer
alongwith 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
utilised for various components shall be those which have established
themselves for use in such applications.
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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 Employer.
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
Employer or as detailed in appropriate section of the technical specifications.
8.13.03 Such nameplates or labels shall be of white nonhygroscopic material with
engraved black lettering or alternately, in the case of indoor circuit breakers,
starters, etc. of transparent plastic material with suitably coloured lettering
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
enamel. 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 Employer's tag number
of a metal tap permanently attached to non pressure parts such as the yoke
by a stainless steel wire. The direction of flow shall also be marked on the
body.
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/cm (abs).
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(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 Contractor shall supply with the equipment one complete set of all special
tools and tackles and other instruments required for the erection, assembly,
disassembly and proper maintenance of the plant and equipment and systems
(including software). These special tools will also include special material
handling equipment, jigs and fixtures for maintenance and calibration /
readjustment, checking and measurement aids etc. A list of such tools and
tackles shall be submitted by the Bidder alongwith the offer.
The price of each tool / tackle shall be deemed to have been included in the
total bid price. These tools and tackles shall be separately packed and sent
to site. The Contractor shall also ensure that these tools and tackles are not
used by him during erection, commissioning and initial operation. For this
period the Contractor should bring his own tools and tackles. All the tools
and tackles shall be of reputed make acceptable to the Employer.
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 equipments to be performed by others the
requirements shall be submitted to the Employer in advance of
commencement of erection work.
8.16.00 COLOUR CODE FOR ALL EQUIPMENTS/ PIPINGS/ PIPE SERVICES
8.16.01 All equipment/ piping/ pipe services are to be painted by the Contractor in
accordance with Employer's standard colour coding scheme, which will be
furnished to the Contractor during detailed engineering stage.
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8.17.00 PROTECTION AND PRESERVATIVE SHOP COATING
8.18.00 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 pipings and conduit equipment connections shall be properly sealed
with suitable devices to protect them from damage. The parts which are likely
to get rusted, due to exposure to weather, should also be properly treated and
protected in a suitable manner. All primers/paints/coatings shall take into
account the hot humid, corrosive & alkaline, subsoil or overground
environment as the case may be. The requirements for painting specification
shall be complied with as detailed out in Part-A & B of the Technical
Specification.
8.19.00 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 as per the requirement covered in the
relevant part of the Technical Specification.
Transformers and other electrical equipments if included shall be shop finished
with one or more coats of primer and two coats of high grade resistance
enamel. The finished colors shall be as per manufacturer's standards, to be
selected and specified by the Employer at a later date.
8.19.01 Shop primer for all steel surfaces which will be exposed to operating
temperature below 95 degrees Celsius shall be selected by the Contractor
after obtaining specific approval of the Employer regarding the quality of primer
proposed to be applied. Special high temperature primer shall be used on
surfaces exposed to temperature higher than 95 degrees Celsius and such
primer shall also be subject to the approval of the Employer.
8.19.02 All other steel surfaces which are not to be painted shall be coated with
suitable rust preventive compound subject to the approval of the Employer.
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8.19.03 All piping shall be cleaned after shop assembly by shot blasting or other
means approved by the Employer. Lube oil piping or carbon steel shall be
pickled.
8.19.04 Painting for Civil structures shall be done as specified under technical
requirements on civil works in relevant part of this specifications.
9.00.00 QUALITY ASSURANCE PROGRAMME
9.01.00 The Contractor shall adopt suitable quality assurance programme to ensure
that the equipment and services under the scope of contract whether
manufactured or performed within the Contractor's works or at his sub-
contractor's premises or at the Employer's site or at any other place of work
are in accordance with the specifications. Such programmes shall be outlined
by the Contractor and shall be finally accepted by the Employer/authorised
representative after discussions before the award of the contract. The QA
programme shall be generally in line with ISO-9001.A quality assurance
programme of the contractor shall generally cover the following:
(a.) His organisation structure for the management and implementation of
the proposed quality assurance programme
(b.) Quality System Manual
(c.) Design Control System
(d.) Documentation and Data Control System
(e.) Qualification data for bidder's key personnel.
(f.) The procedure for purchase of materials, parts, components and
selection of sub-contractor's services including vendor analysis, source
inspection, incoming raw-material inspection, verification of materials
purchased etc.
(g.) System for shop manufacturing and site erection controls including
process, fabrication and assembly.
(h.) Control of non-conforming items and system for corrective actions and
resolution of deviations.
(i.) Inspection and test procedure both for manufacture and field activities.
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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
Employer.
(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 contractor for some of
the major items is given in the respective technical specification which shall
be finalised giving due consideration to the manufacturer's standard and
proven practices being followed. This is, however, not intended to form a
comprehensive programme as it is the contractor's responsibility to draw up
and implement such programme duly approved by the Employer. The detailed
Quality Plans for manufacturing and field activities shall be drawn up by the
Bidder and will be submitted to Employer for approval. Schedule of finalisation
of such quality plans will be finalised before award. Monthly progress reports
on MQP/FQP submission/approval shall be furnished on enclosed format No.
QS-01-QAI-P-02/F1.
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 Contractor's/ Sub-contractor'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 through c-
folders, a web based system of NTPC ERP in addition to hard copy, for
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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 Contractor'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
documents/standards etc. will be subject to Employer's approval without which
manufacturer shall not proceed. These approved documents shall form a part
of the contract. In these approved Quality Plans, Employer shall identify
customer hold points (CHP), i.e. test/checks which shall be carried out in
presence of the Employer's Project Manager or his authorised representative
and beyond which the work will not proceed without consent of Employer in
writing. All deviations to this specification, approved quality plans and
applicable standards must be documented and referred to Employer along with
technical justification for approval and 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 Employer'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 contractor shall submit to the Employer Field Welding Schedule for field
welding activities in the enclosed format No.: QS-01-QAI-P-02/F2. The field
welding schedule shall be submitted to the Employer 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 Employer.
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All welding/brazing procedures shall be submitted to the Employer 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 Contractor's/sub-contractor'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 Employer.
9.02.10 Welding procedure qualification & Welder qualification test results shall be
furnished to the Employer for approval. However, where required by the
Employer, tests shall be conducted in presence of Employer/authorised
representative.
9.02.11 For all IBR pressure parts and high pressure piping welding, the latest
applicable requirements of the IBR (Indian Boiler Regulations) shall also be
essentially complied with. However, for other piping system ASME B31.1 or
other relevant code as applicable shall be followed. Similarly, any other
statutory requirements for the equipment/systems shall also be complied with.
On all back-gauged welds MPI/LPI shall be carried before seal welding.
9.02.12 Unless otherwise proven and specifically agreed with the Employer, 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) / EN / Equivalent. 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 Contractor shall list out all major items/ equipment/ components to be
manufactured in house as well as procured from sub-contractors (BOI). All the
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sub-contractor proposed by the Contractor for procurement of major bought out
items including castings, forging, semi-finished and finished components/
equipment etc., list of which shall be drawn up by the Contractor and finalised
with the Employer, shall be subject to Employer's approval. The contractor's
proposal shall include vendor's facilities established at the respective works,
the process capability, process stabilization, QC systems followed, experience
list, etc. along with his own technical evaluation for identified sub-contractors
enclosed and shall be submitted to the Employer for approval within the
period agreed at the time of pre-awards discussion and identified in "DR"
category prior to any procurement. Monthly progress reports on sub-contractor
detail submission / approval shall be furnished on enclosed on format no. QS-
01-QAI-P-02/F1. Such vendor approval shall not relieve the contractor 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 Employer, the contractor's
purchase specifications and inquiries shall call for quality plans to be submitted
by the suppliers. The quality plans called for from the sub-contractor shall
set out, during the various stages of manufacture and installation, the quality
practices and procedures followed by the vendor's quality control 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 Employer and such approved Quality Plans shall
form a part of the purchase order/contract between the Contractor and sub-
contractor. With in three weeks of the release of the purchase orders /
contracts for such bought out items /components, a copy of the same without
price details but together with the detailed purchase specifications, quality plans
and delivery conditions shall be furnished to the Employer on the monthly
basis by the Contractor along with a report of the Purchase Order placed so
far for the contract.
9.02.18 Employer reserves the right to carry out quality audit and quality surveillance of
the systems and procedures of the Contractor's or their sub-contractor's quality
management and control activities. The contractor shall provide all necessary
assistance to enable the Employer carry out such audit and surveillance.
9.02.19 The contractor shall carry out an inspection and testing programme during
manufacture in his work and that of his sub-contractor's and at site to ensure
the mechanical accuracy of components, compliance with drawings,
conformance to functional and performance requirements, identity and
acceptability of all materials parts and equipment. Contractor shall carry out
all tests/inspection required to establish that the items/equipment conform to
requirements of the specification and the relevant codes/standards specified in
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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 Employer to reject the equipment if it
does not comply with the specification when erected or does not give complete
satisfaction in service and the above shall in no way limit the liabilities and
responsibilities of the Contractor in ensuring complete conformance of the
materials/equipment supplied to relevant specification, standard, data sheets,
drawings, etc.
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 Employer/ authorised representative.
9.02.23 Environmental Stress Screening
All solid state electronic system / equipment / sub assembly shall be free
from infant mortile components. For establishing the compliance to this
requirement, the contractor / sub - contractor should meet the following.
1) The Contractor / Sub - contractor shall furnish the established
procedure being followed for eliminating infant mortile components. The
procedure followed by the Contractor / Sub - contractor should be
substantiated along with the statistical figures to validate the procedure
being followed. The necessary details as required under this clause
shall be furnished at the stage of QP finalization.
Or
In case the Contractor / Sub - contractor do not have any established
procedure to eliminate infant mortile components then two or 10%
which ever is less, most densely populated Panels shall be tested for
Elevated Temperature Cycle Test as per the following procedure.
Elevated Temperature Test Cycle
During the elevated temperature test which shall be for 48 hours, the
ambient temperature shall be maintained at 50 C. The equipment shall
be interconnected with devices and kept under energized conditions so
as to repeatedly perform all operations it is expected to perform in
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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 inside temperature in the zone of highest heat dissipating
components / modules shall be monitored. The temperature rise inside
the cubicle should not exceed 10 C above the ambient
temperature at 50 C.
In case of any failure during the test cycle, the further course of action
should be mutually discussed for demonstrating the intent of the above
requirement.
2) Burn in Test Cycle
The test shall be conducted on all the panels fully assembled and
wired including the panels having undergone the above mentioned
elevated temperature test.
The period of Burn in Test Cycle shall be 120 hrs and process shall
be similar to the elevated temperature 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.
During the Burn in Test the cubicle doors shall be closed (or shall be
in the position same as they are supposed to be in the field) and
inside temperature in the zone of highest heat dissipating components
/ modules shall be monitored. The temperature rise inside the cubicle
should not exceed 10 C above the ambient temperature.
The Contractor / Sub-contractor shall carry out routine test on 100% item
at contractor / sub-contractor's works. The quantum of check / test for
routine & acceptance test by employer 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.
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9.03.00 QA DOCUMENTATION PACKAGE
The Contractor shall be required to submit the QA Documentation in two hard
copies and two CD ROMs, as identified in respective quality plan with tick (9)
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.
(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 Employer
and Contractor for the agreed Customer Hold Points.
(h.) Certificate of Conformance (COC) wherever applicable.
(i.) MDCC
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9.03.03 NOT USED.
9.03.04 Similarly, the contractor shall be required to submit two sets (two hard copies
and two CD ROMs), containing QA Documentation pertaining to field activities
as per Approved Field Quality Plans and other agreed manuals/ procedures,
prior to commissioning of individual system.
9.03.05 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 for 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
QA documentation package shall not be later than 3 weeks after the
despatch of equipment.
9.03.06 TRANSMISSION OF QA DOCUMENTATION
On release of QA Documentation by Inspector, one set of quality document
shall be forwarded to Corporate Quality Assurance Department and other set
to respective Project Site of Employer.
For the particular case of phased/part derivatives of equipment, the complete
quality document of that particular equipment to the Employer shall be issued
not later than 3 weeks after the date of the last delivery of equipment.
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9.04.00 Proj ect Manager' s Supervi si on
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 GCC of Vol.I, the Contractor 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 Contractor's drawing, engineering
data, etc:
(c.) Witness or his authorised representative to witness tests and trials
either at the manufacturer's works or at site, or at any place where
work is performed under the contract :
(d.) Inspect, accept or reject any equipment, material and work under the
contract:
(e.) Issue certificate of acceptance and/or progressive payment and final
payment certificates
(f.) Review and suggest modifications and improvement in completion
schedules from time to time, and
(g.) Supervise Quality Assurance 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 authorised
representative and/or an outside inspection agency acting on behalf of the
Employer to inspect and examine the materials and workmanship of the works
during its manufacture or erection.
9.05.02 The Project Manager or his duly authorised representative and/or an outside
inspection agency acting on behalf of the Employer shall have access at all
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reasonable times to inspect and examine the materials and workmanship of
the works during its manufacture or erection and if part of the works is being
manufactured or assembled on other premises or works, the Contractor shall
obtain for the Project Manager and for his duly authorised representative
permission to inspect as if the works were manufactured or assembled on the
Contractor's own premises or works.
9.05.03 The Contractor shall give the Project Manager/Inspector ten (10) working days
written notice of any material being ready for testing. Such tests shall be to
the Contractor's account except for the expenses of the Inspector's. The
Project Manager/Inspector, unless the witnessing of the tests is virtually waived
and confirmed in writing, will attend such tests within ten (10) working days of
the date on which the equipment is noticed as being ready for test/inspection
failing which the contractor may proceed with test which shall be deemed to
have been made in the inspector's presence and he shall forthwith forward to
the inspector duly certified copies of test reports in two (2) copies.
9.05.04 The Project Manager or Inspector shall within ten (10) working days from the
date of inspection as defined herein give notice in writing to the Contractor, or
any objection to any drawings and all or any equipment and workmanship
which is in his opinion not in accordance with the contract. The Contractor
shall give due consideration to such objections and shall either make
modifications that may be necessary to meet the said objections or shall
inform in writing to the Project Manager/Inspector giving reasons therein, that
no modifications are necessary to comply with the contract.
9.05.05 When the factory tests have been completed at the Contractor's or sub-
contractor's works, the Project Manager /Inspector shall issue a certificate to
this effect ten (10) working days after completion of tests but if the tests are
not witnessed by the Project Manager /Inspectors, the certificate shall be
issued within ten (10) working days of the receipt of the Contractor's test
certificate by the Project Manager /Inspector. Project Manager /Inspector to
issue such a certificate shall not prevent the Contractor from proceeding with
the works. The completion of these tests or the issue of the certificates shall
not bind the Employer to accept the equipment should it, on further tests after
erection be found not to comply with the contract.
9.05.06 In all cases where the contract provides for tests whether at the premises or
works of the Contractor or any sub-contractor, the Contractor, except where
otherwise specified shall provide free of charge such items as labour, material,
electricity, fuel, water, stores, apparatus and instruments as may be reasonably
demanded by the Project Manager /Inspector or his authorised representatives
to carry out effectively such tests on the equipment in accordance with the
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Contractor and shall give facilities to the Project Manager/Inspector or to his
authorised representative to accomplish testing.
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
Contractor 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 Contractor shall
furnish quarterly inspection programme indicating schedule dates of inspection
at Customer Hold Point and final inspection stages. Updated quarterly
inspection plans will be made for each three consecutive months and shall be
furnished before beginning of each calendar month.
9.05.09 All inspection, measuring and test equipment used by contractor shall be
calibrated periodically depending on its use and criticality of the test/
measurement to be done. The Contractor shall maintain all the relevant
records of periodic calibration and instrument identification, and shall produce
the same for inspection by NTPC. Wherever asked specifically, the contractor
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 & Sub-supplier approval.
Format No. QS-01-QAI-P-01/F3-R0
9.06.02 Status of Quality Plan and Sub-supplier approval
Format No. QS-01-QAI-P-02/F1-R0
9.06.03 Field Welding Schedule Format No.: QS-01-QAI-P-02/F2-R0
9.06.04 Manufacturing Quality Plan Format No.: QS-01-QAI-P-09/F1-R0
9.06.05 Field Quality Plan Format No.: QS-01-QAI-P-09/F2-R0
The above formats are enclosed as Annexure-III to 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
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equipment and systems forming part of facilities shall be thoroughly
cleaned and then inspected jointly by the Employer and the Contractor
for correctness of and completeness of facility or part thereof and
acceptability for initial pre-commissioning tests, commissioning and start-
up at Site. The list of pre-commissioning tests to be performed shall
be as mutually agreed and included in the Contractor's quality
assurance programme as well as those included elsewhere in the
Technical Specifications.
(b.) The Contractor's pre-commissioning/ commissioning/start-up engineers,
specially identified as far as possible, shall be responsible for carrying
out all the pre-commissioning tests at Site. On completion of inspection,
checking and after the pre-commissioning tests are satisfactorily over,
the commissioning of the complete facilities shall be commenced during
which period the complete facilities, equipments shall be operated
integral with sub-systems and supporting equipment as a complete
plant.
(c.) All piping system shall be flushed, steam blown, air blown as required
and cleanliness demonstrated using acceptable industry standards.
Procedures to accomplish this work shall be submitted for approval to
the Employer six months prior to the respective implementations. The
Employer will approve final verification of cleanliness. DM water/steam
required for the above purpose (as per employer approved procedure)
shall be provided by the Employer free of charge as per mutually
agreed schedule.
(d.) The time consumed in the inspection and checking of the units shall
be considered as a part of the erection and installation period.
(e.) The check outs during the pre - commissioning period should be
programmed to follow the construction completion schedule. Each
equipment/system, as it is completed in construction and turned over to
Employer's commissioning (start-up) Engineer(s), should be checked out
and cleaned. The checking and inspection of individual systems should
then follow a prescribed commissioning documentation [SLs (Standard
Check List) / TS (Testing Schedule) / CS (Commissioning Schedule)]
approved by the Employer.
(f.) The Contractor during initial operation and performance testing shall
conduct vibration testing to determine the 'base line' of performance of
all plant rotating equipment. These tests shall be conducted when the
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equipment is running at the base load, peak load as well as lowest
sustained operating condition as far as practicable.
(g.) Contractor shall furnish the commissioning organization chart for review
& acceptance of employer at least eighteen months prior to the
schedule date of synchronization of 1st unit. The chart should contain:
(1.) Biodata including experience of the Commissioning Engineers.
(2.) Role and responsibilities of the Commissioning Organisation
members.
(3.) Expected duration of posting of the above Commissioning
Engineers at site.
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 Contractor shall intimate the Employer about the commencement of
initial operation and shall furnish adequate notice to the Employer in
this respect.
e) Any loss of generation due to constraints attributable to the Employer
shall be construed as Deemed Generation.
In the event of test interruptions as a result of Force Majeure or
Employer-Caused-Delay during Initial Operation test, where.
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(i) The total cumulative interrupted time during the test is more
than twenty-four (24) hours.
(ii) The total number of interruptions during the test is more
than four (4).
The test shall not be deemed a successful Initial Operation Test.
The interrupted test resulting from Force Majeure or Employer-Caused-
Delay shall be extended by an amount of time equal to the cumulative
length of the interruptions, including time to return to steady-state
operation; the test data for the period of interruptions shall be excluded
from analysis; and the test data that were collected both before and
after the interruptions shall be included in the analysis.
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 Contractor. 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 Contractor to the full
satisfaction of the Employer 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.
(g) Grid Restriction
Any loss in generation in terms of power (KW) or energy (KWH) during
Initial operation Test due to grid restrictions shall be treated as deemed
generation. however, the total cumulative deemed generation shall not
exceed 5% of the total generation during the test period failing which
the test shall be extended to limit the deemed generation to 5% of the
total generation.
11.00.00 GUARANTEE TESTS
a) The final test as to prove the Functional Guarantees shall be
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conducted at Site by the Contractor in presence of the Employer. The
contractor's Commissioning, Start-up Engineer shall make the unit ready
to conduct such test. Such test will be commenced, within a period
of t hr ee (3) mont hs after the successful completion of Initial
Operations. Any extension of time beyond the above three (3) months
shall be mutually agreed upon.
b) These tests shall be binding on both the parties of the Contract to
determine compliance of the equipment with the functional guarantee.
c) For performance/ demonstration tests instrumentations, of accuracy
class, to the approval of the Employer 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 Employer'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 Contractor,
free of cost.
e) The Guarantee tests and specific tests to be conducted on equipments
have been brought out in detail elsewhere in the specification.
12.00.00 TAKING OVER
Upon successful completion of Initial Operations and all the tests, other than
Guarantee Tests conducted to the Employer's satisfaction, the Employer shall
issue to the Contractor a Taking over Certificate as a proof of the final
acceptance of the equipment. Such certificate shall not unreasonably be with
held nor will the Employer delay the issuance thereof, on account of minor
omissions or defects which do not affect the commercial operation and/or
cause any serious risk to the equipment. Such certificate shall not relieve the
Contractor of any of his obligations which otherwise survive, by the terms and
conditions of the Contract after issuance of such certificate.
13.00.00 TRAINING OF EMPLOYER' S PERSONNEL
13.01.00 The scope of service under training of Employer's engineers shall include a
training module in the areas of Operation & Maintenance.
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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 Employer:
(a.) Training for TG and related equipments.
(b.) TG related C&I system like turbine supervisory system (TSS) etc.
(c.) DDCMIS as detailed in Part-B
(d.) Training for Electric Power Supply systems
(e.) Training for power cycle piping/critical piping.
13.02.00 The scope of services under training shall also necessarily include training of
Employer's Engineering personnel covering a training module of upto 23 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 Employer's Engineering
personnel is attached as Annexure-II.
13.03.00 Bidder shall furnish in his offer, details of training module(s) covering above
requirements which shall be subject to Employer's approval. Consolidated
training period included above (i.e. 35 and 23 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.
13.04.00 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.
13.05.00 In all the above cases, wherever the training of Employer's personnel is
arranged at the works of the manufacturer's it shall be noted that the lodging
and boarding of the Employer's personnel shall be at the cost of Bidder. The
Bidder shall make all necessary arrangements towards the same.
GENERAL TECHNICAL
REQUIREMENTS
PAGE
40 OF 64
SECTION-VI
PART-C
STAGE-II (2X660 MW)
13.06.00 Take off prices (product wise) should be indicated by the Bidder in the Bid
Proposal Sheets. Employer reserves the right to include or exclude these
item(s) during placement of Award.
13.07.00 For training purpose one (1) man month implies 30 working days (excluding
all intervenning holidays) per person.
14.00.00 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 Employer'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.
15.00.00 NOISE LEVEL
The equivalent 'A' weighted sound pressure level measured at a height of 1.5
m above floor level in elevation and at a distance of one (1) metre
horizontally from the nearest surface of any equipment / machine, furnished
and installed under these specifications, expressed in decibels to a reference
of 0.0002 microbar, shall not exceed 85 dBA 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 90 dBA.
16.00.00 PACKAGING AND TRANSPORTATION
All the equipments shall be suitably protected, coated, covered or boxed and
crated to prevent damage or deterioration during transit, handling and storage
at Site till the time of erection. While packing all the materials, the limitation
from the point of view of the sizes of railway wagons available in India should
be taken account of. The Contractor shall be responsible for any loss or
GENERAL TECHNICAL
REQUIREMENTS
PAGE
41 OF 64
SECTION-VI
PART-C
STAGE-II (2X660 MW)
damage during transportation, handling and storage due to improper packing.
The Contractor shall ascertain the availability of Railway wagon sizes from the
Indian Railways or any other agency concerned in India well before effecting
despatch of equipment. Before despatch 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 & preassembly to bare minimum. The Employer's Inspector
shall have right to insist for completion of works in shops before despatch of
materials for transportation.
17.00.00 ELECTRICAL ENCLOSURE
All electrical equipments 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,
18.00.00 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.
18.01.00 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 centimetre (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 - Millimetres of water column (mm wc).
d) Vacuum - Millimeters of mercury column (mm Hg) or water
column (mm Wcl).
e) Flow (Gas) - Tonnes/ hour
GENERAL TECHNICAL
REQUIREMENTS
PAGE
42 OF 64
SECTION-VI
PART-C
STAGE-II (2X660 MW)
f) Flow (Steam) - Tonnes/ hour
g) Flow (Liquid) - Tonnes / hour
h) Flow base - 760 mm Hg. 15 deg.C
i) Density - Grams per cubic centimetre.
18.02.00 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.
18.03.00 NOT USED.
19.00.00 ELECTRICAL NOISE CONTROL
The equipment furnished by the Contractor shall incorporate necessary
techniques to eliminate measurement and control problems caused by electrical
noise. Areas in Contractor's equipment which are vulnerable to electrical noise
shall be hardened to eliminate possible problems. Any additional equipment,
services required for effectively eliminating the noise problems shall be
included in the proposal. The equipment shall be protected against ESD as per
IEC-61000-2. 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 as per EN-50082-2
(1995).
20.00.00 INSTRUMENT AIR SYSTEM
The instrument air supply system as supplied by the Contractor 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.
21.00.00 TAPPING POINTS FOR MEASUREMENTS
Tapping points shall include probes, wherever applicable, for analytical
measurements and sampling.
GENERAL TECHNICAL
REQUIREMENTS
PAGE
43 OF 64
SECTION-VI
PART-C
STAGE-II (2X660 MW)
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 Contractor will be intimated about thread standard to be
adopted.
The following shall be provided on equipment by the Contractor. The standard
which is to be adopted, will be intimated to the Contractor.
(a.) Temperature test pockets with stub and thermowell
(b.) Pressure test pockets
22.00.00 NOT USED
GENERAL TECHNICAL
REQUIREMENTS
PAGE
44 OF 64
SECTION-VI
PART-C
STAGE-II (2X660 MW)
ANNEXURE-1
---------------------------------------------------------------------------------------------------------------------------------------
S.NO. DESCRIPTION OF DOCUMENTS NO OF PRINTS NO. OF CD-ROMs
---------------------------------------------------------------------------------------------------------------------------------------
1. PLANT DEFINITION MANUAL- 2 sets 4 CD-ROMs
2. Drawings "FOR APPROVAL"
i) Layout drawings / P&IDs 6 2 CD - ROMs
ii) Other drawings 2 2 CD - ROMs
3. Drawings "FOR INFORMATION" 2 2 CD - ROMs
4. Drawings "FINAL DRAWING" 15 4 CD-ROMs
5. Drawings "AS BUILT " 15 4 CD-ROMs
6 DATASHEETS, DESIGN
CALCULATIONS, PURCHASE
SPECIFICATIONS, etc. and
Other type of documents
i) For Approval 2 2 CD - ROMs
ii) FINAL 15 4 CD-ROMs -
iii) Analysis reports of equip- 2 2 CD - ROMs
ments/ piping/ structures
components/ systems
employing software
packages as detailed
in the specifications
7. Erection manual "1st Submission" 4 Sets 2 CD - ROMs
8 Erection manual "FINAL" 4 Sets 4 CD ROMs
9 Operation & Maintenance 4 2 CD - ROMs
manual "1st submission"
GENERAL TECHNICAL
REQUIREMENTS
PAGE
45 OF 64
SECTION-VI
PART-C
STAGE-II (2X660 MW)
---------------------------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------------------------
10 Operation & Maintenance 4 Sets 4 CD-ROMs
manual "FINAL"
11 Plant Hand Book "1st Submission" 4 Sets 2 CD ROMs
12 Plant Hand Book "FINAL" 4 Sets 4 CD ROMs
13 Commissioning and Performance 4 Sets 2 CD-ROMs
Procedure manual "1st Submission"
14 Commissioning and Performance
Procedure manual "FINAL" 4 Sets 4 CD ROMs
15 Performance and Functional 4 Sets 4 CD ROMs
GURANTEES TEST REPORT
16 Project completion report 15 4 CD ROMs
17 QA programme including Organi- 1 1 CD ROM
sation for implement-ation and
QA systemmanual (with revision-
servicing)
18 Vendor details in respect of pro- 1 1 CD ROM
posed vendors including contractor's
evaluation report.
19 Manufacturing QPs, Field QPs,
Field welding schedules and their
reference documents like test
procedures, WPS, PQR etc.
(i) For review/comment 2 2 CD-ROMs
(ii) For final approval 2 2 CD ROMs
GENERAL TECHNICAL
REQUIREMENTS
PAGE
46 OF 64
SECTION-VI
PART-C
STAGE-II (2X660 MW)
---------------------------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------------------------
20 Welding Manual, HeatTreatment
Manuals, Storage & preservation
manuals
1st Submission 4 Sets 2 CD ROMs sets
Final 4 sets 4 CD ROMs
21 QA Documentation Packagefor
items / equipmentmanufactured
and and despatched to site 2 sets 4 CD ROMs
22 QA Documentation Package for
field activities on equipment /
systems at site 2 sets 4 CD ROMS
---------------------------------------------------------------------------------------------------------------------------------------
PRODUCT AREAS OF TRAINING REQUIREMENT
SECTION-VI
PART-C
GENERAL TECHNICAL
REQUIREMENTS
PAGE
47 OF 64
PRODUCT DESIGN Plant Visit Visit To Operation & Maintenance of
Manufacturer's Work Plant
TURBINE
GENERATOR AND Turbine cycle optimization and turbine Familiarization of power Manufacturing processes
IT'S INTEGRAL performance in off design condition. plants of various makes of of turbine
AUXILIARIES turbines for super critical
units
Rotor design and strength calculation Collection of data for Assembly of turbine
analysis of availability
of turbines
Rotor dynamic behavior studies wrt Comparative studies for Testing of turbines
natural frequency, critical speed, integral systems of turbine
vibration etc.
Blade profile/root design and blade O&M history/problems Product development in
strength design, blade vibration related to turbine process
analysis
Casing & diaphragm design Failure analysis Future plan for
technology induction
Labyrinth seal selection & design for R&D work in progress
different turbine configurations
Selection of turbine type (i.e. Tandem
vs cross compounding, separate
HP/IP vs combined HP/IP, material
of construction etc.)
Design principle for Up rating/down
rating of existing design/ modules for
the specific project.
ANNEXURE - II
SECTION-VI
PART-C
GENERAL TECHNICAL
REQUIREMENTS
PAGE
48 OF 64
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 Techno-economic syudies for Selection Familiarization of power Manufacturing process of
Pumps of BFP Configuration and its drive plants of various makes various components of
of feed pumps for super BFP
critical units
Criteria for selection of boiler Feed Data collection of BFP Assembly of BFP
Pump parameters parameters and
configuration
Rotor design, strength calculation and Collection of data for Testing, capabilities of
rotor dynamic behavior studies wrt analysis of availability of BFP at works wrt
critical speed, vibration etc BFP performance, NPSH,
thermal shock, dry run,
visual cavitation, string
test, axial thrust
measurement
SECTION-VI
PART-C
GENERAL TECHNICAL
REQUIREMENTS
PAGE
49 OF 64
Impeller design and its hydraulic O&M history/problems Product development in
behavior related to BFP process
Role of critical parameters such as Comparative studies for Future plan for techno-
NPSH(R), Suction specific speed, various types of BFP& its logy induction
running clearances, speed etc. in features
design of feed pumps
Material selection of BFP components R&D work in progress
Guiding factors for selection of BFP
seals
Computation of axial thrust under
various flows
Performance calculation
Transient analysis in pump suction
piping wrt NPSH margin
Latest technological trends in BFP
design
---------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
MANDAYS 20 5 10
---------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
Condenser Selection of condenser type and its Comparative studies of Manufacturing process of
optimization wrt temp rise across salient features various components of
condenser, pressure drop in condenser, condenser Assembly
surface area etc.
SECTION-VI
PART-C
GENERAL TECHNICAL
REQUIREMENTS
PAGE
50 OF 64
Techno economic studies for Selection Collection of data for Testing capability at
of condenser tube material and other analysis of availability of works
parts depending on water quality Condenser
Condenser support selection & design O&M history/problems Product development in
related to condenser process
Sizing of condenser w.r.t. super Future plan for techno-
critical units logy induction
Latest technological trends in R&D work in progress
condenser arrangement and design
Condenser vacuum system design
---------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
MANDAYS 10 5 5
---------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
Feed Thermal and mechanical design Comparative studies of Manufacturing process of
Regenerative calculation of heaters salient features various components of
Equipment's heaters
Basis of selecting horizontal/vertical Analysis of data Assembly
heaters
Selection of TTD and DCAs for various O&M history/problems Testing capability at
heaters, and their effect on turbine heat related to heaters works
rate
Configuration of HP heaters (2x50% Product development in
v/s100% capacity process
SECTION-VI
PART-C
GENERAL TECHNICAL
REQUIREMENTS
PAGE
51 OF 64
Sizing criteria for De- aerator/Heaters Future plan for techno-
logy induction
Selection of tube & tube sheet material R&D work in progress
of heaters
Latest technological trends in heaters
design
---------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
MANDAYS 15 10 10
---------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
3-dimensional CFD model develop ment and validation
CFD modeling of design data for steam turbine, BFP,
CEP, condenser, heaters etc.
---------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
MANDAYS 20
---------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
SECTION-VI
PART-C
GENERAL TECHNICAL
REQUIREMENTS
PAGE
52 OF 64
CONTROL &
INSTRUMENTATION
DDCMIS*-Man Hardware & Software organization of Operational feedback
Machine Interface - the system
Hardware &
Operating System Basis of selection of H/W memory
sizing
Operating system features, interface
with other system, openness & inter-
operability
Upgradability
System testing features
Trouble shooting and fault analysis
---------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
MANDAYS 16 5
---------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
DDCMIS*-Man Specific system customisation Operation feedback
Machine Interface
System Various system
Engineering & Application Modules & interface with OS
Software
Database organisation & development
Development of mimics
Other application like calculations,
logs historical storage functionalities
& use
---------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
MANDAYS 40 5
SECTION-VI
PART-C
GENERAL TECHNICAL
REQUIREMENTS
PAGE
53 OF 64
DDCMIS* - Control Basic design features for system & its Operation feedback Manufacturing processes
System Hardware modules special attention to
handling of the modules
System capabilities & system design Maintenance facilities
techniques
Communication with MMI & other
system
-----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
MANDAYS 20 3 10
-----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
DDCMIS*-Control Database structure Organisation & Operational feedback System integration &
system Application interface between application program System capabilities
Software & database testing
Application for implementation of
Control functions
Study of standard algorithms &
development of new algorithms
-----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
MANDAYS 12 2 4
-----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
DDCMIS* - Control General description of closed loop Specific operational
Loop Study controls of thermal power plant feedback
Critical analysis of few control loops
e.g., TSCS Stress Control etc.
-----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
MANDAYS 4 2
SECTION-VI
PART-C
GENERAL TECHNICAL
REQUIREMENTS
PAGE
54 OF 64
DDCMIS* - EHTC, Basic design concept & features Operational feedback Manufacturing procedure
Turbine stress & precautions
control system, for handling
Turbine protection the system
system & ATRS
Logics of turbine stress control system System testing facilities
Implementation of fail safe philosophy
in turbine protection system
-----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
MANDAYS 10 2 3
-----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
DDCMIS-operator Use of the system at work+at Site
-----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
MANDAYS 4
-----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
24 V DC System Theory & design features
Manufacturing/assembly process
Testing methodology
-----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
MANDAYS 5
-----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
Turbo supervisory Theory & design features
system Trouble shooting and fault analysis
Use of the system at site
-----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
MANDAYS 5
-----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
Wherever "DDCMIS" is indicated, it will mean TG C&I part of DDCMIS, which is in Contractor's Scope .
SECTION-VI
PART-C
GENERAL TECHNICAL
REQUIREMENTS
PAGE
55 OF 64
(ELECTRICAL)
GENERATOR (a) Design aspects of the - Operational feed back (a) Manufacturing
following areas process for
- Insulation system - Familarisation with - Core
different sub-systems
- Cooling medium & arrangement - Winding bars
- Winding & core support systems - Assembly
b) Design aspects of assciated (b) Testing facilities
auxiliary systems
----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
MANDAYS 30 15 15
----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
Generator Design features of various sub-systems - Operational feed back - Manufacturing
Excitation process & testing
System facilities for various
including AVR. equipment of
excitation system
Exciter - Familiarisation with
various equipment
functioning at reference
plants
PMG
Transformer
Controllers & different limiters etc.
PSS & associated system studies
---------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
MANDAYS 30 15 15
---------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
SECTION-VI
PART-C
GENERAL TECHNICAL
REQUIREMENTS
PAGE
56 OF 64
Integral Actuators a) Basic design philosophy of integral Manufacturing
actuator process & testing
facilities for various
b) Design aspects of wiring diagram equipment of actuators
c) Type and range of application of
integral actuators
d) Operation and selection of integral
actuator to various type of loads
e) Methods of fault diagnose system.
--------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
MANDAYS 2 1 1
--------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
CRITICAL PIPING Design familiarization for critical piping Familiarization with feed Cold Setting of spring
& POWER CYCLE of supercritical Plant back (in super critical hanger
PIPING plant) on failure analysis
and vibration analysis of
piping.
Optimization study for sizing including Study of Feed back Cyclic tests carried on
pressure drop calculation and selection regarding hanger setting spring hangers.
of single or double lead together with stretegies and practice
employers engineers
Design and stress analysis of lines Cyclic tests carried on
with Expansion J oints together with expansion joints
employers engineers
Design and stress analysis of piping Manufacturing process of
systems with two phase flow involving critical piping components
employers engineers and appreciation of their
testing fracilities at shop
SECTION-VI
PART-C
GENERAL TECHNICAL
REQUIREMENTS
PAGE
57 OF 64
Transient analysis and optimum sizing
of feed suction piping together with
employers engineers.
Static and dynamic analysis of critical
piping including siesmic and other
occassional load analysis (safety valve
blowing condition). A joint activity
together with employers 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
----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
QUALITY
ASSURANCE &
INSPECTION
QA SYSTEM & Integrated QA Management System for Operating feed backs: z Appreciation of
PROGRAMME enhanced reliability of equipments. implementation of QA
Programmes in
SECTION-VI
PART-C
GENERAL TECHNICAL
REQUIREMENTS
PAGE
58 OF 64
z QA system in design, procurement, z Co-relation of reliability various manufaturing,
manufacturing, installation and and performance of the assembly and
operation of the equipments/ equipment with testing activities.
systems. implementation of QA
system. z Appreciation of
developmental
z QA system for developing and z Appreciation of use of activities for new
establishing new processes and structured Engg./QA processess and
vendors. documentation during vendors
Operational phase of
z System of structured document- plant and during RLA z System of pre-
ation of Engg. and test records studies of plant qualification of
special processes.
--------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
MANDAYS 20 10 26
--------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
STEAM TURBINE, Design familiarization: Operating feedback of Manufacturing and
GENERATORS & various equipments of inspection/testing at
AUXILIARIES z Modular turbines steam turbine, generators various stages of :
and auxiliaries.
z Field validation of modules - Turbine casings,
Appreciation of field blades, rotors,
z Features of turbines deisgn validation of modular governing system
concept of the equipment etc.
z Advanced designed bladings
- Generator compon-
z High Pressure governing and ents and system
control system of turbine like core assembly,
core suspensions,
z Vibrational behaviour of turhbine/ rotor, windings,
generator system and interpretation insulation system,
of field results cooling system etc.
SECTION-VI
PART-C
GENERAL TECHNICAL
REQUIREMENTS
PAGE
59 OF 64
z Features of components/system - Development of
of generator like core suspension, special manufacturing
overhang winding, core clamping, processes/facilities
insulation system, cooling system
etc.
------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
MANDAYS 20 10 50
------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
CONTROLS & Familiarization with control system Feedback on performance Manufacturing activities
INSTRUMENTS and instrumentation of C&I Systems for critical instruments/
Items
QA system for manufacture of reliable
components Implementation of
testing programme to
ensure reliablity
------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
MANDAYS 6 4 4
------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
SECTION-VI
PART-C
GENERAL TECHNICAL
REQUIREMENT
PAGE
60 OF 64
LIST OF ITEMS REQUIRING QUALITY PLAN
AND SUB-SUPPLIER APPROVAL
SUB-SYSTEM :
DOC. NO. :
REV. NO. :
DATE :
PAGE : OF
S.No. ITEM
Project : Stage :
Package :
Supplier :
Contractor No. :
FORMAT NO. : QS-01-QAI-P-1/F3-R0 1 / 1 Engg.Div./QA&I
QP/
Insp.
Cat.
QP No.
QP Sub-
Schedule
QP
approval
schedule
Proposed sub-supplier Place Sub-
Suppliers
approval
status/
category
Sub-supplier
Details
submission
schedule
Remarks
LEGENDS :
1. SYSTEM SUPPLIER / SUB-SUPPLIER APPROVAL STATUS CATEGORY (SHALL BE FILLED BY NTPC)
A - For these items proposed vendor is acceptable to NTPC. To be indicated with letter "A" in the list alongwith the condition of approval, if any.
DR - For these items "Detailed required" for NTPC review. To be identified with letter "DR" in the list.
NOTED - For these items vendors are approved by Main Supplier and accepted by NTPC without specific vendor approval from NTPC. To be identified with "NOTED".
2. QP/INSPN CATEGORY :
CAT-I : For these items the Quality Plans are approved by NTPC and the final acceptance will be on physical inspection witness by NTPC.
CAT-II : For these items the Quality Plans approved by NTPC. However no physical inspection shall be done by NTPC. The final acceptance by NTPC 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 NTPC 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.
ANNEXURE - III
SECTION-VI
PART-C
GENERAL TECHNICAL
REQUIREMENT
PAGE
61 OF 64
STATUS OF ITEM REQUIRING QP &
SUB-SUPPLIER APPROVAL
DOC. NO. :
REV. NO. :
DATE :
PAGE : OF
S.No. ITEM/SERVICE
Project : Stage :
Package :
Contractor :
Contractor No. :
QP/Insp.
Cat.
QP Sub.
Schedule
Approval
Schedule
Date of
Sub-
mission
Date of
commt.
Appl.
Status
Code
C/II/I
Proposed Sub-suppliers Place of manufacturing
works
Approval
Status
Sub-supplier
detail
submission
schedule
Remarks
FORMAT NO. : QS-01-QAI-P-02/F1-R0 1 / 1 Engg.Div./QA&I
ANNEXURE - IV
SECTION-VI
PART-C
GENERAL TECHNICAL
REQUIREMENT
PAGE
62 OF 64
DOC. NO. :
REV. NO. :
DATE :
PAGE : OF
Project : Stage :
Contractor :
Contractor No. :
System :
Sl. DRG No. for Description Matl. Dimensions Process of Type of Electrode WPS. Min. Heat treatment NDT RFF Remarks
No. Weld Location of parts to Spec. welding weld filler spec. No. pre-heat method/
and Identifi- welded Quantum
cation mark
Temp.
Holding
time
Spec. No. ACC Norm
Ref.
NOTES:
SIGNATURE
FORMAT NO.: QS-01-QAI-P-02/F2-R0 1/1 Engg. Div./QA&I
FIELD WELDING SCHEDULE
(To be raised by the contractor)
Welding Code ......................................................
ANNEXURE - V
SECTION-VI
PART-C
GENERAL TECHNICAL
REQUIREMENT
PAGE
63 OF 64
PROJECT :
PACKAGE :
CONTRACT NO. :
MAIN-SUPPLIER :
MANUFACTURING QUALITY PLAN
ITEM QP NO. :
REV.NO. :
SUB-SYSTEM DATE :
PAGE : OF
Manufacturer's Name
& Address
FORMAT - QS-01-QAI-P-09/F1-R1 1/1 ENGINEERING DIV. / QA&I
DOC. NO. : REV.........CAT.........
REVIEWED BY
LEGEND : * RECORDS, IDENTIFIED WITH "TICK" ( ) SHALL BE
ESSENTIALLY INCLUDED BY SUPPLIER IN QA DOCUMENTATION
** M : MANUFACTURER / SUB-SUPPLIER
C : MAIN SUPPLIER, N : NTPC
P : PERFORM W : WITNESS AND V : VERIFICATION, AS
APPROPRIATE
CHP : NTPC SHALL IDENTIFIED IN COLUM "N" AS 'W'
MANUFACTURER / MAIN-SUPPLIER
SUB-SUPPLIER
SIGNATURE
SL.
NO.
COMPONENT &
OPERATIONS
CHARACTERISTICS CLASS
TYPE OF
CHECK
QUANTUM
OF CHECK
REFERENCE
DOCUMENT
ACCEPTANCE
NORMS
FORMAT OF
RECORD
AGENCY
M C N
REMARKS
1
2
3 4 5 6 7 8 9 D* ** 10. 11
APPROVED BY APPROVAL SEAL
FOR
NTPC
USE
MFGR.s LOGO
M C/N
SECTION-VI
PART-C
GENERAL TECHNICAL
REQUIREMENT
PAGE
64 OF 64
PROJECT :
PACKAGE :
CONTRACT NO. :
MAIN-SUPPLIER :
FIELD QUALITY PLAN
ITEM QP NO. :
REV.NO. :
SUB-SYSTEM DATE :
PAGE : OF
Supplier's Name
& Address
FORMAT - QS-01-QAI-P-09/F2-R0 1/1 ENGINEERING DIV. / QA&I
DOC. NO. : REV.........CAT.........
REVIEWED BY
LEGEND : * RECORDS, IDENTIFIED WITH "TICK" ( ) SHALL BE
ESSENTIALLY INCLUDED BY SUPPLIER IN QA DOCUMENTATION
LEGEND TO BE USED : CLASS #: A - CRITICAL, B =MAJ OR,
C =MINOR; "A' SHALL BE WITNESSED BY NTPC FQA, 'B' SHALL
BE WITNESSED BY NTPC ERECTION / CONSTRUCTION DEPTT.
AND 'C' SHALL BE WITNESSED BY ERECTION SUPPLIER (A &
B CHECK SHALL BE NTPC CHP STAGE)
MANUFACTURER / MAIN-SUPPLIER
SUB-SUPPLIER
SIGNATURE
SL.
NO.
ACTIVITY AND
OPERATION
CHARACTERISTICS/INSTRUMENTS
CLASS# OF
CHECK
TYPE OF
CHECK
QUANTUM
OF CHECK
REFERENCE
DOCUMENT
ACCEPTANCE
NORMS
FORMAT OF
RECORD
REMARKS
1
2
3 4 5 6 7 8 9
APPROVED BY APPROVAL SEAL
FOR
NTPC
USE
D*
10.
STAGE-II (2X660 MW)
P PP PPAR AR AR AR ART - D T - D T - D T - D T - D
SECTION - VI
FOR
STAGE-II (2X660 MW)
P PP PPAR AR AR AR ART - D T - D T - D T - D T - D
SECTION - VI
FOR
SECTION-VI
TABLE OF CONTENTS
A Project Synopsis
A A-1 Provenness
A Essential Data
A A-2 General
A A-7 (NOT USED)
A D-1 Civil Works
A Spares
MECHANICAL
B A-2 Layout
SECTION-VI
B A-7 (NOT USED)
ELECTRICAL
B B-2 Motors
B B-7 Lighting
(DDCMIS)
SECTION-VI
CIVIL
B D-1 Civil Works
B E-10 (NOT USED)
B E-16 Motors
SECTION-VI
B E-20 Cabling
B E-21 Lighting
E TENDER DRAWING
F NOT USED
SECTION-VI
PART-D
PART - D
ERECTION CONDITIONS OF CONTRACT
SECTION-VI
PART-D
ERECTION CONDITIONS OF CONTRACT
PART - D
CONTENTS
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1.00.00 General 1
2.00.00 Regulation of Local Authorities and Statutes 1
3.00.00 Welding of Pressure Parts and High Pressure Piping 1
4.00.00 Heat Treatment 2
5.00.00 Weld Edge Preparation 3
6.00.00 Cleaning and Servicing 3
7.00.00 Field Welding Schedule 4
8.00.00 Site Run Miscellaneous Piping 5
9.00.00 Thermal Expansions 5
10.00.00 Piping Supports 5
11.00.00 Pressure Testing 6
12.00.00 Thermowells and Flow Nozzles 6
13.00.00 Insulation, Lagging and Cladding 7
14.00.00 Code Requirements 10
15.00.00 Removal of Material 10
16.00.00 Inspection, Testing and Inspection Certificates 10
17.00.00 Access to site and Works on Site 10
SECTION-VI
PART-D
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18.00.00 Contractor's Site Office Establishment 10
19.00.00 Co-operation with other contractors 11
20.00.00 Discipline of Workmen 11
21.00.00 Contractor's Field Operation 12
22.00.00 Photographs and Progress Report 12
23.00.00 Man-Power Report 12
24.00.00 Protection of Work 13
25.00.00 Employment of Labour 13
26.00.00 Facilities to be provided by the Employer 14
27.00.00 Facilities to be provided by the Contractor 15
28.00.00 Lines and Grades 16
29.00.00 Fire Protection 17
30.00.00 Security 17
31.00.00 Contractor's Area Limits 18
32.00.00 Contractor's Co-operation with the Employer 18
33.00.00 Pre-commissioning and Commissioning Activities 18
34.00.00 Materials Handling and Storage 21
35.00.00 Construction Management 23
36.00.00 Field Office Records 23
37.00.00 Contractor's Materials Brought on to Site 24
38.00.00 Protection of Property and Contractor's Liability 24
SECTION-VI
PART-D
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39.00.00 Painting 25
40.00.00 Insurance 25
41.00.00 Unfavourable Working Conditions 26
42.00.00 Protection of Monuments and Reference Points 27
43.00.00 Work & Safety Regulations 27
44.00.00 Foreign Personnel 38
45.00.00 Foundation Dressing & Grouting for 39
Equipment/Equipment Bases
46.00.00 Shaft Alignments 41
47.00.00 Dowelling 41
48.00.00 Check Out of Control Systems 41
49.00.00 Commissioning Spares 41
50.00.00 Cabling 42
51.00.00 Equipment Delivery and Erection 43
52.00.00 Welding-Special Requirements 51
53.00.00 Deviations Dispositioning 51
54.00.00 Non-Destructive Testing (NDT) 51
55.00.00 Testing Equipment & Facilities 51
Annexure-I Standard Check List 52
Annexure-II Brief Writeup on the contents of 60
testing schedule/commissioning schedule
Annexure-III Safety Plan 61
CLAUSE NO. ERECTION CONDITIONS OF CONTRACT
SECTION-VI
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CONDITIONS OF
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1.00.00 GENERAL
1.01.00 The following provisions shall supplement the conditions already contained in
the other parts of these specifications and documents and shall govern that
portion of the work of this contract which is to be performed at site. The
erection requirements and procedures not specified in these documents shall
be in accordance with the recommendations of the equipment manufacturer, or
as mutually agreed to between the Employer and the Contractor prior to
commencement of erection work.
1.02.00 The Contractor upon signing of the Contract shall, in addition to a Project Co-
ordinator, nominate another responsible officer as his representative at Site
suitably designated for the purpose of overall respon-sibility and co-ordination of
the Works to be performed at Site. Such a person shall function from the Site
office of the Contractor during the pendency of Contract.
2.00.00 REGULATION OF LOCAL AUTHORITIES AND STATUTES
2.01.00 In addition to the local laws and regulations, the Contractor shall also comply
with the Minimum Wages Act and the Payment of Wages Act (both of the
Government of India) and the rules made there under in respect of its labour
and the labour of its sub-contractors currently employed on or connected with
the contract.
2.02.00 All registration and statutory inspection fees, if any, in respect of his work
pursuant to this Contract shall be to the account of the Contractor. However,
any registration, statutory inspection fees lawfully pay-able under the provisions
of the Indian Boiler Regula-tions and any other statutory laws and its
amendments from time to time during erection in respect of the plant
equipment ultimately to be owned by the Employer, shall be to the account of
the Employer. Should any such inspection or registration need to be re-
arranged due to the fault of the Contractor or his Sub-Contractor, the additional
fees for such inspection and/or regis-tration shall be borne by the Contractor.
3.00.00 WELDING OF PRESSURE PARTS AND HIGH PRESSURE PIPING
The welding of all pressure parts and high pressure piping shall be in
accordance with the following requirements :
3.01.00 Qualification of Weld Procedures
Only qualified welding procedures as per ASME Section IX shall be used by
contractor at site. Procedure qualification records along with WPS shall be
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submitted to NTPC for review. Welding procedure shall indicate all essential
and non-essential parameters as per ASME Section IX. Makes of welding
consumables shall be subject to employer's approval.
3.02.00 Welder's Qualification
Only welders who are qualified in accordance with the latest applicable
requirements of the Indian Boiler Regulations, shall be permitted to perform
any welding work on the pressure parts and its attachment welding. In addition
to such statutory qualification requirements, the welders shall also undergo a
satisfactory pre-production qualification test to be conducted by the Contractor
at site as per ASME Sec IX in presence of employer's representative(s), prior
to performing work under these specifications. The services of an independent
testing laboratory shall be retained by the Contractor to perform welder
qualification tests for welders.
All the welders carrying out welding at site shall carry an identification badge,
which shall indicate the category and the grade of welding for which they have
been tested and authorised to carry out welding.
3.03.00 Records
Welders performance shall be monitored regularly and record of their
performance shall be maintained by contractor in a manner acceptable to the
employer. Contractor shall maintain such records including record of
procedure qualification & welder qualification and hand-over to the employer at
the end of work.
3.04.00 MARKING
On completion of each welded joint, the welder shall mark his regularly
assigned identification mark near the joint. The welder's identification numbers,
inspection stamps or code symbol stamps and any other information shall not
be directly stamped on any alloy steel piping. In alloy steel piping, all such
information shall be stamped on separate marking plate which shall be tack
welded on pipe near the weld.
4.00.00 HEAT TREATMENT
4.01.00 Pre-heating, post-heating and post-weld stress relief operations of all welds,
shall be performed in accordance with the requirements of applicable code.
Local post weld stress relieving heat - treatments shall be adopted only in
cases where it is normally impracticable to subject the entire assembly as
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such for stress relieving operations. Heating may be by means of electric
induction coils or electric resistance coils. Oxy-acetylene flame heating or
exothermic chemical heating methods will not be permitted. Complete
recording of the temperatures through out the stress relieving cycle of the
material and the weld subjected to heat treatment shall be made by means of
a potentiometric recorder. Recorders other than those of potentiometric type
shall not be used for such temperature recording during stress relieving
operations.
The contractor & employer's representative, at start and at the end of HT
Cycle shall sign the time and temperature charts for heat-treatment.
4.03.00 After setting up the weld joint for heat treatment operation, the Employer's
signature shall be obtained on the strips chart of the recorder prior to starting
of heat treatment cycle. The right hand corner of the strip chart at the starting
point of the heat treatment cycle shall contain details like the weld number,
material, diameter and thickness, method of heating adopted, prescribed ranges
of heat treatment temperatures, date of heat treatment, reference to item
number of the Field welding Schedule ( as specified at clause no 7.00.00- of
this chapter) etc.
5.00.00 WELD EDGE PREPARATION
Preparation at site of weld joint shall be in accordance with details acceptable
to the Employer. Wherever possible, machining or automatic flame cutting shall
be used for edge preparation. Hand flame cutting will be permitted only where
edge preparation otherwise is impractical. All slag shall be removed from cuts
and all the hand cuts shall be ground smooth to the satisfaction of the
Employer. Flame cutting of alloy steel pipe shall be avoided. Wherever such
cutting is done, a 200mm length at the cut face shall be removed by
machining. Pneumatic hand tools such as edge preparation, tube cutting
machine can be used.
6.00.00 CLEANING AND SERVICING
6.01.00 The inside of all tubes, pipes, valves and fittings shall be free from dirt, and
loose scales before being erected. All the pipelines shall be thoroughly blown
and/or flushed. Each steam and water tubes shall be blown with compressed
air and shall be subjected to 'ball test' before erection to ensure that no
obstructions exist. A system for recording of all such operations shall be
developed and maintained in a manner to ensure that no obstructions are left
inside the tubes and no tubes are left uncleaned and untested.
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6.02.00 All valves and valve actuators, and dampers and damper actuators, if any,
shall be thoroughly cleaned and serviced prior to pre-commissioning tests and/
or Initial Operations of the plant. A system for recording of such servicing
operation shall be developed and maintained in a manner acceptable to the
Employer and to ensure that no valves or dampers including their actuators
are left unserviced.
6.03.00 All interior surfaces of the turbine shall be thoroughly cleaned prior to boxing -
up to remove all traces of oil preservations.
7.00.00 FIELD WELDING SCHEDULE
The Contractor shall submit to the Employer, a certified and complete field
welding schedule for all the field welding activities to be carried out in respect
of the pressure parts involved in the equipment furnished and erected by him,
at least 90 days prior to the scheduled start of erection work at site. Such
schedule will be strictly followed by the Contractor during the process of
erection. The above field-welding schedule to be issued by the Contractor shall
contain the following:
(a.) Drawing No (s)
(b.) Location of the weld
(c.) Size of the weld (outside diameter and thickness)
(d.) Type of joints
(e.) Material specifications
(f.) Size of fillet on backing ring, when the type of joint is with backing
ring
(g.) Electrode/ filler metal specifications
(h.) Number of welds per unit
(i.) Quantity of filler metal per weld
(j.) Indication of required Non-destructive Examination (NDE) for each weld
(k.) Pre-heat temperatures for welding
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(l.) Process of welding
(m.) Post-welding heat treatment temperature ranges, duration, under as
specified at clause no 4.00.00- of this chapter entitled "Heat
Treatment".
(n.) Qualification details of weld procedures to be adopted as specified
under as specified at clause no 3.01.00- of this chapter entitled
'Qualification of Weld Procedures'.
8.00.00 SITE RUN MISCELLANEOUS PIPING
Sketches or diagrams of the proposed routings of all piping, not already
indicated and routed on the shop drawings which were reviewed by the
Employer, shall be submitted to the Employer for review, Employer's
acceptance of such site routings shall be obtained before the piping is erected.
All these site run piping shall be installed in such a manner as to present an
orderly and neat installation. They shall be located as to avoid obstruction of
access and passages. Valves, instruments or any other special items shall be
located convenient for operation by the operating personnel. Pipe runs shall be
plumb or level except where pitch for drainage is required. Pipe runs that are
not parallel to the building structure, walls or column rows shall be avoided so
that deflection of pipes between hangers does not exceed 6 mm. No
miscellaneous pipe shall be routed and installed above or adjacent to electrical
equipment.
9.00.00 THERMAL EXPANSIONS
All piping installation shall be such that no excessive or destructive expansion
forces exist either in the cold condition or under condition of maximum
temperature. All bends, expansion joints and any other special fittings,
necessary to provide proper expansion, shall be incorporated. During
installation of expansion joints and anchors, care must be taken to make sure
that full design movement is available at all times for maximum to minimum
temperature and vice-versa.
10.00.00 PIPING SUPPORTS
10.01.00 Hangers, supports and anchors shall be installed as required to obtain a safe,
reliable and complete pipe installation. All supports shall be properly levelled
and anchored when installed. The anchors shall be so placed that thermal
expansion will be absorbed by bends without subjecting the valves or
equipment to excessive strains.
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10.02.00 The hanger assemblies shall not be used for the attachment of rigging to
hoist the pipe into place. Other means shall be used to securely hold the
pipe in place till the pipe support is completely assembled and attached to the
pipe and building structures and spring support is set to accommodate the
pipe way. All temporary rigging shall be removed in such a way that the pipe
support is not subjected to any sudden load. All piping, having variable spring
type supports, shall be held securely in place by temporary means during the
hydraulic test of pipe system. Constant support type spring hangers used
during hydraulic test shall be pinned or blocked solid during the test. After
complete installation and insulation of the piping and filling of the piping with its
normal operating medium, the pipe support springs shall be adjusted to the
cold positions. If necessary, the spring support shall be re-adjusted to the hot
positions after the line has been placed for service at its normal maximum
operating temperature conditions. Electric arc welding only shall be used to
weld all pipe supports to structural steel members that form part of the
building supporting structure. The structural beams shall not be heated more
than necessary during welding of supports and such welds shall run parallel
to the axis of the span. All lugs or any other attachments welded to the piping
shall be of the same material as the pipe.
11.00.00 PRESSURE TESTING
11.01.00 On completion of erection of pressure parts/boiler external piping/ non boiler
external piping, a hydraulic test in accordance with the requirements of the
Indian Boiler Regulations shall be performed by the Contractor.
11.02.00 All blank flanges, caps, removable plugs, temporary valves, pipes & fittings,
spools, other accessories and services required for carrying out hydraulic
testing of pipings and pressure parts shall be furnished by the Contractor. The
pressurization equipment including water piping needed for the above test shall
also be furnished by the Contractor. Any defects noticed during the testing are
to be rectified and the unit re-tested. If any welding is done on the pressure
parts after the Hydraulic test, the Hydraulic test for that portion of pressure
parts shall be repeated. Water as required for such pressure testing shall be
provided by the Employer.
11.03.00 Thy hydraulic test shall be considered successful only on certification to that
effect by the concerned inspecting Authority as per the provisions of the Indian
Boiler Regulations and the Employer.
12.00.00 THERMOWELLS AND FLOW NOZZLES
12.01.00 All the thermowells and flow nozzles in the equipment furnished under the
technical specifications shall be installed as a part of this work.
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12.02.00 All thermowell connections incorporated in the steam service shall be plugged
during the pressure testing and the blow out of steam piping systems. Upon
completion of the blow out operation, all thermowells shall be installed and
seam welded. Similarly, all flow nozzles in the steam lines shall also be
installed only on completion of steam blowing operations unless otherwise
agreed to by the Employer, depending upon the sequence of cleaning and
purging operations to be adopted by the Contractor at the field.
13.00.00 INSULATION, LAGGING AND CLADDING
The provision of insulation, lagging and cladding of the various equipments and
portion of the equipment covered under the Contract, shall be furnished by the
Contractor as specified elsewhere or agree to separately in writing. Welds
required for holding insulation on pressure parts shall be carried out by IBR
qualified welder.
13.01.00 In case of equipment other than steam turbine, Lugs made out of MS rods of
5 mm dia conforming to IS280 or equivalent shall be welded on the surface at
intervals of 250 mm pitch zigzag to support insulation. Mineral wool mats with
wire netting on both sides shall be applied against the surface with lugs
piercing through. The edges of mattress shall be laced together with
galvanised MS 0.71 mm dia (22 SWG) IS 280 or equivalent (soft) lacing wire.
Galvanized binding wire of 1.63 mm dia (16 SWG) IS 280 or equivalent (soft)
will be used criss-cross between lugs to hold it. The lugs will then be bent
over the netting.
13.02.00 Unless otherwise specified, all equipment insulation shall be covered with
aluminium cladding/ jacketing. The thickness of aluminium sheet shall not be
less than 0.63 mm. Galvanic corrosion shall be prevented by carefully avoiding
permanent contact of aluminium cladding with copper, copper alloys, tin, lead
nickel or nickel alloys including monel metal. Where cladding is attached to
carbon steel or low alloy steels, the steel shall first be prime painted with
zinc chromate and then painted with aluminium paint. The use of lead base
paints for this purpose shall be avoided.
13.03.00 Prior to application of cladding, all surface imperfections such as ducts, cracks
and voids shall be filled with insulation cement so as to form a smooth base
for the final shall be machine rolled and formed. All overlaps at longitudinal
joints shall face downwards. The fixing of cladding shall be by means of
screws and they shall be adequate in number and be so place is such
location as to produce tight joints eliminating 'bellying'. The screws, as far as
possible, shall be uniformly placed and on centres not exceeding 150 mm
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except where insulated outside diameters are smaller than 230 mm in which
case spacing shall be on centres not exceeding 100mm. Self tapping type
screws, of 12 mm size of stainless steel/aluminium alloy as per the
requirements shall be used. All joints wherever possible shall be lapped a
minimum of 50 mm. The overlaps of longitudinal joints shall be a 10 mm
turnback edge. Butt joints such as those at piping tees, shall be made using
a rolled seam. Suitable provisions for expansion movement shall be provided in
joints. Hinged or sliding doors for convenience shall be provided in the
cladding at all access openings, non-projecting connections, important codes
stampings etc.
13.04.00 Piping, Pipe Fittings & Valves
All piping insulation and metal cladding furnished with the equipment to be
erected shall be applied as specified herein.
13.04.01 Piping
The insulation on piping shall be applied using wire loops on 150mm centres.
These wire loops shall be thoroughly embedded into the outer insulation
surface and all cracks, voids and depressions shall be filled with insulating
cement suitable for the piping temperature so as to form a smooth base for
application of cladding. The wires used for piping insulation shall be of 16
SWG. The surface shall be smooth and uniform before applying the outer
covering. All piping insulation ends shall be terminated at a sufficient distance
from flanges to facilitate removal of bolts.
13.04.02 Flanges
Insulation on flanges shall be by means of blocks of insulating material
securely bound to the flange by wire loops. Such blocks of insulation shall be
long enough to overlap the adjacent pipe insulation by an amount equal to the
thickness of adjacent pipe insulation. Smooth finish shall be obtained by the
application of insulating cement. Alternatively, sectional pipe insulation of proper
diameter may be used. Insulation on flanges shall not be done until the pipe
and equipment have been in service during the initial operation and till all the
flange bolts have been retightened.
13.04.03 Bends and Elbows
Insulation on bends and elbows shall be cut into sections sufficiently short to
form a reasonable smooth external surface. After the application of insulation
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material in place, it shall be smoothly coated with insulating cement. Elbows
may be insulated as above or alternatively by means of specially moulded
insulation enclosures.
13.04.04 Cladding
Cladding shall be of aluminium sheet of thickness as per details given in
detail Technical Specification or will be provided during detail engineering shall
be machine rolled and formed to accurately fit insulation curvatures. Cladding
shall be secured using self-tapping screws. Screws shall be adequate number
and so located as to produce tight joints. The spacing of screws shall be as
far as possible uniform and on centres not exceeding 150 mm. For outside
diameters less than 230 mm, spacing of screws shall be on centres not
exceeding 100 mm. adequate number of screws shall be provided for fixing
the cladding and be so placed in such locations, as to produce a smooth
cladding finish without bellying'. Insulated elbows having insulated diameters less
than 330 mm shall be provided with preformed smooth aluminium elbow
jackets. Wherever possible, all joints should be lapped a minimum of 50 mm
with joints facing downwards and so placed that they are obscured from
normal points of vision. All the joints in the cladding shall be made with
suitable provisions for expansions. All butt joints such as those at piping tees
shall be made using rolled seams. In addition, to prevent galvanic corrosion,
suitable action, as specified at clause no 13.02.00- of this chapter, shall be
taken.
13.04.05 Valves and Fittings
All valves and fittings installed in the pipelines shall also be applied with
insulation and furnished with suitably shaped boxes so as to facilitate easy
dismantling of the fittings. The insulation thickness for valves, valve fittings etc.,
shall be same as that used on the line on which they are installed. All voids
shall be properly filled up with insulating material and as per the directions of
the Employer.
13.05.00 Protection of Equipment during Insulation Applications
All equipment and structures shall be suitably protected from damage while
applying insulation after completion of insulation. All equipment and structures
shall be thoroughly cleaned and remove insulating materials which might have
fallen on them.
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PART-D
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14.00.00 CODE REQUIREMENTS
The erection requirements and procedures to be followed during the installation
of the equipment shall be in accordance with the relevant Indian Electricity
Rules & Codes, Indian Boiler Regulations, ASME codes and accepted good
practices, the Employer's Drawings and other applicable Indian recog-nised
codes and laws and regulations of the Government of India.
15.00.00 REMOVAL OF MATERIAL
No material brought to the Site shall be removed from the Site by the
Contractor and/or his Sub-Contractors without the prior written approval of the
Employer.
16.00.00 INSPECTION, TESTING AND INSPECTION CERTIFICATES
The provisions of the clause entitled Inspection, Testing and Inspection
Certificates given in Part - C of Section-VI B of the Technical Specification,
shall also be applicable to the erection portion of the Works. The Employer
shall have the right to re-inspect any equipment though previously inspected
and approved by him at the Contractor's works, before and after the same
are erected at Site. If by the above inspection, the Employer rejects any
equipment, the Contractor shall make good for such rejections either by
replacement or modification/ repairs as may be necessary to the satisfaction of
the Employer. Such replacements will also include the replacements or re-
execution of such of those works of other Contractors and/or agencies, which
might have got damaged or affected by the replacements or re-work done to
the Contractor's work.
17.00.00 ACCESS TO SITE AND WORKS ON SITE
17.01.00 Suitable access to site and permission to work at the Site shall be accorded
to the Contractor by the Employer in reasonable time.
17.02.00 In the execution of the Works, no person other than the Contractor or his duly
appointed representative, Sub-Contractor and workmen, shall be allowed to do
work on the Site, except by the special permission, in writing by the
Employer or his representative.
18.00.00 CONTRACTOR' S SITE OFFICE ESTABLISHMENT
The Contractor shall establish a Office at the Site and keep posted an
authorised representative for the purpose of the Contract. Any written order or
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instruction of the Employer or his duly authorised representative shall be
communicated to the said authorised resident representative of the Contractor
and the same shall be deemed to have been communicated to the Contractor
at his legal address.
19.00.00 CO-OPERATION WITH OTHER CONTRACTORS
19.01.00 Employer, who may be performing other works on behalf of the Employer and
the workmen who may be employed by the Employer and doing work in the
vicinity of the works under the Contract. The Contractor shall also arrange to
perform his work as to minimise, to the maximum extent possible,
interference with the work of other Contracts and their workmen. Any injury or
damage that may be sustained by the employees of the other Contractors and
the Employer, due to the Contractor's work shall promptly be made good at
his own expense. The Employer shall determine the resolu-tion of any
difference or conflict that may arise between the Contractor and other
Contractors or between the Contractor and the workmen of the Employer in
regard to their work. If the work of the Contractor is de-layed because of the
any acts of omission of another Contractor, the Contractor shall have no claim
against the Employer on that account other than an extension of time for
completing his works.
Employer shall have full access to visit the contractor's site at any time for
inspection and surveillance checks.
1902.00 The Employer shall be notified promptly by the Contractor of any defects in
the other Contractor's works that could affect the Contractor's Works. The
Employer shall determine the corrective measures if any, re-quired to rectify
this situation after inspection of the works and such decisions by the Employer
shall be binding on the Contractor.
20.00.00 DISCIPLINE OF WORKMEN
The Contractor shall adhere to the disciplinary procedure set by the Employer
in respect of his employees and workmen at Site. The Employer shall be at
liberty to object to the presence of any representative or employee of the
Contractor at the Site, if in the opinion of the Employer such employee has
mis-conducted himself or is incompetent, negligent or otherwise unde-sirable
then the Contractor shall remove such a person objected to and provide in
his place a competent replacement.
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21.00.00 CONTRACTOR' S FIELD OPERATION
21.01.00 The Contractor shall keep the Employer informed in advance regarding his field
activity plans and sched-ules for carrying out each part of the works. Any
review of such plan or schedule or method of work by the Employer shall not
relieve the Contractor of any of his responsibilities towards the field activities.
Such reviews shall also not be considered as an assumption of any risk or
liability by the Employer or any of his representatives and no claim of the
Contractor will be entertained because of the failure or inefficiency of any such
plan or schedule or method of work reviewed. The Contractor shall be solely
re-sponsible for the safety, adequacy and efficiency of plant and equipment
and his erection methods.
21.02.00 The Contractor shall have the complete responsibility for the conditions of the
Work-Site including the safety of all persons employed by him or his Sub-
Contractor and all the properties under his custody during the performance of
the work. This requirement shall apply continuously till the completion of the
Contract and shall not be limited to normal working hours. The construction
review by the Employer is not intended to include review of Contractor's safety
measures in, on or near the Work-Site, and their adequacy or otherwise.
22.00.00 PHOTOGRAPHS AND PROGRESS REPORT
22.01.00 The Contractor shall furnish three (3) prints each to the Employer of progress
photographs of the work done at Site. Photographs shall be taken as and
when indi-cated by the Employer or his representative. Photo-graphs shall be
adequate in size and number to indicate various stages of erection. Each
photograph shall contain the date, the name of the Contractor and the title of
the photograph.
22.02.00 The above photographs shall accompany the monthly progress report detailing
out the progress achieved on all erection activities as compared to the
schedules. The report shall also indicate the reasons for the variance between
the scheduled and actual progress and the action proposed for corrective
measures, wherever necessary.
22.03.00 The Contractor shall submit the progress of work in video cassettes (2
copies) quarterly highlighting the progress and constraints at site.
23.00.00 MAN-POWER REPORT
23.01.00 The Contractor shall submit to the Employer, on the first day of every month,
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a man hour schedule for the month, detailing the man hours scheduled for
the month, skill-wise and area-wise.
23.02.00 The Contractor shall also submit to the Employer on the first day of every
month, a man power report of the previous month detailing the number of
persons sched-uled to have been employed and actually employed, skill-
wise and the areas of employment of such labour.
24.00.00 PROTECTION OF WORK
The Contractor shall have total responsibility for protecting his works till it is
finally taken over by the Employer. No claim will be entertained by the
Employer or the representative of the Employer for any damage or loss to the
Contractor's works and the Contractor shall be responsible for complete
restoration of the damaged works to original conditions to comply with the
specification and drawings. Should any such damage to the Contractor's
Works occur because of other party not being under his supervision or
control, the Contractor shall make his claim directly with the party concerned.
If disagree-ment or conflict or dispute develops between the Contractor and the
other party or parties concerned regarding the responsibility for damage to the
Contractor's Works the same shall be resolved as per the provisions of the
as specified at clause no 20.00.00- of this chapter entitled "Co-opera-tion with
other Contractors." The Contractor shall not cause any delay in the repair of
such damaged Works because of any delay in the resolution of such dis-
putes. The Contractor shall proceed to repair the Work immediately and no
cause thereof will be assigned pending resolution of such disputes.
25.00.00 EMPLOYMENT OF LABOUR
25.01.00 In addition to all local laws and regulations pertaining to the employment of
labour to be complied with by the Contractor pursuant to GCC, the Contractor
will be expected to employ on the work only his regular skilled employees with
experience of the particular work. No female labour shall be employed after
darkness. No person below the age of eighteen years shall be employed.
25.02.00 All travelling expenses including provisions of all necessary transport to and
from Site, lodging allow-ances and other payments to the Contractor's
employees shall be the sole responsibility of the Contractor.
25.03.00 The hours of work on the Site shall be decided by the Employer and the
Contractor shall adhere to it. Working hours will normally be eight (8) hours
per day - Monday through Saturday.
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25.04.00 Contractor's employees shall wear identification badges while on work at Site.
25.05.00 In case the Employer becomes liable to pay any wages or dues to the labour
or any Government agency under any of the provisions of the Minimum
Wages Act, Workmen Compensation Act, Contact Labour Regulation Abolition
Act or any other law due to act of omission of the Contractor, the Employer
may make such payments and shall recover the same from the Contractor's
Bills.
26.00.00 FACILITIES TO BE PROVIDED BY THE EMPLOYER
26.01.00 Space
The Contractor shall advise the Employer within thirty (30) days from the
date of acceptance of the Notification of Award about his exact requirement
of space for his office, storage area, pre-assembly and fabrication areas,
labour and staff colony area, toilets, etc. The above requirement shall be
reviewed by the Employer and space as decided by Employer will be allotted
to the Contractor for construction of his temporary structures/ facilities like
office, storage sheds, pre-assembly and fabrication areas, labour and staff
colony, toilets, etc. for Contractor's as well as his Sub-Contractor's use.
26.02.00 Electricity
The Contractor shall submit to the Employer within thirty (30) days from the
date of acceptance of the Notification of Award, his electrical power
requirements, if any, to allow the planning of the same by the Employer. The
Contractor shall be provided with free supply of electricity for the purposes of
the Contract, only at maximum three (3) locations in the Employer's Site, at
415V voltage level. The Contractor shall make his own further distribution
arrangement and shall maintain a minimum drawal power factor of 0.8, and all
such devices for maintaining power factor of 0.8, and all such devices for
maintaining power factor of 0.8 or better shall be under the scope of
contractor. All temporary wiring must comply with local regulations and will be
subject to Employer's inspection and approval before connection to supply. The
free supply of power will not be provided for the use in the labour and staff
colony. Power supply for labour and staff colony shall be provided at one point
within the plant boundary either at 11 KV or 415 V depending on the quantum
and distance. It shall be the responsibility of the Contractor to take the power
supply upto the point of his use. The Contractor shall be charged for power
supply to labour and staff colony at rates prevalent at the site.
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26.03.00 Water
Contractor shall make all arrangements himself for the supply of construction
water as well as potable water for labour and other personnel at the worksite/
colony.
Note: Employer shall provide suitable quality water required for pre-
commissioning & commissioning activities of equipments like flushing of pipes,
hydraulic test of tanks, condenser, vessels etc.
26.04.00 Communication
The Employer will extend the telephone facilities, if available at Site, for
purposes of Contract. The Contractor shall be charged at actuals for such
facili-ties.
26.05.00 Cranes
Turbine hall EOT cranes may be used by the Contractor on chargeable basis
for erection of the units / equipments under this package. For the equipments
which cannot be handled by these Turbine hall EOT cranes, the Contractor
shall make his own arrangements.
27.00.00 FACILITIES TO BE PROVIDED BY THE CONTRACTOR
27.01.00 Contractor's site office Establishment
The Contractor shall establish a site office at the site and keep posted an
authorized representative for the purpose of the contract, pursuant to GCC.
27.02.00 Tools, tackles and scaffoldings
The Contractor shall provide all the construction equipments, tools, tackles and
scaffoldings required for pre-assembly, installation, testing, commissioning and
conducting Guarantee tests of the equipments covered under the Contract. He
shall submit a list of all such materials to the Employer before the
commencement of pre-assembly at Site. These tools and tackles shall not be
removed from the Site without the written permission of the Employer. The
Contractor shall arrange Dozer, Hydra, Cranes, Trailer, etc. for the purpose of
fabrication, erection and commissioning.
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27.03.00 Testing Equipment and Facilities:
The contractor shall provide the necessary testing, equipment and facilities.
27.04.00 Site laboratory for civil works:
Contractor shall provide and maintain a site laboratory for the testing of
construction material under the direction and general supervision of employer.
Alternatively, bidder shall make arrangement for testing of material/workmanship
of work in his scope at employer's lab (if available) or any other approved
external laboratory.
27.05.00 First-aid
27.05.01 The Contractor shall provide necessary first-aid facilities for all his employees,
representatives and workmen working at the Site. Enough number of
Contractor's personnel shall be trained in administering first-aid.
27.05.02 The Employer will provide the Contractor, in case of any emergency, the
services of an ambulance for transportation to the nearest hospital.
27.06.00 Cleanliness
27.06.01 The Contractor shall be responsible for keeping the entire area allotted to him
clean and free from rubbish, debris etc. during the period of Contract. The
Contractor shall employ enough number of special personnel to thoroughly
clean his work-area at least once in a day. All such rubbish and scrap
material shall be stacked or disposed in a place to be identified by the
Employer. Materials and stores shall be so arranged to permit easy cleaning
of the area. In areas where equipment might drip oil and cause damage to
the floor surface, a suitable protective cover of a flame resistant, oil proof
sheet shall be provided to protect the floor from such damage.
27.06.02 Similarly the labour colony, the offices and the residential areas of the
Contractor's employees and workmen shall be kept clean and neat to the
entire satisfaction of the Employer. Proper sanitary arrangements shall be
provided by the Contractor, in the work-areas, office and residential areas of
the Contractor.
28.00.00 LINES AND GRADES
All the Works shall be performed to the lines, grades and elevations indicated
on the drawings. The Contractor shall be responsible to locate and layout the
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Works. Basic horizontal and vertical control points will be established and
marked by the Employer at Site at suitable points. These points shall be
used as datum for the works under the Contract. The Contractor shall inform
the Employer well in advance of the times and places at which he wishes
to do work in the area allotted to him so that suitable datum points may be
established and checked by the Employer to enable the Contractor to proceed
with his works. Any work done without being properly located may be
removed and/or dismantled by the Employer at Contractor's expense.
29.00.00 FIRE PROTECTION
29.01.00 The work procedures that are to be used during the erection shall be those
which minimise fire hazards to the extent practicable. Combustible materials,
combustible waste and rubbish shall be collected and removed from the Site
at least once each day. Fuels, oils and volatile or flammable materials shall be
stored away from the construction and equipment and materials storage areas
in safe containers. Untreated canvas, paper, plastic or other flammable flexible
materials shall not at all be used at Site for any other purpose unless
otherwise specified. If any such materials are received with the equipment at
the Site, the same shall be removed and replaced with acceptable material
before moving into the construction or storage area.
29.02.00 Similarly corrugated paper fabricated cartons etc. will not be permitted in the
construction area either for storage or for handling of materials. All such
materi-als used shall be of water proof and flame resistant type. All the other
materials such as working drawings, plans etc. which are combustible but are
essential for the works to be executed shall be protected against combustion
resulting from welding sparks, cutting flames and other similar fire sources.
29.03.00 All the Contractor's supervisory personnel and suffi-cient number of workers
shall be trained for fire-fighting and shall be assigned specific fire protection
duties. Enough of such trained personnel must be avail-able at the Site during
the entire period of the Contract.
29.04.00 The Contractor shall provide enough fire protection equipment of the types and
number for the warehouses, office, temporary structures, labour colony area etc.
Access to such fire protection equipment, shall be easy and kept open at all
time.
30.00.00 SECURITY
The Contractor shall have total responsibility for all equipment and materials in
his custody stores, loose, semi-assembled and/or erected by him at Site. The
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Contractor shall make suitable security arrangements including employment of
security personnel to ensure the protection of all materials, equipment and
works from theft, fire, pilferage and any other damages and loss. All materials
of the Contractor shall enter and leave the Employer Site only with the written
permission of the Employer in the prescribed manner.
31.00.00 CONTRACTOR'S AREA LIMITS
The Employer will mark-out the boundary limits of access roads, parking
spaces, storage and construction areas for the Contractor and the Contractor
shall not trespass the areas not so marked out for him. The Contractor shall
be responsible to ensure that none of his personnel move out of the areas
marked out for his operations. In case of such a need for the Contactor's
personnel to work out of the areas marked out for him the same shall be
done only with the written permission of the Employer.
32.00.00 CONTRACTOR' S CO-OPERATION WITH THE EMPLOYER
In case where the performance of the erection work by the Contractor affects
the operation of the system facilities of the Employer, such erection work of
the Contractor shall be scheduled to be performed only in the manner
stipulated by the Employer and the same shall be acceptable at all times to
the Contractor. The Employer may impose such restrictions on the facilities
provided to the Contractor such as electricity, etc. as he may think fit in the
interest of the Employer and the Contractor shall strictly adhere to such re-
strictions and co-operate with the Employer. It will be the responsibility of the
Contractor to provide all necessary temporary instrumentation and other
measuring devices required during start-up and operation of the equipment
systems which are erected by him. The Contractor shall also be responsible
for flushing and initial filling of all the oil and lubricants required for the
equipment furnished and installed by him, so as to make such equipment
ready for operation. The Contractor shall be responsible for supplying such
flush-ing oil and other lubricants unless otherwise specified elsewhere in
documents and specifications.
33.00.00 PRE-COMMISSIONING AND COMMISSIONING ACTIVITIES
33.01.00 GENERAL
33.01.01 The Contractor upon completion of installation of equipments and systems,
shall conduct pre-commissioning and commissioning activities, to make the
equipment/systems ready for safe, reliable and efficient operation on sustained
basis. All pre-commissioning/commissioning activities considered essential for
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such readiness of the equipment/systems including those mutually agreed and
included in the Contractor's quality assurance programme as well as those
indicated in clauses elsewhere in the technical specifications shall be
performed by the contractor.
33.01.02 The pre-commissioning and commissioning activities including Guarantee tests,
checks and trial operations of the equipment/systems furnished and installed
by the contractor shall be the responsibility of the Contractor as detailed in
relevant clauses in Technical Specification. The Contractor shall provide, in
addition, test instruments, calibrating devices etc. and labour required for
successful performance of these operations. If it is anticipated that the above
test may prolong for a long time, the Contractor's workmen required for the
above test shall always be present at site during such operations.
33.01.03 The following activities shall be carried out by the contractor, 18 month prior
to schedule date of commissioning of the equipment/systems installed by him.
(a.) The contractor shall furnish the organization chart of his operation and
commissioning engineers for the acceptance of employer. Adequate
number of operation and commissioning engineers shall be deployed by
the contractor to effectively meet the requirement of round the clock
operation in shifts also, till the plant is taken over by the employer.
(b.) The contractor shall submit the bio-data containing the details of
experience of his operation and commissioning engineers for the
acceptance of employer.
(c.) The contractor shall furnish the deployment schedule of his operation
and commissioning engineers for the acceptance of the employer.
(d.) Apart from above, contractor shall ensure deployment of sufficient
skilled/semi-skilled/unskilled manpower during pre-commissioning and
commissioning activities.
33.01.04 It shall be the responsibility of the Contractor to provide all necessary
temporary instrumentation and other measuring devices required during start-up
and initial operation of the equipment/systems which are installed by him.
33.01.05 The Contractor shall also be responsible for flushing and initial filling of all oils
and lubricants required for the equipment furnished and installed by him so as
to make such equipment ready for operation. The Contractor shall be
responsible for supplying such flushing oil and other lubricants unless
otherwise specified elsewhere in these specifications and documents.
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33.02.00 COMMISSIONING DOCUMENTATION
33.02.01 The contractor shall submit the commissioning documentation, comprising of
Standard checklists, pre-commissioning procedures, testing schedules,
commissioning schedules and commissioning networks for various equipment/
systems covered under the contract, for the approval of employer.
33.02.02 Standard checklist, as the name suggests, shall be a fairly general
documents, containing the list of all checks required to be carried out for
similar and repetitive type of equipment to ensure consistent and thorough
checking. An indicative list of such equipment is enclosed as Annexure I.
33.02.03 The testing schedule is a document, designed for safe and systematic
commissioning of individual equipment/sub-system (for example Boiler Feed
Pump, condensate pump, compressor etc) Commissioning schedule is a
document envisaged for commissioning of a system (for example feed
system, Condensate system, Compressed Air system, commissioning etc).
The testing/Commissioning schedule shall have a standard format in order to
maintain consistency of presentation, content and reporting. A brief write up
on the contents of the Testing Schedule/Commissioning Schedule is enclosed
as Annexure-II.
33.02.04 The contractor shall submit the list of commissioning documentation to be
submitted by him, alongwith their submission schedule for various equipment/
systems covered under the contract, with in 6(six) month from the date of
award of contract, for the acceptance of employer.
33.02.05 The Contractor shall submit the commissioning documentation, for various
equipment/covered under the contract, for the approval of employer, at least
18 months before the scheduled date of commissioning of the equipment/
systems.
33.03.00 COMMISSIONING ACTIVITIES
33.03.01 Upon completion of pre-commissioning activities/tests, the contractor shall
initiate commissioning of facilities. During commissioning the Contractor shall
carry out system checking and reliability trials on various parts of the facilities.
33.03.02 Contractor shall carry out the checks/tests at site to prove to the Employer
that each equipment of the supply complies with requirements stipulated and
is installed in accordance with requirements specified.
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33.03.03 Before the plant is put into initial operation the Contractor shall be required to
conduct test to demonstrate to the Employer that each item of the plant is
capable of correctly performing the functions for which it was specified and its
performance, parameters etc. are as per the specified/approved values. These
tests may be conducted concurrently with those required under commissioning
sequence.
33.03.04 The Contractor shall also demonstrate the performance of all C&I equipment,
the tests on main equipment of prior to that as the case may be.
33.03.05 Other tests shall be conducted, if required by the Employer, to establish that
the plant equipment are in accordance with requirements of the specifications.
33.03.06 The Contractor shall conduct all the commissioning tests and undertake
commissioning activities pertaining to all other auxiliaries and equipments
including all electrical and C&I equipment/systems not specifically brought out
above but are within the scope of work and facilities being supplied and
installed by the Contractor and follow the guidelines indicated above or
elsewhere in these technical specifications.
Upon completion of system checking/Tests as above and as a part of
commissioning of facilities, complete plant/facilities shall be put on initial
operation as stipulated in General Technical Requirements.
34.00.00 MATERIALS HANDLING AND STORAGE
34.01.00 All the equipments furnished under the Contract and arriving at Site shall be
promptly received, unloaded and transported and stored in the storage spaces
by the Contractor.
34.02.00 Contractor shall be responsible for examining all the shipment and notify the
Employer immediately of any damage, shortage, discrepancy etc. for the
purpose of Employer's information only. The Contractor shall submit to the
Employer every week a report detailing all the receipts during the week.
However, the Contractor shall be solely responsible for any shortages or
damage in transit, handling and / or in storage and erection of the equipment
at Site. Any demurrage, wharfage and other such charges claimed by the
transporters, railways etc. shall be to the account of the Contractor.
34.03.00 The Contractor shall maintain an accurate and exhaustive record detailing out
the list of all equipment received by him for the purpose of erection and keep
such record open for the inspection of the Employer.
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34.04.00 All equipment shall be handled very carefully to prevent any damage or loss.
No bare wire ropes, slings, etc. shall be used for unloading and/or handling
of the equipment without the specific written permission of the Employer. The
equipment stored shall be properly protected to prevent damage either to the
equipment or to the floor where they are stored. The equipment from the
store shall be moved to the actual location at the appropriate time so as to
avoid damage of such equip-ment at Site.
34.05.00 All electrical panels, controls gear, motors and such other devices shall be
properly dried by heating before they are installed and energised. Motor
bearings, slip rings, commutators and other exposed parts shall be protected
against moisture ingress and corrosion during storage and periodically
inspected. Heavy rotating parts in assembled conditions shall be periodically
rotated to prevent corrosion due to prolonged storage.
34.06.00 All the electrical equipment such as motors, generators, etc. shall be tested
for insulation resistance at least once in three months from the date of
receipt till the date of commissioning and a record of such measured
insulation values maintained by the Contractor. Such records shall be open
for inspection by the Employer.
34.07.00 The Contractor shall ensure that all the packing materials and protection
devices used for the various equipments during transit and storage are
removed before the equipment are installed.
34.08.00 The consumables and other supplies likely to deteriorate due to storage must
be thoroughly protected and stored in a suitable manner to prevent damage or
dete-rioration in quality by storage.
34.09.00 All the materials stored in the open or dusty location must be covered with
suitable weatherproof and flame-proof covering material wherever applicable.
34.10.00 If the materials belonging to the Contractor are stored in areas other than
those earmarked for him, the Employer will have the right to get it moved to
the area earmarked for the Contractor at the Contractor's cost.
34.11.00 The Contractor shall be responsible for making suitable indoor storage facilities
to store all equipment which require indoor storage. Normally, all the electrical
equipments such as motors, control gear, generators, exciters and
consumables like electrodes, lubricants etc. shall be stored in the closed
storage space. The Employer, in addition, may direct the Contractor to move
certain other materials, which in his opinion will require indoor storage, to
indoor storage areas which the Contractor shall strictly comply with.
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35.00.00 CONSTRUCTION MANAGEMENT
35.01.00 The field activities of the Contractors working at Site, will be coordinated by
the Employer and the Employer decision shall be final in resolving any
disputes or conflicts between the Contractor and other Contractors and
tradesmen of the Employer regarding scheduling and coordination of work.
Such decision by the Employer shall not be a cause for extra compensation
or extension of time for the Contractor.
35.02.00 The Employer shall hold weekly meetings of all the Contractors working at
Site, at a time and place to be designated by the Employer. The Contractor
shall attend such meetings and take notes of discussions during the meeting
and the decisions of the Employer and shall strictly adhere to those decisions
in performing his Works. In addition to the above weekly meeting, the
Employer may call for other meeting either with individual Contractors or with
selected number of Contractors and in such a case the Contractor if called,
will also attend such meetings.
35.03.00 Time is the essence of the Contract and the Contractor shall be responsible
for performance of his works in accordance with the specified construction
schedule. If at any time, the Contractor is falling behind the schedule, he shall
take necessary action to make good for such delays by increasing his work
force or by working overtime or otherwise accelerate the progress of the work
to comply with the schedule and shall communicate such actions in writing to
the Employer, satisfying that his action will compensate for the delay. The
Contractor shall not be allowed any extra compensation for such action.
35.04.00 The Employer shall however not be responsible for provision of additional
labour and/or materials or supply or any other services to the Contractor
except for the co-ordination work between various Contractors as set out
earlier.
36.00.00 FIELD OFFICE RECORDS
The Contractor shall maintain at his Site Office up-to- date copies of all
drawings, specifications and other Contract Documents and any other
supplementary data complete with all the latest revisions thereto. The
Contractor shall also maintain in addition the continu-ous record of all changes
to the above Contract Docu-ments, drawings, specifications, supplementary
data, etc. effected at the field and on completion of his total assignment under
the Contract shall incorporate all such changes on the drawings and other
Engineering data to indicate as installed conditions of the equipment furnished
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and erected under the Contract. Such drawings and Engineering data shall be
submitted to the Employer in required number of copies.
37.00.00 CONTRACTOR' S MATERIALS BROUGHT ON TO SITE
37.01.00 The Contractor shall bring to Site all equipment, components, parts, materials,
including construction equipment, tools and tackles for the purpose of the
Works under intimation to the Employer. All such goods shall, from the time
of their being brought vest in the Employer, but may be used for the purpose
of the Works only and shall not on any account be removed or taken away
by the Contractor without the written permission of the Employer. The
Contractor shall nevertheless be solely liable and responsible for any loss or
destruction thereof and damage thereto.
37.02.00 The Employer shall have a lien on such goods for any sum or sums which
may at any time be due or owing to him by the Contractor, under, in respect
of or by reasons of the Contract. After giving a fifteen (15) days notice in
writing of his intention to do so, the Employer shall be at liberty to sell and
dispose off any such goods, in such manner as he shall think fit including
public auction or private treaty and to apply the proceeds in or towards the
satisfaction of such sum or sums due as aforesaid.
37.03.00 After the completion of the Works, the Contractor shall remove from the Site
under the direction of the Employer the materials such as construction
equipment, erection tools and tackles, scaffolding etc. with the written
permission of the Employer. If the Contractor fails to remove such materials,
within fifteen (15) days of issue of a notice by the Employer to do so then
the Employer shall have the liberty to dispose off such materials as detailed
under as specified at clause no 38.02.00- of this chapter and credit the
proceeds thereto to the account of the Contractor.
38.00.00 PROTECTION OF PROPERTY AND CONTRACTOR' S LIABILITY
38.01.00 The Contractor shall be responsible for any damage resulting from his
operations. He shall also be re-sponsible for protection of all persons including
members of public and employees of the Employer and the employees of
other Contractors and Sub- Contractors and all public and private property
including structures, building, other plants and equipments and utilities either
above or below the ground.
38.02.00 The Contractor will ensure provision of necessary safety equipment such as
barriers, sign - boards, warning lights and alarms, etc. to provide adequate
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protection to persons and property. The Contractor shall be responsible to give
reasonable notice to the Employer and the Employers of public or private
property and utili-ties when such property and utilities are likely to get
damaged or injured during the performance of his Works and shall make all
necessary arrangements with such Employers, related to removal and/or
replacement or pro-tection of such property and utilities.
39.00.00 PAINTING
All exposed metal parts of the equipment including pipings, structure railings,
etc. wherever applicable, after installation unless otherwise surface protected, shall
be first painted with at least two coats of suit-able primer which matches the
shop primer paint used, after throughly cleaning all such parts of all dirt, rust,
scales, greases, oils and other foreign materials by wire brushing, scraping or
sand blasting and the same being inspected and approved by the Employer for
painting. Afterwards, the above parts shall be fin-ished painted with three coats
of allowed resin machin-ery enamel paints. The minimum thickness of paint film
shall not be less than 100 microns. The quality of the finish paint shall be as
per the standards of Bureau of Indian Standards (BIS) or equivalent and to be
of the colour as approved by the Employer.
Painting for structures shall confirm to the painting specification specified in
Part-'B' under "Civil".
40.00.00 INSURANCE
40.01.00 In addition to the conditions covered under the Clause entitled "Insurance" in
Section General Conditions of Contract (GCC), the following provisions will also
apply to the portion of works to be done beyond the Contractor's own or his
Sub-Contractor's manufacturing Works.
40.02.00 Workmen's Compensation Insurance
This insurance shall protect the Contractor against all claims applicable under
the Workmen's Compensation Act, 1948 (Government of India). This policy
shall also cover the Contractor against claims for injury, disa-bility disease or
death of his or his Sub-Contractor's employees, which for any reason are not
covered under the Workmen's Compensation Act, 1948. The liabili-ties shall
not be less than the following:
Workmen's Compensation - As per Statutory Provisions
Employee's Liability - As per Statutory Provisions
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40.03.00 Comprehensive Automobile Insurance
This insurance shall be in such a form to protect the Contractor against all
claims for injuries, disability, disease and death to members of public
including the Employer's men and damage to the property of other arising
from the use of motor vehicles during on or off the Site operations,
irrespective of the Ownership of such vehicles. The liability covered shall be
as herein indicated :
Fatal Injury : Rs.100,000 each person
: Rs.200,000 each occurrence
Property Damage : Rs.100,000 each occurrence
40.04.00 Comprehensive General Liability Insurance
40.04.01 The insurance shall protect the Contractor against all claims arising from
injuries, disabilities, disease or death of members of public or damage to
property of others, due to any act or omission on the part of the Contractor,
his agents, his employees, his representa-tives and Sub-Contractors or from
riots, strikes and civil commotion. This insurance shall also cover all the
liabilities of the Contractor arising out of the Clause entitled "Defence of
Suits" in Section General Conditions of Contract (GCC).
40.04.02 The hazards to be covered will pertain to all the Works and areas where
the Contractor, his Sub-Contractors, his agents and his employees have to
perform work pursuant to the Contract.
40.05.00 The above are only illustrative list of insurance covers normally required and it
will be the responsi-bility of the Contractor to maintain all necessary insurance
coverage to the extent both in time and amount to take care of all his
liabilities either direct or indirect, in pursuance of the Contract.
41.00.00 UNFAVOURABLE WORKING CONDITIONS
The Contractor shall confine all his field operations to those works which can
be performed without subject-ing the equipment and materials to adverse
effects during inclement weather conditions, like monsoon, storms, etc. and
during other unfavourable construction conditions. No field activities shall be
performed by the Contractor under conditions which might adversely affect the
quality and efficiency thereof, unless special precautions or measures are
taken by the Contractor in a proper and satisfactory manner in the
performance of such Works and with the concurrence of the Employer. Such
unfavourable construction condi-tions will in no way relieve the Contractor of
his responsibility to perform the Works as per the schedule.
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42.00.00 PROTECTION OF MONUMENTS AND REFERENCE POINTS
The Contractor shall ensure that any finds such as relic, antiquity, coins,
fossils, etc. which he may come across during the course of performance of
his Works either during excavation or elsewhere, are properly protected and
handed over to the Employer. Similarly the Contractor shall ensure that the
bench marks, reference points, etc., which are marked either with the help of
Employer or by the Employer shall not be disturbed in any way during the
performance of his Works. If, any work is to be preformed which disturb such
reference, the same shall be done only after these are transferred to other
suitable locations under the direction of the Employer. The Contractor shall
pro-vide all necessary materials and assistance for such relocation of
reference points etc.
43.00.00 WORK & SAFETY REGULATIONS
43.01.00 General
i) The contractor shall comply with all the requirements of "The Building
and Other Construction Workers (Regulation of Employment &
Conditions of Service) Act," 1996 and its Central Rule 1998 / State
Rules and any other statutory requirements as applicable.
ii) The Contractor shall follow NTPC Safety Rules as issued from time to
time with respect to safety in construction & erection.
iii) The contractor shall have the approved Safety, Health and Environment
(SHE) Policy in respect of Safety and health of Building Workers and it
shall be circulated widely and displayed at conspicuous place in Hindi
and local language understood by the majority of the workers. A copy of
the safety policy should be submitted to Engineer in charge.
iv) The contractor shall submit the safety plan comprising of methods to
implement the Safety Policy/ Rules, Risk assessment and ensuring
Safety at work areas, Safety audits, inspections and its compliance,
Supervision and responsibility to ensure Safety at various levels, Safety
training to employees, review of Safety and accident analysis, ensure
Health and Safety Procedures to prevent accidents to Engineer I/c for
approval as per the format of Safety plan as annexed at Annexure - I.
v) The Contractors shall ensure proper safety of all the workmen,
materials, plant and equipment belonging to him or to the Employer or
to others, working at the Site.
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vi) All equipments used in construction and erection by the contractor shall
meet BIS / International Standards and where such standards do not
exist, the Contractor shall ensure these to be absolutely safe. All
equipments shall be strictly operated and maintained by the contractor
in accordance with manufacturer's operation manual. The contractor
should also follow Guidelines / Rules of the Employer in this regard.
vii) The Contractors shall provide suitable latest Personal Protective
Equipments of prescribed standard to all their employees and workmen
according to the need. The Engineer I/c shall have the right to examine
these safety equipments to determine their suitability, reliability,
acceptability and adaptability. The contractor should also ensure these
before their use at worksite.
viii) The Contractor shall provide safe working conditions to all workmen
and employees at his workplace including safe means of access,
railings, stairs, and ladders, scaffolding, work platforms, toe boards etc.
The scaffoldings shall be erected under the control and supervision of
an experienced and competent person. For erection of scaffolds,
access, work platforms etc. shall be good and the contractor shall use
standard quality of material.
ix) The Contractor shall follow and comply with all the Safety Rules,
standards, code of practices of NTPC and relevant provisions of
applicable laws pertaining to the safety of workmen, employees, plant
and equipment as may be prescribed from time to time without any
protest or contest or reservation. In case of any unconformity between
statutory requirement and the Safety Rules of the Employer referred
above, the latter shall be binding on the Contractor unless the statutory
provisions are more stringent. As and when required he can refer /
obtain copy of NTPC safety documents as stated above.
x) The contractor shall have his own arrangements with nearby hospitals
for shifting and treatment of sick and injured.
The medical examination of the workers employed in hazardous areas
shall be conducted as per Rule 223 0f The Building and Other
Construction Worker (Regulation of Employment and Condition of
Service) Central Rule 1998 Their health records shall be maintained
accordingly and to be submitted to Engineer I/c when asked for. If any
worker found suffering from occupational health hazard, the worker
should be shifted to suitable place of working and properly treated
under intimation to Engineer I/c. The medical fitness certificate to be
submitted to Engineer (I/c).
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xi) First Aid boxes equipped with requisite articles as specified in the Rule
231 of The Building and Other Construction Worker (Regulation of
Employment and Condition of Service) Central Rule 1998 shall be
provided at construction sites for the use of workers. Training has to
be provided on first aid to workmen & office bearers working at site.
43.01.01 Emergency Action Plan
The contractor shall prepare an emergency action plan approved by his
competent authority to handle any emergency occurred during construction
work. Regular mock drills shall be organized to practice this emergency plan.
The Emergency Action Plan should be widely circulated to all the employees
and suitable infrastructure shall be provided to handle the emergencies.
43.01.02 Scaffolding
The contractor shall take all precautions to prevent any accidental collapse of
scaffolding or fall of persons from scaffolding. The contractor should ensure
that scaffolding are designed by a competent person and it erection and
repairs should be done under the expert supervision. The scaffolding shall
meet the required strength and other requirements for the purpose for which
the scaffold is erected. The material used for scaffold should conform to the
BIS / International standards.
43.01.03 Openi ng
The contractor shall ensure that there is no opening in any working platform/
any floor of the building, which may cause fall of workers or material. When
ever an opening on a platform/any floor of the building is unavoidable, the
opening should be suitably fenced and necessary measures for protection
against falling objects or building workers from such platform are taken by
providing suitable safety nets, safety belts or other similar means.
43.01.04 Expl osi ves
The contractor shall take all precautions while handling, using, storing or
transporting of all explosives. Before usage of any explosive necessary warning
/ danger signals be erected at conspicuous places to warn the workers and
general public. The contractor should strictly ensure that all measures and
precautions required to be complied for use, handling, storing or transportation
of explosives under the rules framed under the Explosives Act, 1884.
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43.02.00 Fencing of Machinery
The contractor shall provide suitable fencing or guard to all dangerous and
moving parts of machinery.
The contractor shall not allow any of the employees to clean, lubricate, repair,
adjust or examine during machinery in motion, which may cause injury to the
person.
43.03.00 Carrying of Excessive Weight by a Worker
The worker shall not be allowed to lift by hand or carry over his head, back
or shoulder more than the maximum limit set by the prescribed rules for the
construction Workers.
43.04.00 Dangerous and Harmful Gases / Equipment
The contractor shall ensure that the workers are not exposed to any harmful
gases during any construction activity including excavation, tunneling, confined
spaces etc.
The contractor should not allow any worker to go into the confined space
unless it is certified by Engineer (I/c) to be safe and fit for the entry to such
work place. Proper record and work permits should be followed to carry out
such works.
43.05.00 Overhead Protecti on
The contractor shall ensure that any area exposed to risk of falling materials,
articles or objects is roped off or cordoned off or otherwise suitably guarded
from inadvertent entry of any person.
Wherever there is a possibility of falling of any material, equipment or
construction workers while working at heights, a suitable and adequate safety
net should be provided. The safety net should be in accordance with BIS
Standards.
43.06.00 Working at Heights
All working platforms, ways and other places of construction work shall be
free from accumulations of debris or any other material causing obstructions
and tripping.
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Wherever workers are exposed to the hazard of falling into water, the
contractor shall provide adequate equipment for saving the employees from
drowning and rescuing from such hazards. The contractor shall provide boat
or launch equipped with sufficient number of life buoys, life jackets etc.
manned with trained personnel at the site of such work.
Every opening at elevation from ground level through which a building worker,
vehicle, material equipment etc. may fall at a construction work shall be
covered and/or guarded suitably by the contractor to prevent such falls.
Wherever the workers are exposed to the hazards of falling from height, the
contractor shall provide full harness safety belts fitted with fall arresting
systems to all the employees working at higher elevations and life line of 8
mm diameter wire rope with turn buckles for anchoring the safety belts while
working or moving at higher elevations. Safety nets shall also be provided for
saving them from fall from heights and such equipment should be in
accordance with BIS standards.
Wherever there is a possibility of falling of any material, equipment or
construction workers while working at heights, a suitable and adequate safety
net should be provided. The safety net should be in accordance with BIS
Standards.
The contractor shall provide standard prefabricated ladders on the columns
where the workers are required to use them as an access for higher
elevations till permanent staircase is provided. The workers shall be provided
with safety belts fitted with suitable fall arresting system (Fall arrestors) for
climbing/getting down through ladders to prevent fall from height.
43.07.00 Handling of Hazardous Chemicals
The Contractor will notify well in advance to the Engineer I/c of his intention to
bring to the Site any container filled with liquid or gaseous fuel or explosive or
petroleum substance or such chemicals which may involve hazards. NTPC
shall have the right to prescribe the conditions, under which such container is
to be stored, handled and used during the performance of the works and the
Contract shall strictly adhere to and comply with such instructions. The
Engineer I/c shall have the right at his sole discretion to inspect any such
container or such construction plant / equipment for which material in the
container is required to be used and if in his opinion, its use is not safe, he
may forbid its use. No claim due to such prohibition shall be entertained by
NTPC and NTPC shall not entertain any claim of the Contractor towards
additional safety provisions / conditions to be provided for / constructed.
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Further, any such decision of the Engineer I/c shall not, in any way, absolve
the Contractor of his responsibilities and in case, use of such a container or
entry thereof into the Site area is forbidden by NTPC, the Contractor shall use
alternative methods with the approval of the NTPC without any cost implication
to the NTPC or extension of work schedule.
Where it is necessary to provide and / or store petroleum products or petroleum
mixtures and explosives, the Contractor shall be responsible for carrying-out such
provision and / or storage in accordance with the rules and regulations laid down
in Petroleum Act 1934, Explosives Act 1948, and Petroleum and Carbide of Calcium
Manual published by the Chief Inspector of Explosives of India. All such storage
shall have prior approval of the Engineer I/c. In case any approvals are necessary
from the Chief Inspector (Explosives) or any statutory authorities, the Contractor
shall be responsible for obtaining the same.
The Contractor shall be fully responsible for the safe storage of his and his
Sub-contractor's radio-active sources in accordance with BARC/DAE (Bhabha
Atomic Research Centre/ Department of Atomic Energy, Govt. of India) Rules
and other applicable provisions. All precautionary measures stipulated by
BARC/DAE in connection with use, the contractor would take storage and
handling of such material.
The contractor shall provide suitable personal protective equipments to the
workers who are handling the hazardous and corrosive substances including
alkalis and acids.
As a precautionary measure the contractor should keep the bottles filled with
distilled water in cupboard / Boxes near work place for emergency eye wash
by worker exposed to such hazardous chemicals.
43.08.00 Eye Protection
The contractor shall provide suitable personal protective equipment to his
workmen depending upon the nature of hazards and ensure their usage by
the workers engaged in operations like welding, cutting, chipping, grinding or
similar operations which may cause injuries to his eyes.
43.09.00 Excavation
The contractor shall take all necessary measures during excavation to prevent
the hazards of falling or sliding material or article from any bank or side of
such excavation which is more than one and a half meter above his footing
by providing adequate piling, shoring, bracing etc. against such bank or sides.
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Adequate and suitable warning signs shall be put up at conspicuous places at
the excavation work to prevent any persons or vehicles falling into the
excavation trench. No worker should be allowed to work where he may be
stuck or endangered by excavation machinery or collapse of excavations or
trenches.
43.10.00 Electrical Hazards
The contractor should ensure that all electrical installations at the construction
work comply with the requirements of latest electricity acts / rules.
The contractor shall take all adequate measures to prevent any worker from
coming into physical contact with any electrical equipment or apparatus,
machines or live electrical circuits which may cause electrical hazards during
the construction work. The contractor shall provide the sufficient ELCBs /
RCCBs for all the portable equipments, electrical switchboards, distribution
panels etc. to prevent electrical shocks.
The contractor should ensure use of single / double insulated hand tools or
low voltage i.e., 110 volts hand tools.
The contractor should also ensure that all temporary electrical installations at
the construction works are provided with earth leakage circuit breakers.
43.11.00 Vehicular Traffic
The contractor should employ vehicle drivers who hold a valid driving license
under the Motor Vehicles Act, 1988.
43.12.00 Lifting Appliances, Tools & Tackles, Lifting Gear And Pressure Plant &
Equipment etc.
The contractor shall ensure all the lifting appliances, tools & tackles including
cranes etc., lifting gear including fixed or movable and any plant or gear,
hoists, Pressure Plant and equipment etc. are in good condition and shall be
examined by competent person and only certified shall be used at sites.
Periodical Examination and the tests for all lifting / hoisting equipment &
tackles shall be carried out. A register of such examinations and tests shall be
properly maintained by the Contractor and will be promptly produced as and
when desired by the Engineer I/c or by the person authorized by him.
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43.13.00 Excessive Noise, Vibration
The contractor shall take adequate measures to protect the workers against
the harmful effect of excessive noise or vibration. The noise should not
exceed the limits prescribed under the concerned rules, Noise Pollution
(Regulation and Control) Rules, 2000.
43.14.00 Electrical Installations
43.14.01 The Contractor shall not interfere or disturb electric fuses, wiring and other
electrical equipment belonging to the Employer or other contractors under any
circumstances, whatsoever, unless expressly permitted in writing by the
Engineer I/c to handle such fuses, wiring or electrical equipment.
Before the Contractor connects any electrical appliances to any plug or socket
belonging to the other contractor or the NTPC, he shall
i) Satisfy the Engineer I/C that the appliance is in good working condition;
ii) Inform the Engineer I/C of the maximum current rating, voltage and
phases of the appliances;
iii) Obtain permission of the Engineer I/C detailing the sockets to which
the appliances may be connected.
The Engineer I/C will not grant permission to connect until he is
satisfied that:
The appliance is in good condition and is fitted with suitable plug;
having earth connection with the body.
Wherever armored / metallic sheathed multi core cable is used, the
same armored / sheathed should be connected to earth.
iv) No repair work shall be carried out on any live equipment. The
Engineer I/c must declare the equipment safe and a permit to work
shall be issued by the NTPC / contractor as the case may be to
carry out any repair / maintenance work. While working on electric
lines / equipments whether live or dead, suitable type and sufficient
quantity of tools will have to be provided by the contractor to
electricians / workmen / Officers.
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v) The contractor shall employ necessary number of qualified, full time
Electricians / Electrical Supervisors to maintain his temporary electrical
installation.
The installations are provided with suitable ELCBs and RCCBs
wherever required.
43.15.00 Safety Organisation
43.15.01 The contractor employing more than 250 workmen whether temporary, casual,
probationary, regular or permanent shall employ at least one full time safety
officer exclusively to supervise safety aspects of the equipments and
workmen, who will coordinate with the NTPC Safety Officer. Further
requirement of safety officers, if any, shall be guided by Rule 209 of The
Building and Other Construction Worker (Regulation of Employment and
Conditions of Service) Central Rule 1998. In case the work is being carried
out through subcontractor, the employees / workmen of the sub contractor
shall also be considered as the contractor's employees/workmen for the above
purpose.
In case of contractor deploying less than 250 workmen he should designate
one of his Engr / supervisor or the contractor himself (if he is directly
supervising the work) as safety officer in addition to his existing
responsibilities. The Engr./ supervisor should get atleast 2days safety training
from any reputed organization or from NTPC before resuming the work. If
already trained in past the declaration along with trg. certificate to be furnished
to NTPC safety officer.
43.15.02 The name and address of such Safety Officer of the Contractor will be
promptly informed in writing to the EIC with a copy to the Project Safety
Officer before he starts work or immediately after any change of the
incumbent is made during currency of the Contract.
43.16.00 Reporting of Accident and Investigation
In case any accident occurs during the construction / erection or other
associated activities undertaken by the Contractor thereby causing any near
miss, minor or major or fatal injury to his employees due to any reason,
whatsoever, it shall be the responsibility of the Contractor to promptly inform
the same to the Engineer I/C, NTPC Safety Officer with a copy to NTPC
Head of Project in the prescribed form and also to all the authorities
envisaged under the applicable laws.
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43.17.00 Right to stop Work
43.17.01 The Engineer I/C shall have the right at his sole discretion to stop the work,
if in his opinion the work is being carried out in such a way that it may
cause accidents and endanger the safety of the persons and / or property,
and / or equipments. In such cases, the contractor shall be informed in
writing about the nature of hazards and possible injury / accident and he shall
comply to remove shortcomings promptly. The Contractor after stopping the
specific work can, if felt necessary appeal against the order of stoppage of
work to the Project Manager within 3 days of such stoppage of work and
decision of the Project Manager in this respect shall be conclusive and binding
on the Contractor.
43.17.02 The Contractor shall not be entitled for any damages / compensation for
stoppage of work, {Sub-Clause XVIII (I)} due to safety reasons and the period
of such stoppage of work shall not be taken as an extension of time for
Completion of the Facilities and will not be the ground for waiver of levy of
liquidated damages.
43.18.00 Fi re Protecti on
The contractor shall provide sufficient fire extinguishers at place /s of work.
The fire extinguishers shall be properly maintained as per relevant BIS
Standards. The employees shall be trained to operate the fire extinguishers /
equipment.
43.19.00 Penal ti es
I If the Contractor fails in providing safe working environment as per the
Safety Rules of NTPC or continues the work even after being
instructed to stop the work by the Engineer I/C as provided in Clause
XVIII (1) above, the Contractor shall be penalized at the rate of Rs.
25,000/- per day or part thereof till the instructions are complied with
and so certified by the Engineer I/C. However, in case of accident, the
provisions contained in Sub-Clause XX (II) below shall also apply in
addition to the penalties mentioned in this sub-clause.
II If the Contractor does not take all safety precautions and / or fails to
comply with the Safety Rules as prescribed by the Employer or under
the applicable law for the safety of the plant and equipment and for the
safety of personnel and the contractor does not prevent hazardous
conditions which cause injury to this own employees or employees of
other contractors, or NTPC's employees or any other person who are
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at the Site or adjacent thereto, the Contractor shall be responsible for
payment of penalty to NTPC as per the following schedule:-
a) Fatal injury or accident causing death:
Penalty @10% of contract value or Rs. 5,00,000/- per person,
which ever is less.
b) Major injuries or accident causing 25% or more permanent
disablement to workmen or employees:
Penalty @2.5% of contract value or Rs. 1,00,000/- per person
which ever is less
Permanent disablement shall have the same meaning as
indicated in The Workmen's Compensation Act' 1923. The
penalty mentioned above shall be in addition to the
compensation payable to the workmen / employees under the
relevant provisions of the Workmen's Compensation Act' 1923
and rules framed there under or any other applicable laws as
applicable from time to time.
III If any contractor worker found working without using the safety
equipment like safety helmet, safety shoes, safety belts, etc. or without
anchoring the safety belts while working at height the Engineer I/c /
Safety Officer of NTPC shall have the right to penalize the contractor
for Rs. 200/- per person per day and such worker shall be sent out of
the workplace immediately and shall not be allowed to work on that
day. Engineer I/c / Safety Officer of NTPC will also issue a notice in
this regard to the contractor.
IV If two or more fatal accidents occur at same NTPC site under the
control of contractor during the period of contract and he has
(1) not complied with keeping adequate PPEs in stock or
(2) defaulted in providing PPEs to his workmen
(3) not followed statutory requirements / NTPC safety rules
(4) been issued warning notice/s by NTPC head of the project on
non observance of safety norms
(5) not provided safety training to all his workmen, the contractor
can be debarred from getting tender documents in NTPC for two
years from the date of last accident.
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The safety performance will also be one of the overriding criteria for
evaluation of overall performance of the contractors by NTPC. The contractor
shall submit the accident data including fatal / non-fatal accidents for the last
3 years where he has undertaken the construction activities Projects-wise
along with the tender documents. This will also be considered for evolution of
tender documents. If the information given by the contractor found incorrect,
his contract will be liable to be terminated.
43.20.00 Award
If the Contractor's performance on safety front is found satisfactory i.e. without
any fatal/reportable accident in the year of consideration; he may be
considered for suitable award "ACCIDENT FREE SAFETY MERITORIOUS
AWARD" as per scheme of the employer.
44.00.00 FOREIGN PERSONNEL
44.01.00 The Contractor shall submit to the Employer data on all personnel he
proposes to bring into India from abroad for the performance of the Works
under the Contract, at least thirty (30) days prior to their departure to India.
Such data will include for each person the name, his present address, his
assignment and responsibility in connection with the works, and a short
resume of his qualification, experience etc. in relation to the work to be
performed by him.
44.02.00 Any person unsuitable and unacceptable to the Employer shall not be brought
to India. Any person brought to India, if found unsuitable or unacceptable by
the Employer, the Contractor shall within a reasonable time make alternate
arrangements for providing a suitable replacement and repatriation of such
unsuitable personnel.
44.03.00 No person brought to India for the purposes of the works shall be repatriated
without the consent of the Employer in writing, based on a written request
from the Contractor for such repatriation giving reasons for such an action to
the Employer. The Employer may give permission for such repatriation
provided he is satis-fied that the progress of work will not suffer due to such
repatriation.
44.04.00 The cost of passports, visas and all other travel expenses to and from India,
incurred by the Contractor shall be to his account. The Employer will not
provide any residential accommodation and/or furniture for any of the
Contractor's personnel including foreign personnel and Contractor shall make
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his own arrangements for such facilities in the area allotted at Site, to him by
the Employer for that purpose.
44.05.00 The Contractor and his expatriate personnel shall respect all Indian Acts, Laws,
rules and regulations and shall not in any way interfere with Indian political and
religious affairs and shall conform to any other rules and regulations which the
Government of India and the Employer may establish from time to time, on
them. The Contractor's expatriate personnel shall work and live in close co-
operation and coordination with their co-workers and the community and shall
not engage themselves in any other employment neither part-time or full-time
nor shall they take part in any local politics.
44.06.00 The Employer shall assist the Contractor, to the extent possible, in obtaining
necessary permits to travel to India and back, by issue of necessary
certificates and other information needed by the Government agencies.
45.00.00 FOUNDATION DRESSING & GROUTING FOR EQUIPMENT/ EQUIPMENT
BASES
45.01.00 The surfaces of foundations shall be dressed by Bidder to bring the top
surface of the foundations to the required level, prior to placement of
equipment/equipment bases on the foundations.
45.02.00 All the equipment/ equipment bases, shall be grouted and finished by Bidder
as per these specifications unless otherwise recommended by the equipment
manufacturer.
45.03.00 The concrete foundation surfaces shall be properly prepared by Bidder by
chipping, grinding as required to bring the top of such foundation to the
required level, to provide the necessary roughness for bondage and to assure
enough bearing strength.
45.04.00 Grout
The grout for equipment foundations shall be high strength grout having a
minimum characteristic compressive strength of 60 N/mm2 at 28 days. The
grout shall be ready mix non-shrink, chloride - free, cement based, free
flowing, non-metallic grout as recommended by equipment manufacturer. The
ready mix grout shall be of reputed make as approved by the Employer.
The Grout shall have good flowability even at very low water/ grout powder
ratio.
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The Grout shall have characteristics of controlled expansion to be able to
occupy its original volume to fill the voids and to compensate for shrinkage.
Grout shall be of pre-mix variety so that only water needs to be added before
use.
The mixing of the Grout shall conform to the recommendations of the
manufacturer of the Grout.
45.05.00 Placing of Grout
45.05.01 After the base has been prepared, its alignment and level has been checked
and approved and before actually placing the grout, a low dam shall be set
around the base at a distance that will permit pouring and manipu-lation of the
grout. The height of such dam shall be at least 25mm above the bottom of
the base. Suitable size and number of chains shall be introduced under the
base before placing the grout, so that such chains can be moved back & forth
to push the grout into every part of the space under the base.
45.05.02 The grout shall be poured either through grout holes if provided or shall be
poured at one side or at two adjacent sides to make the grout move in a
solid mass under the base and out in the opposite side. Pouring shall be
continued until the entire space below the base is thoroughly filled and the
grout stands at least 25 mm higher all around than the bottom of the base.
Enough care should be taken to avoid any air or water pockets beneath the
bases.
45.05.03 In addition to the above, recommendations of Grout manufacturer shall also be
followed.
45.06.00 Finishing of the Edges of the Grout
The poured grout should be allowed to stand undisturbed until it is well set.
Immediately thereafter, the dam shall be removed and grout which extends
beyond the edges of the structural or equipment base plates shall be cut off,
flushed and removed. The edges of the grout shall then be pointed and
finished with 1:2 cement mortar pressed firmly to bond with the body of the
grout and smoothened with a tool to present a smooth vertical surface. The
work shall be done in a clean and scientific manner and the adjacent floor
spaces, exposed edges of the foundations, and structural steel and equipment
base plates shall be thoroughly cleaned of any spillage of the grout.
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45.07.00 Checking of Equipment After Grouting
After the grout is set and cured, the Contractor shall check and verify the
alignment of equipments, alignment of shafts of rotating machinery, the slopes
of all bearing pedestals, centering of rotors with respect to their sealing bores,
couplings, etc. as applicable and the like items to ensure that no
displacement had taken place during grouting. The values recorded prior
to grouting shall be used during such post grouting checkup and
verifications. Such pre and post grout records of alignment details shall be
maintained by the Contractor in a manner acceptable to the Employer.
46.00.00 SHAFT ALIGNMENTS
All the shafts of rotating equipment shall be properly aligned to those of the
matching equipments to as perfect an accuracy as practicable. The
equipment shall be free from excessive vibration so as to avoid overheating of
bearings or other conditions which may tend to shorten the life of the
equipment. The vibration level of rotating equipments measured at bearing
housing shall Zone A of ISO 10816. All bearings, shafts and other rotating
parts shall be thoroughly cleaned and suitably lubricated before starting.
47.00.00 DOWELLING
All the motors and other equipment shall be suitably doweled after alignment
of shafts with tapered machined dowels as per the direction of the Employer.
48.00.00 CHECK OUT OF CONTROL SYSTEMS
After completion of wiring, cabling furnished under separate specification and
laid and terminated by the Employer, the Contractor shall check out the
operation of all control systems for the equipment furnished and installed
under these specifications and documents.
49.00.00 COMMISSIONING SPARES
49.01.00 It will be the responsibility of the Contractor to provide all commissioning
spares including consumable spares required for initial operation till the
Completion of Facilities. The Contractor shall furnish a list of all commissioning
spares within 60 days from the date of Notification of Award and such list
shall be reviewed by the Employer and mutually agreed to. However. such
review and agreement will not absolve the Contractor of his responsibilities to
supply all commissioning spares so that initial operation do not suffer for want
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of commissioning spares. All commissioning spares shall be deemed to be
included in the scope of the Contract at no extra cost to the Employer.
49.02.00 These spare will be received and stored by the Contractor atleast 3 months
prior to the schedule date of commencement of initial operation of the
respective equipment and utilised as and when required. The unutilised
spares and replaced parts, if any, at the end of successful completion of
guarantee tests shall be the property of the Contractor and he will be
allowed to take these parts back at his own cost with the permission of
Employer.
50.00.00 CABLING
50.01.00 All cables shall be supported by conduits or cable tray run in air or in cable
channels. These shall be installed in exposed runs parallel or perpendicular to
dominant surfaces with right angle turn made of symmetrical bends or fittings.
When cables are run on cable trays, they shall be clamped at a minimum
intervals of 2000mm or otherwise as directed by the Employer.
50.02.00 Each cable, whether power or control, shall be provided with a metallic or
plastic tag of an approved type, bearing a cable reference number indicated in
the cable and conduit list (prepared by the Contractor), at every 5 meter run
or part thereof and at both ends of the cable adjacent to the terminations.
Cable routing is to be done in such a way that cables are accessible for any
maintenance and for easy identification.
50.03.00 Sharp bending and kinking of cables shall be avoided. The minimum radii for
PVC insulted cables 1100 V grade shall be 15 D where D is the overall
diameter of the cable. Installation of other cables like high voltage, coaxial,
screened, compensating, mineral insulated shall be in accordance with the
cable manufacturer's recommendations. Wherever cables cross roads and
water, oil, sewage or gaslines, special care should be taken for the protection
of the cables in designing the cable channels.
50.04.00 In each cable run some extra length shall be kept at a suitable point to
enable one or two straight through joints to be made, should the cable
develop fault at a later date.
50.05.00 Control cable terminations shall be made in accordance with wiring diagrams,
using identifying codes subject to the Employer's approval. Multicore control
cable jackets shall be removed as required to train and terminate the
conductors. The cable jacket shall be left on the cable, as far as possible,
to the point of the first conductor branch. The insulated conductors from
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which the jacket is removed shall be neatly twined in bundles and terminated.
The bundles shall be firmly but not tightly tied utilising plastic or nylon ties or
specifically treated fungus protected cord made for this purpose. Control cable
conductor insulation shall be securely and evenly cut.
50.06.00 The connectors for control cables shall be covered with a transparent
insulating sleeve so as to prevent accidental contact with ground or adjacent
terminals and shall preferably terminate in Elmex terminals and washers. The
insulating sleeve shall be fire resistant and shall be long enough to over pass
the conductor insulation. All control cables shall be fanned out and connection
made to terminal blocks and test equipment for proper operation before cables
are corded together.
51.00.00 EQUIPMENT DELIVERY AND ERECTION
51.01.00 General Requi rements
(a.) This part covers Contractor's responsibilities for packing, shipping, ware-
housing and the installation of all equipment and materials furnished
and installed under this specification.
(b.) The Contractor shall submit for Employer's approval draft manual for
Equipment Delivery and Erection (EDE Manual) covering detailed
instructions, write up, technical data, drawings, check-lists,
documentation formats for all activities after equipment manufacture upto
installation of equipment. This manual shall cover general instructions
for all equipment and specific instructions for individual equipment
wherever required and shall include at least the following :
(1.) Instructions for packing, shipping, receiving handling, ware-
housing and storage.
(2.) Instructions for location and installation of equipment furnished by
this specification.
(3.) Installation drawings for field mounted equipment, panels,
cubicles and other equipment covered under this specification.
(4.) Instruction relating installation of piping/ tubing, support and
routing drawings of impulse pipes/signal tubes and tube/cable
trays.
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(5.) Check lists and quality assurance hold points.
(6.) Format for all related documentation.
(c.) The EDE Manual shall conform to the requirements of this specification,
all applicable codes and standards, recommendations of equipment
manufacturers and accepted good engineering practices and shall be
subject to Employer approval during detailed engineering.
(d.) The Contractor shall ensure that all work under this part shall be
performed as per the requirements of this specification, Employer
approved EDE Manual and drawing/documents approved by the
Employer during detailed engg.
51.02.00 Crating
(a.) All equipment and materials shall be suitably coated, wrapped, or
covered and boxed or crated for moist humid tropical shipment and to
prevent damage or deterioration during handling and storage at the site.
(b.) Equipment shall be packed with suitable desiccants, sealed in water
proof vapour-proof wrapping and packed in lumber of plywood
enclosures, suitably braced, tied and skidded. Lumber enclosures shall
be solid, not slatted.
(c.) Desiccants shall be either silica gel or calcium sulphate, sufficiently
ground to provide the required surface area and activated prior to
placing in the packaging. Calcium sulphate desiccants shall be of a
chemical nature to absorb moisture. In any case, the desiccant shall
not be of a type that will absorb enough moisture to go into solution.
Desiccants shall be packed in porous containers, strong enough to
withstand handling encountered during normal shipment. Enough
desiccant shall be used for the volumes enclosed in wrapping.
(d.) Review by the Employer of the Contractor's proposed packaging
methods shall not relieve the Contractor of responsibility for damage or
deterioration to the equipment and materials specified.
(e.) All accessory items shall be shipped with the equipment. ; Boxes and
crates containing accessory items shall be marked so that they are
identified with the main equipment. The contents of each box and
crates shall be indicated by markings on the exterior.
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(f.) All boxes, crates, cases bundles, loose pieces, etc. shall be marked
consecutively from No.1 upward throughout all shipments from a given
port to completion of the order without repeating the same number.
(g.) An itemized list of contents shall be enclosed inside each case and
one other copy securely fastened to the outside of the case in a tin or
light weight sheet metal envelope or pocket. The lists shall be plainly
marked and placed in accessible locations to facilitate receipt and
inspection. The packing list shall indicate whether shipment is partial
or complete and shall incorporate the following information on each
container, etc., according to its individual shipping number :
a) Export case markings
b) Case number
c) Gross weight and net weight in Kilograms
d) Dimensions in centimeters
e) Complete description of material
(h.) Packaging or shipping units shall be designed within the limitations of
unloading facilities and the equipment which will be used for transport.
Complications involved with ocean shipment and the limitations of ports,
railways and roads shall be considered. It shall be the Contractor's
responsibility to investigate these limitations and to provide suitable
packaging to permit safe handling during transit and at the job site.
(i.) Electrical equipment, control and instrumentation shall be protected
against moisture and water damage. All external gasket surfaces and
flange faces, couplings, motor pump shafts, bearing and like items shall
be thoroughly cleaned and coated with rust preventive compound as
specified above and protected with suitable wood, metal or other
substantial type covering to ensure their full protection.
(j.) Equipment having antifriction or sleeve bearings shall be protected by
weather tight enclosures.
(k.) Coated surfaces shall be protected against impact, abrasion,
discolouration and other damage. Surfaces which are damaged shall be
repaired.
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(l.) All exposed threaded parts shall be greased and protected with metallic
or other substantial type protectors. All female threaded openings shall
be closed with forged steel plugs. All pipings, tubing, and conduit
equipment and other equipment openings shall be sealed with metallic
or other rough usage covers and tapped to seal the interior of the
equipment piping, tubing, or conduit.
(m.) Provisions shall be made to ensure that water does not enter any
equipment during shipment or in storage at the plant site.
(n.) Returnable containers and special shipping devices shall be returned by
the manufacturer's field representative at the Contractor's expense.
(o.) While packaging the material, care shall be taken for the limitation from
the point of view of availability of railway wagon sizes in India.
51.03.00 Factory Assembly
(a.) Instrument enclosures shall be supplied and erected completely in the
factory with instrument, air supply and blow down piping with necessary
valves, fittings, etc. and also all electrical wiring between the
instruments and the enclosure terminal blocks. Control panel and
cubicles shall also be fully wired in the factory. Control panel mounted
equipments are to be dismounted from the panels before shipment and
individually packed for shipment. Electronic control modules of the plug-
in type are to be removed from equipment racks after factory checkout
are individually packed for shipment. Other equipment shall be fully
assembled at the factory, except for necessary shipping splits in
panels.
(b.) All separately packaged accessories items and parts shall be shipped
with the equipment. Containers for separately packaged items shall be
marked so that they are identified with the main equipment. An itemized
packing slip, indicating what is in that carton only, shall be attached to
the outside and inside of each container used for packing.
A master packing slip covering all accessories items for a given piece
of equipment which are shipped in separate containers, shall be
attached to one container.
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51.04.00 Equipment Installation
(a.) General Requi rements
(1.) The Contractor shall furnish all construction materials, tools and
equipment and shall perform all work required for complete
installation of all control and instrument equipment furnished
under this specification.
(2.) Contractor shall prepare detailed installation drawings for each
equipment furnished under this specification for Employer's
approval. Installation of all equipment/systems furnished by this
specification shall be as per Employer's approval.
(3.) Erection procedures not specified herein shall be in accordance
with the recommendations of the equipment manufacturers. The
procedures shall be acceptable to the Employer.
(4.) The Contractor shall coordinate his work with other suppliers
where their instruments and devices are to be installed under
specifications.
(b.) Installation Materials
All materials required for installation, testing and commissioning of the
equipment shall be furnished by the Contractor.
(c.) Regulatory Requirements
All installation procedures shall confirm with the accepted good
engineering practice and with all applicable governmental laws,
regulations and codes.
(d.) Cleaning
All equipment shall be cleaned of all sand, dirt and other foreign
materials immediately after removal from storage and before the
equipment is brought inside the power plant building or to other
installation sites. All piping and tubes shall be air blown.
(e.) Equipment Assembly
Equipment installed under these specifications shall be assembled if
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shipped unassembled. The equipment shall be dismantled and
reassembled as required to perform the installation and commi ssioning
work described in these specifications.
(f.) Equipment Setting
Field mounted instruments and accessories shall be bracket or sub
panel mounted on the nearest suitable firm steel work or masonry.
The brackets, stands, supports and other miscellaneous hardware
required for mounting instruments and accessories such as receiver
gauge, air set, valve manifold, purge-meter etc. shall be furnished and
installed. No field mounted instruments shall be installed such that it
depends for support or rigidity on the impulse piping or on electrical
connection to it.
Indicating type field mounted instruments shall be installed in such a
way that centre of indicating dial shall be about 1600-1800mm from
operating floor level. Non-indicating type field instruments shall be
installed such that operating handle of manifold block / isolating cock
comes within 1600 mm from operating floor level.
(g.) Free-Standing Equipment
Free-standing Cabinets shall be attached to the floor, concrete
equipment bases or supporting steel as indicated on the manufacturer's
drawings and the Employer's Plant Arrangement Drawings. The cabinets
shall be shimmed for proper alignment before bolting them to the floor.
Adjacent enclosures shall be shimmed to maintain mutually level
appearance before they are attached to floor. Vibration dampening
mounts shall be installed between supporting structures and panels
when specified.
(h.) Non-free Standing Equipment
(1.) Non-free standing local enclosures and cabinets shall be
mounted in accessible locations on columns, walls, or stands in
locations as indicated on the Employer's Plant Arrangement
Drawings. Bracket and stands shall be fabricated as required to
install the local enclosures and cabinets in a workman like
manner.
(2.) Rough edges and welds on all fabricated supports shall be
ground smooth. The supports shall be finished with two coats
of primer and two coats of paint as specified in this part.
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(i.) Equipment Location
(1.) All individual items of equipment not located in cabinets or on
panels and racks are located approximately according to the
floor elevation and the nearest building column designated by the
Employer.
(2.) Solenoid valves not located in enclosures or mounted on valves
shall be mounted in easily accessible protected locations near
the components with which they are associated.
(3.) All brackets, stands, supports and other miscellaneous hardware
required for mounting devices shall be furnished and installed.
(4.) Thermometers shall be installed in the process lines and ducts
as required and adjusted for ease in reading.
(5.) Permanent temperature wells on the main steam, hot reheat
and cold reheat piping shall not be installed until steam blowing
has been completed. Temporary temperature wells shall be
installed in the main and reheat steam piping during steam blow
and discarded after completion.
(6.) Any required adapting hardware such as pipe bushings, nipples,
drilled caps and the like shall be provided for complete
installation of control devices into process connections.
For location of C&I related equipment/devices, the requirement
specified elsewhere in the technical specification may be
referred.
(j.) Installation of Field Mounted Instruments and Devices
The Contractor shall submit installation drawings for all field mounted
equipment furnished under this specification for Employer's approval.
These drawings shall meet the requirements of this specification,
installation drawings, applicable codes and standards and
recommendations of manufacturers of instruments/devices. All
installation work under this specification shall be strictly as per
installation drawings approved by the Employer during detailed
engineering stage.
In addition to above relevant Portion as specified elsewhere in technical
specification may be referred.
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(k.) Piping Connections
(1.) All equipment having piping connections shall be levelled, aligned
and wedged in place but shall not be grouted or bolted prior to
the initial fitting and alignment of connecting piping. All
equipment shall, however, be grouted or bolted to its foundation
prior to final bolting or welding of the connection piping.
(2.) All flanged joints shall be checked and retightened after
approximately 10 days of operation at normal operating
temperature.
(l.) Equipment Checkout
(1.) All equipment shall be cleaned after installation. Equipment
subject to pressure differentials shall be checked for leakage.
(2.) After erection, all equipment having moving parts, having
electrical apparatus, or subject to pressure differentials shall be
trial-operated.
(m.) Defects
(1.) All defects in erection shall be corrected to the satisfaction of
the Employer and the Project Manager. The dismantling and
reassembly of Contractor furnished equipment to remove
defective parts, replace parts, or make adjustments shall be
included as a part of the work under these specifications.
(2.) The removal of control and instrument equipment in order to
allow bench calibration, if required, and the re-installation of the
said equipment after calibration shall also be included as a part
of the work under these specifications.
(n.) Equipment Protection
(1.) All equipment to be erected under these specifications shall be
protected from damage of any kind from the time of contract
award until commissioning of each unit.
(2.) The equipment shall be protected during storage as described
herein.
(3.) Equipment shall be protected from weld spatter during
construction.
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(4.) Suitable guards shall be provided for protection of personnel on
all exposed rotating or moving machine parts. All such guards
with necessary spares and accessories shall be designed for
easy removal and maintenance.
(5.) Equipment having glass components such as gauges, or
equipment having other easily breakable components, shall be
protected during the construction period with plywood enclosures
or other suitable means. Broken, stolen, or lost components
shall be replaced by the Contractor.
(6.) Machine finished surfaces, polished surfaces, or other bare
metal surfaces which are not to be painted, such as machinery
shafts and couplings shall be provided temporary protection
during storage and constructional periods by a coating of a
suitable non- drying, oily type, rust preventive compound.
52.00.00 WELDING - SPECIAL REQUIREMENTS
If the manufacturer has special requirements relating to the welding procedures
for welds at the terminals of the equipments to be performed under separate
specifi-cations, the requirements shall be submitted to the Project Manager in
advance of commencement of erection work.
53.00.00 DEVIATIONS DISPOSITIONING:
Any deviation to the contract and employer approved documents shall be
properly recorded in the format prescribed by NTPC. Al the deviations shall
be bought to the knowledge of employer's representative for suitable
dispositioning.
54.00.00 NON-DESTRUCTIVE TESTING (NDT):
The contractor shall record results of NDTs carried out at site in the format
acceptable to employer. All the radiographs & its report duly signed &
correlated to the job shall be handed over to the employer. Sensitivity of all
the test equipment shall be compatible to the job & acceptance norms agreed.
55.00.00 TESTING EQUIPMENT & FACILITIES:
Contractor shall provide the testing equipment and facilities necessary to carry
out tests & inspections.
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ANNEXURE-I
STANDARD CHECKLIST
COMMISSIONING/TESTING ESSENTIAL PRE-REQUISITE
1. MECHANICAL
(A.) VALVES
(1.) MANUALLY OPERATED VALVE
(2.) ELECTRICALLY OPERATED VALVE
(3.) PNEUMATICALLY ACTUATED VALVE
(4.) HYDRAULICALLY ACTUATED VALVE
(5.) SAFETY VALVE
(6.) ELECTROMATIC RELIEF VALVE
(7.) STEAM TRAP
(8.) BUTTERFLY VALVE(ELECTRICALLY OPERATED)
(9.) BUTTERFLY VALVE (MANUALLY OPERATED)
(10.) BUTTERFLY VALVE(FOUR WAY-ELECTRICAL)
(11.) NON-RETURN VALVE(INCLUDING HYDRAULIC/PNEUMATIC
FCNRVS)
(12.) THREE WAY CONTROL VALVE
(13.) RELIEF VALVE
(14.) DIFFERENTIAL PRESSURE REGULATING VALVE
(15.) FLOAT OPERATED VALVES
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(B.) TANKS AND PRESSURRE VESSELS
(1.) TANKS (METAL)UPTO 20 M2
(2.) TANKS (LARGE STORAGE)
(3.) PRESSURE VESSEL (BELOW 17 BARS)
(4.) AIR RECEIVER
(5.) PRESSURE VESSEL-ACCESS DOOR
(6.) TURBINE MAIN OIL TANK
(C.) PUMPS
(1.) PUMP LOW PRESSURE CENTRIFUGAL (MOTOR DRIVEN)
(2.) PUMP UP TO 350 HP (260 KW)
(3.) PUMP SUMP INSTALLATION
(4.) GEAR PUMP/SCREW PUMP
(D.) PIPE WORK SYSTEM
(1.) STEAM SERVICES
(2.) WATER SERVICES
(3.) OIL/FIRE RESISTANT FLUID SYSTEM
(4.) AIR SERVICES (COMPRESSOR)
(5.) HIGH PRESSURE SERVICES
(6.) CONSTANT LOAD SUPPORT
(7.) SPRING SUPPORTS
(8.) HANGERS AND OTHER SUPPORTS
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(E.) STRAINER AND FILTER
(1.) STRAINER/FILTER BASKET TYPE
(2.) STRAINER ROTARY(LOW PRESSURE)
(3.) FILTER & STRAINERS CENTRIFUGAL SEPARATORS
(4.) FILTER & STRAINER Y-TYPE
(5.) FILTER & STRAINER (PLATE TYPE)
(6.) PURIFIER
(7.) FILTER-COMPRESSED AIR LINE
(F.) HEAT EXCHANGER
(1.) HEAT EXCHANGER (GENERAL)
(2.) HEAT EXCHANGER-OIL/WATER
(3.) ROTARY AIR HEATER
(G.) FANS AND COMPRESSORS
(1.) FANS-NON-PRESSURE LUBRICATED
(2.) FANS-AXIAL FLOW PRESSURE LUBRICATED
(3.) COMPRESSORS-GENERAL
(4.) DAMPERS AND GATES
(H.) CRANES AND ELEVATORS
(1.) AUXILIARY OVERHEAD CRANE
(2.) TRAVEL SUPPORT STRUCTURE FOR CRANE
(3.) LONG TRAVEL & CROSS TRAVERSE MOTION OF CRANE
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(4.) MAIN AUX. HOIST MOTION (CRANE)
(5.) ELECTRIC HOIST
(I.) POWER TRANMISSION
(1.) POWER TRANSMISSION GEAR BOX
(2.) BEARING
(3.) FLUID COUPLINGS
2. ELECTRICAL
(1.) D.C. MOTOR
(2.) HV SQUIRREL CAGE INDUCTION MOTOR
(3.) 415 V SQUIRREL CAGE INDUCTION MOTOR
(4.) MOTOR OPERATED ACTUATORS
(5.) LT SWITCHGEARS/MCC
(I.) STANDARD CHECKLISTS FOR ALL TYPES OF RELAYS
USED IN SWITCHGEARS PROTECTION SYSTEM
(II.) PT CARRIAGE AND CUBICLES
(III.) CABLE/BUS DUCT/BUS BARS
(IV.) CONTACTOR MODULE
(V.) SWITCH FUSE MODULE
(VI.) MASTER PANEL OF LUBE OIL PANEL
(VII.) FEEDER PANEL OF LUBE OIL PANEL
(VIII.) SPACE HEATER AND CABLE MODULE
(IX.) CONTROL TRANSFORMER MODULE
(X.) 415 V CIRCUIT BREAKER
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(6.) POWER CABLE
(7.) CONTROL CABLE
(8.) EXPLOSION PROOF ELECTRICAL EQUIPMENT (IF
APPLICABLE)
(9.) J UNCTION BOX
(10.) BRUSH GEAR ASSEMBLY
(11.) AUX. CONTROL AND RELAY PANEL
(12.) INDICATING INSTRUMENT
(13.) RECORDING INSTRUMENT
3. CONTROL & INSTRUMENTATION
(A.) CONDUCTIVITY ANALYSING EQUIPMENT INCLUDING TEST
PROCEDURES
(B.) PH ANALYSER INCLUDING TEST PROCEDURE
(C.) SILICA ANALYSER
(D.) LEVEL SWITCH (FLOAT ACTUATED)
(E.) LEVEL SWITCH (ELECTRODE TYPE)
(F.) LEVEL SWITCH DISPLACED ACTUATED)
(G.) TRANSMITTER (FLOAT OPERATED PNEUMATIC OUTPUT) INCLUDING
TESTING PROCEDURE
(H.) LEVEL INDICATOR (FLOAT/PULLEY TYPE)
(I.) LOCAL TEMPERATURE INDICATORS INCLUDING TEST PROCEDURE
(J .) RESISTANCE THERMOMETER ELEMENT INCLUDING TEST
PROCEDURE
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(K.) THERMOCOUPLE ELEMENT AND CONNECTING CABLE
(L.) THERMOCOUPLE AND RESISTANCE THERMOMETER CONVERTOR/
TRANSMITTER INCLUDING TEST PROCEDURES.
(M.) TEMPERATURE SWITCH/THERMOSTAT INCLUDING TEST
PROCEDURES
(N.) COLD J UNCTION BOXES
(O.) ZENER BARRIER
(P.) O2 ANALYSER
(Q.) O2 IN HYDROGEN INCLUDING TEST PROCEDURES
(R.) PRESSURE AND VACUUM GAUGE
(S.) PRESSURE AND VACUUM SWITCH INCLUDING TEST PROCEDURE
(T.) DIFFERENTIAL PRESSURE TRANSMITTER INCLUDING TEST
PROCEDURE
(U.) DIFFERENTIAL PRESSURE SWITCH INCLUDING TEST PROCEDURE.
(V.) FLOW INDICATOR (VARIABLE AREA)
(W.) ORIFICE PLATE
(X.) TURBINE FLOW MEASUREMENT
(I.) FLOW SWITCH
(II.) WEIR
(III.) NOZZLE
(IV.) FLOW INDICATOR (PNEUMATIC INPUT) INCLUDING TEST
PROCEDURE
(V.) FLOW INTEGRATOR (PNEUMATIC INPUT)INCLUDING TEST
PROCEDURE
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(VI.) FLOW INDICATOR (FLOAT OPERATED) INCLUDING TEST
PROCEDURE
(VII.) VENTURI (FLUID)
(VIII.) FLOW SWITCH (MAGNETIC TYPE)
(IX.) AVERAGING INLET
(X.) LIMIT SWITCHES
(Y.) TURBINE SUPERVISORY MEASURING SYSTEM
(Z.) POSITION MEASUREMENT AND INDICATION INCLUDING TEST
PROCEDURES
(AA.) TACHOMETER
(BB.) VIBRATION MEASUREMENT
(CC.) DIGITAL INDICATOR
(DD.) MOVING COIL INDICATOR INCLUDING TEST PROCEDURE
(EE.) RECORDER INCLUDING TEST PROCEDURE
(FF.) FLAME SCANNER
(GG.) ELECTRICAL AUTO MANUAL CONTROL STATION
(HH.) PUSH BUTTON MODULE
(II.) ALARM ANNUNCIATOR EQUIPMENT INCLUDING TEST PROCEDURE
(J J .) TEST PROCEDURE FOR ELECTRONIC MODULES OF DDCMIS
(KK.) THERMO CONTROL VALVE
(LL.) TEST PROCEDURE FOR ADJ USTMENT OF MODULATING
CONTROLLER - PID TERMS
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(MM.) TEST PROCEDURE INDICATING CONTROLLER-ELECTRICAL INPUT
AND PNEUMATIC OUTPUT
Note: The items which are not part of this specification may be considered
as not applicable.
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ANNEXURE-II
BRIEF WRITE UP ON THE CONTENTS OF TESTING
SCHEDULE / COMMISSIONING SCHEDULE
Testing Schedules should be designed to ensure that the plant area,
equipment or apparatus are tested and commissioned and will operate as per
the employer's specifications and good engineering practices.
Testing Schedule/Commissioning Schedule is required to be of a standard
format in order to maintain consistency of presentation, content and reporting.
Testing Schedule/Commissioning Schedule should contain the following sections
to make the document a self contained one:
1. Plant Details/Design data
2. Testing Objective/Proposals
3. State of the Plant
a) Erection Status with respect to Mech. Elect and C&I
b) Availability of the services required
c) Safety requirements as per Manufacturer's
4. Test method including completion/acceptance criteria
5. Results
6. Appendix
a) Testing Programme
b) Mech/Elect/C&I -Plant item completing list
c) List of Drawing/documents required for carrying out the testing.
SECTION-VI
PART-D
ERECTION
CONDITIONS OF
CONTRACT
PAGE
61 OF 61
STAGE-II (2X660 MW)
Annexure - III
Safety Plan
01. Safety Policy of the Contractor to be enclosed:
02. When was the Safety Policy last reviewed:
03. Details of implementation procedure / methods to implement Safety
Policy / Safety Rules :
04. Name, Qualification, experience of Safety Officer
05. Review of Accidents Analysis Method, Methods to ensure Safety and
Health:
06. Unit executive responsible to ensure Safety at various levels in work
area:
07. List of employees trained in safety employed before execution of the
job. Give the details of training:
08. Safety Training Targets, Schedules, methods Adopting to providing safety
training to all employees:
09. Details of checklist for different jobs / work and responsible person to
ensure compliance (copy of checklist to be enclosed):
10. Regular Safety Inspection Methods and Periodicity and list of members
to be enclosed:
11. Risk Assessment, Safety Audit by Professional Agencies, Periodicity:
12. Implementation of Recommendations of Audit / Inspections. Procedures
for implementation and follow up:
13. Provision for treatment of injured persons at work site:
14. Review of overall safety by top Management and Periodicity:
15. System for Implementation of Statutory legislations:
16. Issue of PPEs to employees, Periodicity / stock on hand etc:
Signature
Head of the Organisation
with date & stamp
NTPC Limited
STAGE-II (2X660 MW)
PART - E
SECTION - VI
TENDER DRAWING LIST
FOR
NTPC Limited
STAGE-II (2X660 MW)
PART - E
SECTION - VI
TENDER DRAWING LIST
FOR
LIST OF TENDER DRAWINGS
CLAUSE NO. LIST OF TENDER DRAWINGS
SECTION-VI
PART-E
LIST OF TENDER
DRAWINGS
PAGE
1 OF 3
STAGE-II (2X660 MW)
The drawings listed below shall form part of the specification and shall supplement the
requirements specified in these technical specifications. The scope and terminal points
of the equipment to be furnished under this Steam Turbine Generator Package shall
be as identified in these drawings read in conjunction with text of the specification.
---------------------------------------------------------------------------------------------------------------------------------------
Sl. No. Drawing Name Drawing No. Rev
---------------------------------------------------------------------------------------------------------------------------------------
1 General layout plan 9562-999-POC-F-001
2 Equipment layout plan at 0.0 M 9562-999-POM-A-001 B
3 Equipment layout plan
at 8.5 M./17.0M/24.0M/32.0M/38.0M 9562-999-POM-A-002 B
4 Main plant cross section 9562-999-POM-A-003 B
5 Main steam, Hot reheat 9562-999-POM-A-004 A
& Cold reheat P&ID
6 HP LP Bypass system P&ID 9562-999-POM-A-005 A
7 Auxiliary steam system P&ID 9562-999-POM-A-006 A
8 Extraction steam P&ID for heaters 9562-999-POM-A-007 A
9 Extraction steam P&ID 9562-999-POM-A-008 A
for BFP Turbine
10 Condensate P&ID 9562-999-POM-A-009 A
11 Feed water P&ID 9562-999-POM-A-010 A
12 Heater vents and drains P&ID 9562-999-POM-A-011 A
13 Steam drain P&ID 9562-999-POM-A-012 A
14 Symbols/ legends 9562-999-POM-A-013 A
15 Central Turbine lube oil storage 9562-999-POM-A-015 A
and purification system
16 Air extraction system and Condenser 9562-999-POM-A-016 A
on load tube cleaning system
17 P& ID of Equipment Cooling Water 0000-999-POM-A-025 A
System (Unit Auxiliaries)
SECTION-VI
PART-E
LIST OF TENDER
DRAWINGS
PAGE
2 OF 3
STAGE-II (2X660 MW)
---------------------------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------------------------
18 P&ID Condensate Polishing Plant 9562-110-POM-A-001 A
(2 Sheets)
19 DDCMIS Configuration diagram 0000-110-POI-A-001 A
20 HMIPIS Configuration diagram alternative-1 0000-110-POI-A-011 A
21 MMIPIS Configuration diagram alternative-2 0000-110-POI-A-012 A
22 Standard Configuration diagram for PLC 0000-110-POI-A-013 A
based offsite control systems
23 Scheme of programmer's room hardware 0000-110-POI-A-014 A
multiflexing
24 Local J unction Box Connection Details 0000-999-POI-A-017 D
25 Scheme for 24VDC power supply system 0000-405-POI-A-019 A
(2 sheets)
26 Instrumentation Cabling Diagram 0000-110-POI-A-021 A/B
(4 sheets)
27 Instrument Installation Diagram 0000-110-POI-A-022 A
(For Pressure Gauge)
(Pressure Measurement Using Press/DP
Transmitters (Inst./Service, Dirty Air/Flue Gas)
(Pressure Transmitter Fuel Oil)
(Pressure Measurement Using Press/DP
Transmitters Steam/Liquid Vacuum)
Flow Measurement (Using Flow Nozzles)
Steam & Feedwater
(Flow Measurement (Using Orifice Plates)
Copndensate & Service Water)
SECTION-VI
PART-E
LIST OF TENDER
DRAWINGS
PAGE
3 OF 3
STAGE-II (2X660 MW)
---------------------------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------------------------
(Flow Measurement Air/Gas)
(Flow Measurement Dirty air/Flue Gas)
Diff. Press Measurement
(Liquid, Oil, Air/Gas Service)
(Level Gauge & Switches)
(Level Measurement Using D/P Transmitters) (2 Sheets)
(Level Measurement-Open Vessel)
Typical Purge Air Connection & Blowdown
Header Connection Inside Instrument Rack
40 Instrument Source Connection Details 0000-110-POI-A-035 A
(14 Sheets)
41 Typical GA of Local Instrument 0000-999-POI-A-064 D
Enclosure/Rack (3 Sheets)
42 Interfacing of Field Intruments 0000-999-POI-A-065 A/B/C
(14 Sheets)
43 C&I KKS Code List & Guidelines 9562-110-POI-G-001 0
44 Excel formats for I/O List, Drive List, 9562-999-POI-G-002 A
Instrument Schedule & J B Grouping (5 Sheets)
45 Interfacing of Actuators 0000-999-POI-A-063 A
---------------------------------------------------------------------------------------------------------------------------------------
SAMPLEINLET A
fl COOLINGWATER IIL-
FILTER
TO THE REQUIRED
REGENERATION
VESSELS
r OIL FILTER
I INSTRUMENT AIR
~ 9 , AIR BLOWERS(2~100%C8pdty) I
~ 9 1 DM VATPI b REGENERATDN
AT 10.0 M FBOM
TEE FoUNDI'110N
4wNmm8AT -
emwmlrlcfit TO RESPECTIVE REGENERATION/
RESIN SEPARATION VESSELS
From Service.v DMWATER
Water Line
--- -----------
REFER NOTE 1
-------------------------------------
1. TO DRAIN TRENCH
LEADING TO
NEMmUUSAnON PIT - MECSURINO
ORIFICE BOARD
SERVICE WATER
I I I 1 I
I h
RECIRCULATION
I - ILc. I
& AGITATAION
-
EFFLUENTNEUTRALISINGSYSTEM
AClDDOSlWOPUIPL)
AClD UNLOADINGPUMPS
NOTES:
1) THE REGENERATION VESSELS ARRANGEMENT SHOWN HERE IS INDICATIVE ONLY.
BIDDER SHOULD FURNISH WEIR SCHEME OF VESSEL ARRANGEMENT IN DETAIL
ALONGWITH THE COMPLETE MJSTRUMENTATION.
2) FOR OTHER NOTES & LEGEFDS b REFER SHEET 1 OF THIS DRAWING.
3) COLLECTON k DISPOSAL AR~NAGMENT OF DM WASTE WATER USED FOR RESIN
TRANSFER FROM REGENERATION SYSTEM TO CPU SERVICE VESSELS AND CPU SERVICE
VESSELS TO REGENERATION 'SYSTEM IS NOT SHOWN IN THIS DRAWING. THE SAME SHALL
BE PROVIDED AS PER TECHNICAL SPECIFICATION. ADDITIONAL PNEUMATIC OPERATED VALVES
AS REQUIRED SHALL BE PROVIDED IN SERVICE VESSEL & RENGENERATION AREA BY CONTRACTOR.
5) PUMP RECIRULATION LINE WITH VALVES AT TANK END SHALL BE PROVIDED FOR EACH SET OF
PUMPING SYSTEM BY BIDDER.
6. FOR C & I NOTES & LEGENDS REFER TO DRG. NO, 9562-1 10-POI-G-001.
I FOR TENDER PURPOSE ONLY (
I ( , ~ ~ i NTPC L1lMITE.D
( A GOVT. OF INDIA ENTERPRISE )
ENGINEERING DIVISION
PROJECT
TAMDA THERMAL POWER PROJECT
A
i
I I I I
REV.
7 6 5 8
CAD FILE NAME : 9562-1 10-POM-A-001 (2/2)
RELEASED FOR TENDER
DESCRIPTION
STAGE-11 (2~aeoun)
TITLE P&I DIAGRAM
SIZE
C
DRAWN M j l G N CHKO.
CLEARED BY
SCALE ' DRG.NO.
Do
I
9562- 110-POM-A-001 ( s ~ . 2 or 21, A
h
FIRE WALL

`
SEE NOTE-5
THE REMOTE I/O CABINET SHALL BE APPLICABLE IF MENTIONED IN PART-A OF TECHNICAL SPECIFICATIONS

`
`
COLD
NOTE:
This configuration diagram is applicable only for H2
Generation Plant PLC

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25 mm
SEE NOTE-4
100 mm
150 mm
NOTES: -
1. J.UNC'TION BOXES SHALL HAVE CLAND PLATES AT THE EOTTOM'
OF THE BOX ONLY
2, TUBULrAN TYPE GASXEIS WILL BE USEO.
ipf;;!$l',llfi i*'fl
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TYPICAL THERI\,IAL POWER PLANT
LOCAL JUNCTION BOX CONNECTION DETAILS
D E S C R I P T I O N
DRC. NO.
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:
I. THE UAIERU! SFECIfICATION TNO SCHEDULI NO, OF IIiPUISE PIP & NIPPLT A USIED
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pEA
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ptprNc
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5, CAUCES S|1^!! NOI
gE
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on f&|lrE oR l Rfcx..
6.
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SLQPE APPSOX. 40 U / I'EIRE.
OR TENDER PURPOSE ONLY
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NTPCLI MI TED
( A COVERttiVaiT Ot o{rt^ EMtEfpRrsE
)
TYI)ICAL THERMAL POWER PROJECT
INSTRUIVENT INSTALLATION DIAGRAM
(FOR PRESSURE GAUGE)
DRC. NO.
0000-1 10-Pot -A-022
O E S C R I P T ' O N
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NOTES:-
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2-VArVa UAN|FOI6
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ptn
IECBN|C.AL SpECtnO]tONS
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5/4' 5W a tY Y VAVE
1,/2' N8 SETItLESS Gr Ptpt
3/a' r 1/2' S.S. IUEE UNTON
PsqrEcr
TyplcAL THERMAL
powER pRoJEcr
]TTLE
INSTRUMENT INSTALLATION DIAGMM
(PRESSURE I,lEASUREI,IENT USING PRESS / OP TRANSIVlITTERS
(t NST. / SERV| CE,
Dt RTy AI R/ FLUE GAS)
D E S C N I P T I O N
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LIST OT MATERIALS
]RAC'NC
slE Jt/
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TR^CINC
HEAY/ FUEL PRESS. MEASUREMENT USING WAFER TYPE TRANSMITTER WITH REMOTE SEAL
NOTES:-
1. SAM NOIES .s tiNoER oRG. N0.0000-1lo-FOl--A-023.
I, TON !'O STEAM IMCINC NOT TPPUCIBLE.
V"I d
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r,/,1' CHRO a MOLY SIETL PIPE
r/2' NPS SCH. ,10160 CS PrF,
llf $r J16 SS ISOUTIoN VAVf-
TYPICAL THERMAL POWER PROJECT
INSTRUI\4ENT INSTALLATION DlAGRAlvl
(PRESSURE TRANST\4rrrER FUEL OtL)
O E S C R I P T I O N
0000-1 1 0-Po r-4-024
_
F!oo&
!!g_
ELEVATION
TRANSMITTER MOUNTED BELOW INSTRUMENT SOURCE POINT
TRAXSMMER
EULXHEAD
of L@AL
IMTBUVEl,T
ET.ICLOSUBE/
SIOPE
ELEVATION
TRANSMITTER MOUNTED ABOVE INSTRUMENT SOURCE POINT
LIOUID PRESSURE MEASUREMENT
TRANSMITTER MOUNTED ABOVE
i E POINT INSTRUMENT SOURCE POINT
STEAN4 PRESSURE MEASUREMENT
LIST OF MATERIALS
ELEVATION
VACCUM PRESSURE [ / EASUREI V, t NI
NOTESi -
r. $lrE NqIEJ UNDER DRG. NO. 0000- l 10-PO|-
-02J.
? Oi VACUIJM APPUCT-flON OI}iER POR' O' IRAiSVIIIER SML! 9T KEPI
OPEN IO AIMOSPI]'RE.
FOR TENDER
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1,/2'NPS SCH. 801160 swrl/2'CS/AS couPlti
1/2' PIPE , I/2' ILIBE UNION
1/2'llPS SCli. 80,/100 Swrl /2'
NTPCLI MI TED
( A GOVERNUENI OF INDA ENTERPR'SI )
TYF' ICAL THERMAL POWER PROJECT
(TG PACKAGE)
TnLE ,NSTRUMENT INSTALLATION OIAGMM
(PRESS URE MEASUREMENT USING PRESS /DP
TRAI' ISMITTERS STEAIV/LIOUID
\/ACUUM)
0000-1 10-Pot-4-025 D E S C R I P ] I O N
Cf- - ------ ^""& .BE--
ELEVATION
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( .
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LIST OF MATERIALS
_
FLOOLUIE-
-TO
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,--l--r-----
l r f f i - - r l
I T T $ E I
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NOTES:-
L S.Aff NOIES UNDEA DR6. NO. 0000- 1 t 0-p0r-A-02J,
2. CONDENSATE POTS sI'Q. BT PROVIDID TOR AI], STE{T SERVICES,
f. FoR
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st-urL EE
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OETAIL OF 5 VALVE MANIFOLD
FF'O/AT'FIIPERAIIN{ $/ATTR FLOW I/EAURFIIFITI IN HORI'OMIAI
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NTPCLI MI TED
( A oo\aNMEMI oF |NDA o{rERpRtsE )
(TG PACKAGE)
IT INSTRUMENT INSTALLATION DIAGRAI\,,I
FLOW IMEASUREIVENT (USING
FLOW NOZZLES)
STEAM & FEEDWATER
ORG. NO,
0000-1 10-Pot-4-026
E
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HORITOMIII PIP' RUN
TRArlSUrtrER !OU{Tm IEa\/F tr.lslRur,trvr souRca
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u4
NTPCLI MI TED
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(TG PACKAGE)
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SULXHECD OF I-OC|!
TNSTBUMENI
ENCIOSUSE/RACK
LIST OF MATERIALS
sLoPE (APPRoX. SOmh/Mh,)
EULI(|']TID COUPUNO
cT-
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6l Flo_gn LtNt
-'O
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ELEVATION
TRAfl SUfi TR MOUMIFN rFO\,f INSIRUMF|II SOIIRCF PAI]\II
ELEVATION
TRANSM' ITIR MOUMT' N FNOW NSIRUVF|IT SOUR' F POINT
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PIPE t l/2' IUBE UNroN
(TG
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INSTRUMENT INSTALLATION DIAGRAM
(FLOW MEASUREMENT AIR/GAS)
o000-110-Pol-A-028
CAD FILE NAMEi Djl
5
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LIST OF MATERIALS
3
I
TO DRAIN IIDR IN I]T
SETT]-ING
cH raEns
TO D&qIN HOR IN UE
oR DUCI
2, roR v cuu lpPltcAllolt o-ltER PoF4 0a TRANSMIIIER SftAL! 8E xEPr
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\
ELEVATION
DIRTY AIR/FLUE GAs FLOW MEASUREMENT USING HEAD fi PE PRIMARY ELEMENT
EULXHIAD Of
LOC|L ITISIiUNENI
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1. MATERIAL OF THE BOSS AND NIPPLE SHALL BE THE SAUE AS THE PIPE II.ITO WHICH
IT IS WELDED AND CONFIRM TO ANSI B 16.11.
2. THE LENGTH OF THE NIPPLE SHOULD BE 25omm.
3.
I1E.oItqR
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OF MATERIAL AS PER ANSI B 16.1.
4- TWO ISOLATED VALVES ARE TO BE USED FOR PRESSURE =
>+O Kg/Cm2 OR TEMp.= >280.C.
5. EDGE HOLE MUST BE CLEAN AND SOUARE OR ROUNOED SUGHTLY (1//64' RAD'US)
FREE FROM BURRS, WIRE EDGES OR OTHER IRREGUTARTIES.
6. ORIENTATION OF TAP WILL BE VARY WTH TYPE OF PROCESS FLUID AND NATURE OF
RUN OF THE PIPE.
7. ACTIVITIES TO 8E COMPLETED AT THE SHOP. WELD THE COUPLING (OR
BOSS) ON
THE PIPE AND DRILL PRESSURE CONNECTION HOLE (SAME
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THE PIPE IN ALLIGNMENT WTH HOLE IN THE COUPLING.
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MAIN PROCESS
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1, THIS ryPE OF THERMOWELL INSTALLATION IS SUITABLE FOR THE PROCESS
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2. FOR STTAM SERVICE THIS TYPE OF IHERMOWELL INSTALLATION 90' BEND
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J. THE LENGTH OF THE I-ARGER PIPE SECTlOi.l SHALL BE MINIMUIJ r50mm
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THERMOWELL SUITABLE
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TEMP. BOSS
DI MENSI ONS SUI TABLE
INCLINED INSTALLATION
CONNECTIONS AS PER
FOR
SCREWED WELDTD
PROCESS CONNECTION.
1. INCLINED INSTALLATION OF THERMOWELL SHALL BE APPLTCABLE FOR 4" AND
SMALLER LINE SIZE BUT LIMITED TO MIN. 3" LINE SIZE.
2. FOR 2' ' AND SMALLER LINE SIZE NECESSARY EXPANDER OF MIN. 3' ' SIZE OF
MAIN PIPING SPECIFICATION
SHALL BE USED.
3. THIS TYPE OF 'NSTALI,AT'ON
IS APPLICABLE FOR HORIZONTAL AND VERTICAL
PIPE SECTION,
4. FOR STEAM SERVICES EXPANDER SECTION MAY BE USED ONLY IN VERTICAL RUN.
5. THE EXPANDER SECTION SHALL BE OF ADEOUATE LENGTH
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eqa d & BBe
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1. FLOW INSTALLATION OF THERMOWELL SHALL BE APPLICABLE FOR 4- AND SMALLER
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2' FOR 2'AND SIV'IALLER UNE SIZE NECESSARY EXPANDER OF ELBOW FORM
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NOTES:-
THIS TYPE OF TEMPERATURE EOSS
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PRESS EAUAL/AeoVE aO Ks/cnz(s).
THE MATERIAL OF THE BOSS SHOULD
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MATERIAL OF SPECIFICATION,
ALL WELD TO BE TESIED IN
ACCORDANCE WITH APPLICABLE
CODES BY MANUFACTURER.
MATER'AL OF THE THERMOWELL SHALL
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IHERMOWELL SMLL BE DRILLED
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SHOULD BE SELECTED BASED ON THE
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SHALL BE SUBJECT TO VARATION
BASED ON THE INIERNAL BORE OF
THERMOWELL AND THICKNESS OF
THERMOWELL MATERIAL TO WITHSTAND
THE PROCESS PRESS.AND TEMP.,AS
PER ASME,PTC_ t 9.3.
THE TYPE OF TAPERED THERMOWELL
SHALL 8E USED FOR LIOUIO V[LO-
crTrEs uP To 92M.P.S.(300F.T.P.S.).
THERMOWELL WITH THE INSULATION
LAG EXTENSIONS
SHALL BE USED
WHEREVER APPLICABLE.
ACTIVITIES TO BE COMPLETED AT THE
SHOP. WELD THE BOSS ON THE PIPE
AND DRILL THE HOLE IN THE PIPE IN
ALLIGNMENI WITH HOLE IN THE BOSS.
PROVIDE INTERNAL THREAD AS PER
lsi554 IO MATCH IVITH IHE THERMO-
WELL ETTERNAL THREAD.
ALL DIMENSIONS ARE IN MM UNLESS
OTHERWSE STATED.
WIILL BE SUIABLE TO MATCH THE
STUB DIMENSIONS AS PER RC 1ll2
THE
"U"
&
"1,'
DIMENSIONS SHALL BE
BE SELECTED BASED ON PARTICUTAR
APPLICATION AND THE SAME SHALL BE
il
r
14 ns PER rs;ss4
1 .
SHOP 2.
WELD
5.
NOTE- 6
7.
t1.
sEE NOTE-7
10.
SEE NOTE_I?
1 t .
SUBJECT TO OIVNER'S APPROVAL
DURING DFTAILED ENGINEERING.
14. ALL DIMENSIONS ARE INDICATIVE ONLY,
@
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TEMP. MEASUREMENT
1/2' NPT EOUIVALLENT AS
PER
STANDARD
EXIERNAT TAPERS IHRTAD
R1 TO MATCH WITH INTERNAL TAPER
THREADED Rc 1AS PER tS:55+.
SHOP
WELD
NOTES:-
1.
llls
TypE
OF TEITPERATURE
BOSS tS APPLICABLE
FOR THE
_
PR0CESS
PRESSURE
BELOW 40 Kq,/Cm2(o)
-
2. FOR PRESSURE
TIGIIT
JOINTS TTIT' ' EOSS' dfiOULD
HAVE INTERNAL
TAPERED
PIPE THREAD
RC 1 AS PTN iS-:SS+, }UE LENGTH OF
_
THIEAD
ENGAGEMENT
SHOULD er As
ptR-ebovE
STANDARD.
3.
prpEs
HAVTNG
PROBABLTrY
Os
pnoior.rctb
ileRArroN
Senf
'wrr_orr.rc
MAY BE^DONE
ALL AROUND AFTER TIGHTENINC
THCNVOWET-i
Wrrrrr.r
-
I n c DU) S-
4. SEE NOTES_2
TO i 4 0F DRc. NO. 0000_110_pot _A_0J5,
sh_6 0f 14.
SEE NOIE_6 OF DRG.
NO.0000- 1 10-pOt-A-035,
Sh_6 0f 14.
sEE NOTE-7 OF DRG.
NO.O000- 1 10-pol -A-035,
Sh-6 0f 14.
N TP C LITITED
( ^ cors.-[r d rot E{tEir6r
)
PiOEc'
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INSTRUMNT
SOURCE CONNECTION DETAILS
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CAD FILE NAME: C: DRCS\0000-1
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DUCT WALL
INSULATION
+
AI R TO
FLUI GAS
PATH
172
"NPT
3oo tbs
FLANGE AS PER
ANSI B 16.5
NOTES:-
I, THIS TYPE OF TEMPERATURE CONNECflONS SHALL BE PROVIDED FOR
TEMPEMTURE MEASUREMENT IN A]R AND FLUE GAS DUCT.
2. MATERIAL OF THERMOWELL SHALL BE OF J16SS.
J. ETTERNAL CONNECTION SHALL BE OF SLIP ON FLANGED TYPE AND THERMOWELL
DESTGN Sr-lALL BE As
pER
ASME-PIC-19.5 (REFER
NOTES 9&'10 OF DRG.NO.
0000- 1 1o-Por-A-055, sh-6 of 14).
4. B'DDER TO SUPPLY AND INSTALL THE COUNTER FLANGED AND THERMOWELL
(ALONG
WTH TEMP. ELEMENT).
5. ALL DIMENSIONS ARE INDICATIVE ONLY.
42.4 x 4.O5
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SOCKET WELDED
3/47 1" cLoBE vLv
SOCKET TO SUIT
NIPPLE.
NTPPLE 3/4"
OF MAIN PIPE CLASS
SCHEDULE
SI DE VI EW
SAME AS
MAIN PIPE
NOIES:-
1. THIS MFTHOD OF CONNECTING NIPPLES AND VALVES ON THE HORIZONTAL PIPE
IS APPLICABLE FOR MASUREMENT OF STFAM AT TEMP. ABOVE 455C ,
2. FOR STEAM SERVICE IN HORIZONTAL PIPE THE PRESSURE HOLES AND CONNECTING
NIPPLES SHOULD BE IN THE HORIZONTAL PLANE OF THE PIPE CENTRE LINE.
3. THE ENTIRE LENGTH OF THESE NIPPLES AS WELL AS SHUI OFF VALVES SHOULD
BE LAGGED IN WITH STEAM LINE AS SHOWN IN IHE DRAWNG.
4. FLOW ELEMENIS SHALL BE PROVIDED WTH 3 PAIRS OF TIPPINC POINTS.
(l c.^rEirlron 6 tJl oflE?irsE
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FLOW MEASUNEHIEI.IT
NTPPLE 3/4"
't"
SCHEDULE 160 MATERIAL
SAME AS
I+]AT
OF
MA' N PIPT
SOCK$ WELDED
3/4"/ 1" 9LOBE VALVE
OF MAIN PIPE CLASS
o
z.
=
o
INSULATIQN
ELEVATION
NOTES: -
1. THIS METHOD OF CONNECTING NIPPLES AND VALVES ON THE VERTICAL STFAM PIPE
IS APPLICABLE FOR MFASUREMENT OF STEAM AT TEMP. ABOVE 455'C
2. THE ENTIRE LENGTH OF THESE NIPPLES A5 WELL AS SHUT OFF VALVES SHOULD
BE LAGGED IN WITH STEAM LINE AS SHOWN IN THE DRAWING.
J. ON VERTICAL STFJM PIPE BOTH HIGH TEMPERATURE (SPECIAL VENTS) NIPPLES
WILL BE LONG ENOUGH SO THAT HIGH AND LOW PRESSURE CONNECTION NIPPLES
WILL BE AT SAME LEVEL
4. UP STREAM AND DOWN STREAM PRESSURE CONNECTIONS MUST BE INSTAI.LEO IN
DIFFERENT PIANES PASSING THROUGH THE CENTRE OF THE PIPE.
5. FLOW ELEMENTS SHALL BE PROVIDED WITH 3 PAIRS OF TAPPING POINTS.
NTPCLIMITED
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4D MI N 2D MI N
5D MIN
3D MI N
SEE
EASUREMENT
TONGUE AROUND
NOZZLE
0 + O . 1 5 O + O . 1 5
_ 0.30 _ o.o0
NOTES: -
DETAI L- . A'
1. COMPLETE FLOW NOZZLE BRANCH ASSEMBLY ALONC WITH NIPPLES AND SOURCE
ISOLATION VALVES SHALL BE SUPPLIED BY THE BIDDER. 'HE BIDDER ALSO TO INS]ALL
FLOW NOZZLE WITHIN THE MACHINED BRANCH. PRESSURE SfUBS ON THE BRANCH
PIPE
(FOR
ORIENTA]ION OF PRESSURE TAP REF, NOTE-3) ALONG WITH NIPPLE AND
SOURCE TSOLATION VALVES-
2. THE MACHTNING OF BRANCH PIPE SHOULD BE DONE AFTER PRESSURE CONNECTIONS
I.IAVE BEEN WELDED TO PIPE AND ALSO EXTEND FOR ATLEAST 4D IN THE INLFT
SECTION. 2D IN THE OTJTLET SECTION. MEASURED FROM THE INLET FACE OF FLOW
NOZZLE. TOIAL BRANCH PIPE ASSEMBLY SHOULD BE ATLEAST A LENGTH OF 8Dl5D
IN THE INLET SECTION AND 5D tN THE OI'TLET SECTION, MEASURED FROM THE
INLET FACE OF THE FLOW NOZZLE AS SHOWN ABOVE,
3. ON HORIZONTAL PIPE RUN PRESSURE COf{NECTIONS ARE IO BE LOCATED ON SIDES
OF I}tE PIPE FOR LIOUID AND STEAM SERr'ICE AND ON THE TOP FOR DRY GAS
SERVICE FOR PROCESS LIQUIDS, TNSTALLATION OF.PRESS. TAPS MAY BE ALLOWED
WTHIN AN ANGLE OF 45' ELBOW HORIZONIAL FOR SPECIAL CASES BUT NO
BOTTOM CONNECTIONS ARE ALLOWED.
4, THE LOCATION OF PRESSURE TAPS MUST BE WITHIN 1.5
.'|'fi(1/16.)
OF DISTANCE
SPECIFIED AND NUMBER OF PAIRS OF PRESSURE TAPS TO BE PROVIDED WILL BE
AS PER FLOW MEASUREMENT DATA SHEFT.
5. PRESSURE TAPS SHOUI.D BE DRILLED MDIALLY h'TTH RESPECT TO PIPE AND THIS
ORILLING SHOULD BE OONE AFTER Alf/ COUPUNG FOR ATTACHING TNE PRESSURE
TUBING IIAS BEEN WET,DED TO THE PIPE. THE HOLE WHERE IT BREAKS THROUGH
THE INNER SURFACE OF'IHE PIPE MUSI BE FREE OF BURRS OR WIRE EDGE
AND CORNER OF EDGE HOLE LEFI ROUNDED VERY SLIGHTLY
(1/64" RADIOUS).
6. RECOMMENDED MAXIMUM DIAMFI-ERS OF PRESSURE TAP HOLES IN THE BRANCH
PIPES WILL BE AS PER ASME PTC 19.5, THE DIAMFIER FOR HOLE SHOULD
REMAIN SAME FOR DISIANCE NOT LESS I}|/qN 2,5 TIME OF DIA FROM THE INNER
SURFACE OF THE PIPE.
7. FLOW NOZZLE S|IALL BE CENTRED lN THE PIPE vJlTHlN O.8 nm (1/32) OF rHE
PIPE AXIS. INSIDE DIAME ER MEASURED AT FOUR POINTS AT AI'T' CROSS SECTION
SHALL NOT DIFFER BT MORE THAN 1%,
8. BRANCH PIPE SHALL BE AS PER MAIN PIPING MATERIAL SPECIFICATION' INTERNAL
SURFACE OF BORED SECTIONS MUST BE SMOOTH AND STRAIGHT, FREE FROM
SCALES, PTTS, BURRS OR ANY IRREGULARTIES.
9. FLOW NOZZLE MATERIAL SHALL 8E 516 SS AND THE DESIGN AS PER ASME.
1O, MAXIMUM UPSTREAM AND DOWN STRAM STRAIGHT LENGTH REOUIRED FROM
INLET FACE OF FLOW NOZZLE SHALL BE AS PER ASME, PTC-19.5.
INCREASES WITH I
SHOULD BE
THE PIPE SIZE
I
MIN' 21 mm
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FLOW MEASUREMENT
LENGTH TO BE NOT LESS THAN
2, 5
TI Mr S Dr a
DF
PRFSSTJRE
HOLES
EXTERNAL TAPERED THREAD
R 1/2" rO MATCH W| TH
INTERNAL TAPER THREAD
RC 1/2" A,S PER rS:554
NOTES: -
1 .
,
7.
al.
ORIFICE PLATE M0UNTED BFfWEEN FTANGES WTH FTANGE TAPPING (As
sHowN ABoVE)
SHOULD BE LIMITED TO PIPE SIZES OF 2'' OR TARGER.
ORIFICE PLATE SHALL BE MOUNTED BETWEEN PIPING FLANGES WITH THE SHARP EDGE
FACING UPSTREAM SUCH THAT CENTRE OF THE CONCENIRIC ORIFICE SHOULD BE
wl THrN o.79 mm (1/32' )
OF THE AX| S OF THE
ptpE.
TWO GASKM SHALL BE INSERTED EEIWEEN THE PLATE AND THE FLANGES AND INSIDE
DAMETER OF I}1E GASKETS SHOULD BE ATLEAST 1.5 MM (1/'16")
GREATER THAN THE
INSIDE DIAMEIER OF THE PIPE SO THAT THEf DO NOT PROTRUDE'INTO THE PIPE.
PIPING FLANGES SHALL BE ANSI WELD NECK, RAISED FACE TYPE. THE FLANGE IS TO
BE ALIGNED WITH THE FACE PERPENDICULAR TO THE FLOW AXIS.
BIDDER TO SUPPLY ORIFICE PLATE SPECIAL TYPE (HAVING PRESS. CONNECTIONS) OF
FLANGES ALONG WITH GASKETS, NIPPLES AND SOUIICE VALVES.
ON HORIZONIAL PIPE RUN PRESSURE CONNECTIONS ARE TO BE TAKEN FROM SIDES FOR
LIQUID ANO STEAM STRVICE AND FROM TOP FOR DRY GAS SERVICE FOR PROCESS
LIOUIDS INSTALTAIION OF PRESSURE TAPS MAY BE ALLOWED WITHIN AN ANGLE OF 45'
ELBOII'/ THE HORIZONTAL IN SPECIAL Cr'.sFS BUT NO BOTTOM CONNECTIONS ARE ALLOWED.
IHE. LOCANON OF PRESSURE TAPS MUST BE WITHIN ],5 mm (1/16")
oF THE DISTANCE
SPECIFIED.
MAXIMUM DIAMEIER OF PRESS. CONNECTION HOLES SHALL BE AS PER RECOMMENDATIONS
OF ASME PTC 19,5. THE DLqMETER OF THE HOLE SHOULD REMAIN IHE SAME FOR A
DISTANCE NOT LESS IHAN 2,5 TIMES OF IHE DIAMEIER BEFORE EXPANOING 'NIO THE
PRESSURE PIPE.
THERE MUST BE NO BURRS WIRE EDGES OR OTHER IRREGULARTIES ALONG THE EDGE
OF THE HOLE AND IT MUST BE SQUARE AND ROUNDED SLIGHILY (1//64'
MDIUS).
oRrFrcE PLATE SHOULD BE FLAT W|IHIN 0.02 mm
(O.0Or")
AND THt SURFACE
ROUGHNESS
SHOULD NOT EXCEED 20 MICRO INCH. THE I}iICKNESS OF THE ORIFICE
PLATE SHOULD BE AS PER ASME,PTC-19.5.
FOR HORIZONTAL PIPE RUN DMIN HOLES IN ORIFICE PLATES ARE AT THE BOTTOM
(APPROX.
TANGENT TO TNSIDE DIA OF PIPE) FOR STEAM OR GAS SERVICE, VENI HOLES
SHOULD BE LOCATED ON UPPER SIDE FOR INCOMPRESSIBLE FLUID.
ORIFICE PLATE SHOULD BE OF 516 SS
(ASTM
A167-54 GMDE_II).
RECOMMENDED MINIMUM LENGTHS OF STRAIGHT PIPE PRECEDING AruO TOLLOWII.IC
ORIFICES SHALL BE AS PER ASME.PTC-I9.5.
THREE PAIRS OF PRESSURE TAPS SI-IALL BE PROVIDED WITH NIPPLES OF REQUIRED
LENGTH AND SOURCE VALVES AND THE UN-USED TAPS ARE PLUGCED.
THE INTERNAL TAPERED CONNECTION WITHIN THE FLANGE FOR PRESSURE TAPS SHOULD
9E_!9 il?".4!.q_LHqlgll_E,srrouLD
ALso oF EnERNAL THREcDED
c tiz' as-cla
IS:554. THE LENGIH OF THREADED ENGAGEMENI SHALL BE AS PER ABoVE'STANDARD.
t n
' 1 1 .
12.
1+.
15.
FLOW
eq*dzf r BBe
NTPCLIMT| ED
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3/471" NTPPLE
3/4/1" SOCKfr WELDED GLOBE,/
VALVE MATERIAL AS PER ANSI
B 3 1 . 1
socKFr TO SU|T NTPPLE
OF 3/471"
or*rFJ-
c&r coNTRAcroR's
scb-ii
scoPE
LEVEL MEASUREMENT
3/4'/1" NTPPLE rO AE
CONNECTED WTTH LEVEL GAUGE/
SWITCH THROUGH SOCKFT
WELDED EQUAL UNION
t\l nTtrq. -
VESSEL/TANK
WALL
1. THIS- TYPE OF PROCESS CONNECTION SFI,ALL BE USED FOR LEVEL GAUGE AND
EXTERNAL CAGE TYPE FLOAT OR DISPLACER OERATE-D
LilEiiWTCH.
2. FOR
GAUGES. 3/4' NIPPLE ALONG WITH 3/4" SW SOURCE VALVE AND FOR
s-ytr_cHEs 1' NrppLE ALoNG wnH r' s$r'sounCe
-viivi-sniir_
ee
pRovtDED
AS PROCESS
CONNECTON.
3.
:ggRcq
CoNNECTTON ON VES-SF! SHOULD NOT BE LOCATED
Ar
pLAcES
SUB\,ECTED
TO INTERFACE
AND TURBULENCE rNOU r|,r-r-Iifir,iO
OUrr-NS,
4.
ll_lguER
coNNECTtON
ts TAKEN,FROM
BOTTOM OF THE VESSEL THEN THE
NIPPLE MUST BE IOO MM TO 150 rrlrN ABOVE iiE'E'OrrOT"Or
IHE VESSEL.
VESSELAANK
WALL
4- ANSI MATCHING FLANGE
ATIACHED WIIH FLUSH
DJAPHRAGM
OF LEVEL
TRANSMITTER
4" NPS VESSEL
NOZZLE
4" BUTT WELDED
GATE VALVE
4' ANSI Joo rbs
NOTES:-
2.
L TIIS
]]Iq
OF PROCESS
CONN-ECTION
S||ALL BE PROVJDED FOR TANK LEVEL MEASUREMENT
9J
yLsqqus oR coRRostvE
Lroujt usjNc
-FLUSH
ilb-H-riAdiw;iER
rypE LEVEL
TRANSMITTER.
WELDING
OF MATCHING
FLANGE IO GATE VALVE SHALL BE DONE BY BIDDER.
R.F. WELD NECK
FTANGE
FOR TENDER
pUnpOSf
Ot' it-y
lG-a-d#l
Lse_sJ
ear et El
NTPC
PRC'EC'
ryPICALTH-qBMALPOWERPROJECT
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0000-' 1 10-PO|-A-035
cAD FILE MME: D:\NgRrH KAMNpUna\ oooo-ll o-EolJ]iilifiiTi",^
LEVEL' MEASUREMEi -i T
2" NPS VESSEL
NOZZLE
2" NIPPLE TO BE
CONNECTED WITH LEVEL
TRANSMITTER
2" SOCKET WELDED GLOBE
VALVE MATERIAL AS PER ANSI
B J 1. 1
SOCKET TO SUIT
N}PPLE OF 2"
VESSEL/TANK
WALL
NOTES: -
1. THIS Tt'PE OF PROCESS CONNECTION SI-'ALL BE USED FOR DISPLACER TYPE
LEVEL TRANSMITTER.
2. SOURCE CONNECIION ON VESSEL SHOULD NOT BE LOCATED AT PLACES
SUBJECTED TO INTERFACE AND TURBULENCE rNOU IIIIrri IHO OUrrrrS.
3. IF.LOWER CONNECTION IS TAKEN FROM BOTIOM OF ]HE VESSEL THEN THE
NIPPLE MUST BE IOO mm TO 150 rnm ABOVE THE AOTTOM- Or rHr vEiSer.
eqAdz f r
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SWGR SWITCH (COC) TERMINATION DETAILS
D I S C R I P T I O N
DRG. NO.
0000-999-Por-A-065
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KKS CODE
GUIDELINES
DOCUMENT NO: 0000-110-POI-G-001
NTPC Limited
(A GOVERNMENT OF INDIA ENTERPRISE)
STANDARD 660 MW TG PKG
APPD
BY
CHKD
BY
PREP BY REV
0 AS AB
Thursday, December 09, 2010 Page 1 of 25
9562
KKS_CODE DESCRI PTI ON I NST/DRI VE TYPE
AMMONI A DOSI NG SYS
QCD01AA101 AMMONIA DOSING PUMP-1 STROKE CTL CLCS
QCD01AP001 AMMONIA DOSING PUMP-1 LT
QCD02AA101 AMMONIA DOSING PUMP-2 STROKE CTL CLCS
QCD02AP001 AMMONIA DOSING PUMP-2 LT
QCD02AP201 AMMONIA MIX/STRG TANK AGITATOR LT
BULK AMMONI A STORAGE CUM TRANSFER SYS
QCD11AP001 AMMONIA DOSING TFR PMP-1 LT
QCD11AP002 AMMONIA DOSING TFR PMP-2 LT
CENTRAL LUBE OI L STORAGE & PURI FI CATI ON SYS
MGV10CL201 DIRTY OIL TANK LEVEL LS
MGV10CL202 DIRTY OIL TANK LEVEL LS
MGV10CL301 DIRTY OIL TANK LEVEL LG
MGV10CP201 DOT PUMP STAINER CLEANER DIFF PRESS DPS
MGV10CP301 Dirty Oil Tnk PUMP STAINER CLEANER DIFF PRESS DPG
MGV10CP302 DIRTY OIL TNK PUMP DISCH PRESS PG
MGV10CP303 DIRTY OIL TNK PUMP SUCTION PRESS PG
MGV20CL201 CLEAN OIL TANK LEVEL LS
MGV20CL202 CLEAN OIL TANK LEVEL LS
MGV20CL301 CLEAN OIL TANK LEVEL LG
MGV20CP201 COT PUMP STAINER CLEANER DIFF PRESS DPS
MGV20CP301 Clean Oil Tnk PUMP STAINER CLEANER DIFF PRESS DPG
MGV20CP302 CLEAN OIL TNK PUMP DISCH PRESS PG
MGV20CP303 CLEAN OIL TNK PUMP SUCTION PRESS PG
CONDENSATE SYS
LAA01AA201 D/A OVERFLOW TO LPD F/T CV SOV/O/L
LAA01CL101 DEAERATOR LEVEL LT
LAA01CL301 DEAERATOR LEVEL LG
LAA01CP302 DEAERATOR PRESS PG
LAA01CT101 DEAERATOR FST TEMP TE
LAA01CT102 DEAERATOR FST TEMP TE
LAA01CT301 DEAERATOR FST TEMP TG
LAA01CT305 DEAERATOR FST TEMP TG
LAA02AA201 D/A OVERFLOW TO LPD F/T STBY VLV MOV
LCA00CT101 CEP SUCTION TEMP TE
LCA01AA202 CEP-A DIS VLV MOV
LCA01AA212 CEP-A DIS VLV-IBV MOV
LCA01AP001 CEP-A HT
LCA01CF101 CEP-A DISCH FLOW FT
LCA01CF102 CEP-A DISCH FLOW FT
LCA01CP101 CEP-A DISCH HDR PRESS PT
LCA01CP102 CEP-A DISCH HDR PRESS PT
LCA01CP103 CEP-A SUCTION PRESS ACROSS STAINER DPT
LCA01CP301 CEP-A SUCTION PRESS ACROSS STAINER DPG
LCA01CP302 CEP-A SUCTION PRESS PG
LCA01CP303 CEP-A DISCH HDR PRESS PG
LCA01CT301 CEP-A SUCTION TEMP TG
LCA01CT302 CEP-A DISCHARGE TEMP TG
LCA02AA202 CEP-B DIS VLV MOV
LCA02AA212 CEP-B DIS VLV-IBV MOV
LCA02AP001 CEP-B HT
LCA02CF101 CEP-B DISCH FLOW FT
LCA02CF102 CEP-B DISCH FLOW FT
LCA02CP101 CEP-B DISCH HDR PRESS PT
LCA02CP102 CEP-B DISCH HDR PRESS PT
LCA02CP103 CEP-B SUCTION PRESS ACROSS STAINER DPT
LCA02CP301 CEP-B SUCTION PRESS ACROSS STAINER DPG
LCA02CP302 CEP-B SUCTION PRESS PG
LCA02CP303 CEP-B DISCH HDR PRESS PG
LCA02CT301 CEP-B SUCTION TEMP TG
LCA02CT302 CEP-B DISCHARGE TEMP TG
LCA03AA202 CEP-C DIS VLV MOV
LCA03AA212 CEP-C DIS VLV-IBV MOV
LCA03AP001 CEP-C HT
LCA03CF101 CEP-C DISCH FLOW FT
LCA03CF102 CEP-C DISCH FLOW FT
LCA03CP101 CEP-C DISCH HDR PRESS PT
LCA03CP102 CEP-C DISCH HDR PRESS PT
LCA03CP103 CEP-C SUCTION PRESS ACROSS STAINER DPT
LCA03CP301 CEP-C SUCTION PRESS ACROSS STAINER DPG
LCA03CP302 CEP-C SUCTION PRESS PG
LCA03CP303 CEP-C DISCH HDR PRESS PG
LCA03CT301 CEP-C SUCTION TEMP TG
LCA03CT302 CEP-C DISCHARGE TEMP TG
LCA11AA101 CEP-A MIN RECIRC CV CLCS
LCA12AA101 CEP-B MIN RECIRC CV CLCS
LCA13AA101 CEP-C MIN RECIRC CV CLCS
LCA20CF101 COND. FLOW AT GSC O/L FT
LCA20CF102 COND. FLOW AT GSC O/L FT
LCA20CP101 COND. DISCH HDR PRESS PT
LCA20CP301 COND. DISCH HDR PRESS PG
LCA20CP302 COND. PRESS AT GSC O/L PG
LCA20CP303 COND PRESS AFT CPU PG
LCA20CQ101 COND. CAT CONDUCTIVITY CCT
LCA20CQ102 CONDENSATE SODIUM NaT
LCA20CQ103 CONDENSATE DISS O2 DOT
LCA20CQ104 CONDENSATE pH pHT
LCA20CQ105 CONDENSATE CONDUCTVITY CT
LCA20CT101 COND. TEMP AT GSC I/L TE
LCA20CT102 COND. TEMP AT GSC O/L TE
LCA31AA101 GSC MIN RECIRC FLOW CV CLCS
LCA32AA201 GSC MIN RECIRC FLOW BYP VLV MOVI
LCA33AA101 COND TO VALVE GLD SEALING CV CLCS
LCA33CP101 GLAND SEAL WATER HDR PR PT
LCA33CP102 GLAND SEAL WATER HDR PR PT
LCA41AA101 EXCESS COND DUMP TO CST CV CLCS
LCA41CP301 EXCESS COND PR BEF CV 43 PG
LCA41CP302 EXCESS COND PR AFT CV 43 PG
LCA42AA201 EXCESS COND DUMP TO CST BYP VLV MOVI
LCA50CQ101 COND SODIUM AFT CPU NaT
LCA50CQ102 COND SILICA AFT CPU SiT
LCA50CQ103 COND CONDUCTVITY AFT CPU CT
LCA50CQ104 COND pH AFT CPU pHT
LCA50CQ105 COND CAT CONDVTY AFT CPU CCT
LCA51AA101 DEA LVL CONTROL STN MAIN CONT VLV CLCS
LCA51AA201 DEA LVL CONTROL STN MAIN CV ISO VLV MOV
LCA52AA101 DEA LVL CONTROL STN STBY CV CLCS
LCA52AA201 DEA LVL CONTROL STN STBY CV ISO VLV MOV
LCA53AA201 DEA LVL CONTROL STN BYPAS VLV MOVI
LCA61AA201 LPH-1 BYP VLV MOV
LCA62AA201 COND I/L TO DC & LPH-1 ISO VLV MOV
LCA62AA202 COND O/L FROM LPH-1 ISO VLV MOV
LCA62AA211 COND I/L TO DC & LPH-1 ISO VLV-IBV MOV
LCA62CP101 LPH-1 COND I/L PRESS PT
LCA62CP102 LPH-1 COND O/L PRESS PT
LCA62CP103 DRAIN CLR I/L PRESS PT
LCA62CT101 LPH-1 COND I/L TEMP TE
LCA62CT103 DRAIN COOLER I/L TEMP TE
LCA62CT301 DRAIN COOLER I/L TEMP TG
LCA62CT302 DRAIN COOLER O/L TEMP TG
LCA62CT303 LPH-1 COND I/L TEMP TG
LCA62CT304 LPH-1 COND O/L TEMP TG
LCA71AA201 LPH-2 BYP VLV MOVI
LCA72AA201 COND TO LPH-2 I/L ISO VLV MOV
LCA72AA202 COND FROM LPH-2 O/L ISO VLV MOV
LCA72AA211 COND TO LPH-2 I/L ISO VLV -IBV MOV
LCA72CT102 LPH-2 COND O/L TEMP TE
LCA81AA201 LPH-3 BYP MOVI
LCA82AA201 COND TO LPH-3 I/L ISO VLV MOV
LCA82AA202 COND FROM LPH-3 O/L ISO VLV MOV
LCA82AA211 COND TO LPH-3 I/L ISO VLV-IBV MOV
LCA90CF101 CONDENSATE FLOW TO DEA FT
LCA90CF102 CONDENSATE FLOW TO DEA FT
LCA90CP101 DEA FEED STR TNK I/L PRESS PT
LCA90CT101 COND. TEMP AT DEA I/L TE
LCB01AA201 CEP-A VENT TO LPDFT VLV SOV/O/L
LCB02AA201 CEP-B VENT TO LPDFT VLV SOV/O/L
LCB03AA201 CEP-C VENT TO LPDFT VLV SOV/O/L
LCJ 15CT301 GSC I/L TEMP TG
LCJ 15CT302 GSC O/L TEMP TG
LCR34CP101 DM MU TO STATOR WTR COOLING SYS PT
LCR41AA101 DM NORMAL M/U TO HOTWELL CV CLCS
LCR41AA201 DM NORMAL M/U CV ISO VLV MOV
LCR41CF101 NORMAL MU FLOW TO COND FT
LCR41CF102 NORMAL MU FLOW TO COND FT
LCR42AA201 DM NORMAL M/U TO HOTWELL BYP VLV MOVI
LCR80CF101 EMER MU FLOW TO COND FT
LCR80CF102 EMER MU FLOW TO COND FT
LCR80CP101 EMER MU TO COND I/L PRESS PT
LCR81AA101 DM EMERG M/U TO HOTWELL CV CLCS
LCR81AA201 DM EMERG M/U CV ISO VLV MOV
LCR82AA201 DM EMERG M/U TO HOTWELL BYP VLV MOVI
MAG10CL101 HOTWELL LEVEL LT
MAG10CL301 HOTWELL LEVEL LG
MAG10CQ101 HOTWELL CONDUCTVTY (L) CT
MAG10CQ102 HOTWELL CONDUCTVTY (R) CT
CW & ACW SYS
PAB11CP011 DP ACROSS COND DPT
PAB11CP501 CONDENSER I/L PRESS PG
PAB11CP502 CONDENSER O/L PRESS PG
PAB11CP511 DP ACROSS COND DPG
PAB11CT001 CONDENSER I/L TEMP TE
PAB11CT002 CONDENSER O/L TEMP TE
PAB11CT501 CONDENSER I/L TEMP TG
PAB11CT502 CONDENSER O/L TEMP TG
PAB12CP011 DP ACROSS COND DPT
PAB12CP501 CONDENSER I/L PRESS PG
PAB12CP502 CONDENSER O/L PRESS PG
PAB12CP511 DP ACROSS COND DPG
PAB12CT001 CONDENSER I/L TEMP TE
PAB12CT002 CONDENSER O/L TEMP TE
PAB12CT501 CONDENSER I/L TEMP TG
PAB12CT502 CONDENSER O/L TEMP TG
PAB31CP511 DP ACROSS PHE A DPS
PAB32CP511 DP ACROSS PHE B DPS
PAB33CP511 DP ACROSS PHE C DPS
PAB41CP511 DP ACROSS VACUUM PMP H EXCH DPS
PAB42CP511 DP ACROSS VACUUM PMP H EXCH DPS
PAB51CP511 DP ACROSS PHE FOR BOILER AUX-1 DPS
PAB52CP511 DP ACROSS PHE FOR BOILER AUX-2 DPS
PCB00CP001 ACW PUMP's I/L PRES PT
PCB01CP001 ACW PUMP-A DISCH HDR PRES PT
PCB01CP501 ACW PMP-A SUCTION PRESS PG
PCB01CP502 ACW PMP-A DISCHARGE PRESS PG
PCB02CP001 ACW PUMP-B DISCH HDR PRES PT
PCB02CP501 ACW PMP-B SUCTION PRESS PG
PCB02CP502 ACW PMP-B DISCHARGE PRESS PG
PCB03CP001 ACW PUMP-C DISCH HDR PRES PT
PCB03CP501 ACW PMP-C SUCTION PRESS PG
PCB03CP502 ACW PMP-C DISCHARGE PRESS PG
PCB10CP001 ACW PUMP's O/L PRES PT
PCB10CP501 ACW PMP DISCHARGE HDR PRESS PG
PCB10CT001 ACW PUMP's O/L TEMP TE
PCB10CT501 ACW PUMP's O/L TEMP TG
PCB20CF001 AUTO SELF CLEANING FLTR O/L FLOW FT
PCB30AA201 ACW PUMPS CMN RECIRC VLV MOV
PCB30CF100 I/L FLOW TO PHE's FOR TG AUX ROTAMETER
PCB31AA201 ACW PUMP-A SUC VLV MOV
PCB31AA202 ACW PUMP-A DIS VLV MOV
PCB31AP001 ACW PUMP-A LT
PCB31CP111 DP ACROSS PHE A DPG
PCB31CT001 PHE A I/L TEMP TE
PCB31CT002 PHE A O/L TEMP TE
PCB31CT501 PHE A I/L TEMP TG
PCB31CT502 PHE A O/L TEMP TG
PCB32AA201 ACW PUMP-B SUC VLV MOV
PCB32AA202 ACW PUMP-B DIS VLV MOV
PCB32AP001 ACW PUMP-B LT
PCB32CP111 DP ACROSS PHE B DPG
PCB32CT001 PHE B I/L TEMP TE
PCB32CT002 PHE B O/L TEMP TE
PCB32CT501 PHE B I/L TEMP TG
PCB32CT502 PHE B O/L TEMP TG
PCB33AA201 ACW PUMP-C SUC VLV MOV
PCB33AA202 ACW PUMP-C DIS VLV MOV
PCB33AP001 ACW PUMP-C LT
PCB33CP111 DP ACROSS PHE C DPG
PCB33CT001 PHE C I/L TEMP TE
PCB33CT002 PHE C O/L TEMP TE
PCB33CT501 PHE C I/L TEMP TG
PCB33CT502 PHE C O/L TEMP TG
PCB40CF100 VACUUM PMP's I/L FLOW ROTAMETER
PCB41CP111 DP ACROSS VACUUM PMP H EXCH DPG
PCB41CP501 I/L PRESS VACUUM PMP H EXCH PG
PCB41CT001 I/L TEMP VACUUM PMP H EXCH TE
PCB41CT002 O/L TEMP VACUUM PMP H EXCH TE
PCB41CT501 I/L TEMP VACUUM PMP H EXCH TG
PCB41CT502 O/L TEMP VACUUM PMP H EXCH TG
PCB42CP111 DP ACROSS VACUUM PMP H EXCH DPG
PCB42CP501 I/L PRESS VACUUM PMP H EXCH PG
PCB42CT001 I/L TEMP VACUUM PMP H EXCH TE
PCB42CT002 O/L TEMP VACUUM PMP H EXCH TE
PCB42CT501 I/L TEMP VACUUM PMP H EXCH TG
PCB42CT502 O/L TEMP VACUUM PMP H EXCH TG
PCB51CF100 I/L FLOW TO PHE-1 FOR BOILER AUX ROTAMETER
PCB51CF100 PHE FOR BOILER AUX-1 I/L FLOW FE
PCB51CF501 PHE FOR BOILER AUX-1 I/L FLOW FG
PCB51CP111 DP ACROSS PHE FOR BOILER AUX-1 DPG
PCB51CT001 PHE FOR BOILER AUX-1 I/L TEMP TE
PCB51CT002 PHE FOR BOILER AUX-1 O/L TEMP TE
PCB51CT501 PHE FOR BOILER AUX-1 I/L TEMP TG
PCB51CT502 PHE FOR BOILER AUX-1 O/L TEMP TG
PCB52CF100 PHE FOR BOILER AUX-2 I/L FLOW FE
PCB52CF100 I/L FLOW TO PHE-2 FOR BOILER AUX ROTAMETER
PCB52CF501 PHE FOR BOILER AUX-2 I/L FLOW FG
PCB52CP111 DP ACROSS PHE FOR BOILER AUX-2 DPG
PCB52CT001 PHE FOR BOILER AUX-2 I/L TEMP TE
PCB52CT002 PHE FOR BOILER AUX-2 O/L TEMP TE
PCB52CT501 PHE FOR BOILER AUX-2 I/L TEMP TG
PCB52CT502 PHE FOR BOILER AUX-2 0/L TEMP TG
DM COOLI NG WATER (DMCW) SYS FOR TG AUX
LCP02AA209 DMCW NORMAL M/U TO ECW OH TANK (TG) MOV
LCP02AA210 DMCW EMERG M/U TO ECW O/H TANK (TG) MOV
PGB00AA201 ECW PUMPS (TG) CMN RECIRC VLV MOV
PGB01AA201 ECW PUMP-A (TG) SUC VLV MOV
PGB01AA202 ECW PUMP-A (TG) DIS VLV MOV
PGB01AP001 ECW PUMP-A (TG) HT
PGB01CL001 DMCW OVR HEAD TNK LEVEL LT
PGB01CL002 DMCW OVR HEAD TNK LEVEL LT
PGB01CL501 DMCW OVR HEAD TNK LEVEL LG
PGB02AA201 ECW PUMP-B (TG) SUC VLV MOV
PGB02AA202 ECW PUMP-B (TG) DIS VLV MOV
PGB02AP001 ECW PUMP-B (TG) HT
PGB03AA201 ECW PUMP-C (TG) SUC VLV MOV
PGB03AA202 ECW PUMP-C (TG) DIS VLV MOV
PGB03AP001 ECW PUMP-C (TG) HT
PGB04AA101 ECW PUMP-(TG) I/O HDR DP CV CLCS
PGB41AA201 MDBFP-C CW VALVE MOV
PGC00CF100 DMCW PMP's I/L FLOW ROTAMETER
PGC00CP001 DMCW TNK O/L PRESS PT
PGC00CP501 DMCW TNK O/L PRESS PG
PGC00CT501 DMCW TNK O/L TEMP TG
PGC01CP001 DMCW PMP-A DISCH PRESS PT
PGC01CP501 DMCW PMP-A SUCTION PRESS PG
PGC01CP502 DMCW PMP-A DISCH PRESS PG
PGC02CP001 DMCW PMP-B DISCH PRESS PT
PGC02CP501 DMCW PMP-B SUCTION PRESS PG
PGC02CP502 DMCW PMP-B DISCH PRESS PG
PGC03CP001 DMCW PMP-C DISCH PRESS PT
PGC03CP501 DMCW PMP-C SUCTION PRESS PG
PGC03CP502 DMCW PMP-C DISCH PRESS PG
PGC10CF001 DMCW PMP's O/L FLOW FT
PGC10CP001 DMCW PMP HDR DISCH PRESS PT
PGC10CP501 DMCW PMP HDR DISCH PRESS PG
PGC10CQ001 DMCW PMP's DISCHARGE pH pHT
PGC10CT001 DMCW PMP HDR O/L TEMP TE
PGC10CT501 DMCW PMP's O/L TEMP TG
PGC11CP101 DPS ACROSS PHE-A DPS
PGC11CP551 DP ACROSS PHE-A DPG
PGC11CT001 PHE-A O/L TEMP TE
PGC11CT501 PHE-A I/L TEMP TG
PGC11CT502 PHE-A O/L TEMP TG
PGC12CP101 DPS ACROSS PHE-B DPS
PGC12CP551 DP ACROSS PHE-B DPG
PGC12CT001 PHE-B O/L TEMP TE
PGC12CT501 PHE-B I/L TEMP TG
PGC12CT502 PHE-B O/L TEMP TG
PGC13CP101 DPS ACROSS PHE-C DPS
PGC13CP551 DP ACROSS PHE-C DPG
PGC13CT001 PHE-C O/L TEMP TE
PGC13CT501 PHE-C I/L TEMP TG
PGC13CT502 PHE-C O/L TEMP TG
PGC15CP011 DP ACROSS I/L DMCW PMP's AND O/L OF PHE DPT
PGC15CP012 DP ACROSS I/L DMCW PMP's AND O/L OF PHE DPT
PGC15CP511 DP ACROSS I/L DMCW PMP's AND O/L OF PHE DPG
PGC20CP001 PHE DISCH PRESS PT
PGC20CP501 PHE DISCH PRESS PG
PGC20CT001 PHE HDR O/L TEMP TE
PGC20CT501 PHE HDR O/L TEMP TG
PGC30CP001 PRESS AT I/L HDR OF BFP MTR AND DUPLEX WRK OIL CLR PT
PGH10CP501 TURBINE OIL CLR I/L PRESS PG
PGH10CP502 TURBINE OIL CLR O/L PRESS PG
PGH10CT501 TURBINE OIL CLR I/L TEMP TG
PGH10CT502 TURBINE OIL CLR O/L TEMP TG
PGH20CF100 OIL CLR's I/L FLOW ROTAMETER
PGH21CP501 HYDROGEN CLR I/L PRESS PG
PGH21CP502 HYDROGEN CLR O/L PRESS PG
PGH21CT501 HYDROGEN CLR I/L TEMP TG
PGH21CT502 HYDROGEN CLR O/L TEMP TG
PGH22CP501 PRIMARY WTR CLR I/L PRESS PG
PGH22CP502 PRIMARY WTR CLR O/L PRESS PG
PGH22CT501 PRIMARY WTR CLR I/L TEMP TG
PGH22CT502 PRIMARY WTR CLR O/L TEMP TG
PGH23CP501 SEAL OIL CLR I/L PRESS PG
PGH23CP502 SEAL OIL CLR O/L PRESS PG
PGH23CT501 SEAL OIL CLR I/L TEMP TG
PGH23CT502 SEAL OIL CLR O/L TEMP TG
PGH24CP501 CLR FOR HPSU I/L PRESS PG
PGH24CP502 CLR FOR HPSU O/L PRESS PG
PGH24CT501 CLR FOR HPSU I/L TEMP TG
PGH24CT502 CLR FOR HPSU O/L TEMP TG
PGH25CP501 CLR FOR HPSU (LPBV) I/L PRESS PG
PGH25CP502 CLR FOR HPSU (LPBV) O/L PRESS PG
PGH25CT501 CLR FOR HPSU (LPBV) I/L TEMP TG
PGH25CT502 CLR FOR HPSU (LPBV) O/L TEMP TG
PGL00CF100 COMBINE BFP CLR's I/L FLOW ROTAMETER
PGL11CP501 TD-BFP-A TURB OIL CLR I/L PRESS PG
PGL11CP502 TD-BFP-A TURB OIL CLR O/L PRESS PG
PGL11CT501 TD-BFP-A TURB OIL CLR I/L TEMP TG
PGL11CT502 TD-BFP-A TURB OIL CLR O/L TEMP TG
PGL12CP501 BSTR PMP-A SEAL J KT CLR I/L PRESS PG
PGL12CP502 BSTR PMP-A SEAL J KT CLR O/L PRESS PG
PGL12CT501 BSTR PMP-A SEAL J KT CLR I/L TEMP TG
PGL12CT502 BSTR PMP-A SEAL J KT CLR O/L TEMP TG
PGL13CP501 TD-BFP-A SEAL J KT. CLR I/L PRESS PG
PGL13CP502 TD-BFP-A SEAL J KT. CLR O/L PRESS PG
PGL13CT501 TD-BFP-A SEAL J KT. CLR I/L TEMP TG
PGL13CT502 TD-BFP-A SEAL J KT. CLR O/L TEMP TG
PGL21CP501 TD-BFP-B TURB OIL CLR I/L PRESS PG
PGL21CP502 TD-BFP-B TURB OIL CLR O/L PRESS PG
PGL21CT501 TD-BFP-B TURB OIL CLR I/L TEMP TG
PGL21CT502 TD-BFP-B TURB OIL CLR O/L TEMP TG
PGL22CP501 BSTR PMP-B SEAL J KT CLR I/L PRESS PG
PGL22CP502 BSTR PMP-B SEAL J KT CLR O/L PRESS PG
PGL22CT501 BSTR PMP-B SEAL J KT CLR I/L TEMP TG
PGL22CT502 BSTR PMP-B SEAL J KT CLR O/L TEMP TG
PGL23CP501 TD-BFP-B SEAL J KT. CLR I/L PRESS PG
PGL23CP502 TD-BFP-B SEAL J KT. CLR O/L PRESS PG
PGL23CT501 TD-BFP-B SEAL J KT. CLR I/L TEMP TG
PGL23CT502 TD-BFP-B SEAL J KT. CLR O/L TEMP TG
PGL31CP501 COOLING DUPLEX WORKING OIL CLR I/L PRESS PG
PGL31CP502 COOLING DUPLEX WORKING OIL CLR O/L PRESS PG
PGL31CP503 COOLING DUPLEX WORKING OIL CLR I/L PRESS PG
PGL31CP504 COOLING DUPLEX WORKING OIL CLR O/L PRESS PG
PGL31CT501 COOLING DUPLEX WORKING OIL CLR I/L TEMP TG
PGL31CT502 COOLING DUPLEX WORKING OIL CLR O/L TEMP TG
PGL31CT503 COOLING DUPLEX WORKING OIL CLR I/L TEMP TG
PGL31CT504 COOLING DUPLEX WORKING OIL CLR O/L TEMP TG
PGL32CP501 BFP MTR CLR I/L PRESS PG
PGL32CP502 BFP MTR CLR CLR O/L PRESS PG
PGL32CP503 BFP MTR CLR I/L PRESS PG
PGL32CP504 BFP MTR CLR O/L PRESS PG
PGL32CT501 BFP MTR CLR I/L TEMP TG
PGL32CT502 BFP MTR CLR O/L TEMP TG
PGL32CT503 BFP MTR CLR I/L TEMP TG
PGL32CT504 BFP MTR CLR O/L TEMP TG
PGL33CP501 COOLING DUPLEX LUBE OIL CLR I/L PRESS PG
PGL33CP502 COOLING DUPLEX LUBE OIL CLR O/L PRESS PG
PGL33CP503 COOLING DUPLEX LUBE OIL CLR I/L PRESS PG
PGL33CP504 COOLING DUPLEX LUBE OIL CLR O/L PRESS PG
PGL33CT501 COOLING DUPLEX LUBE OIL CLR I/L TEMP TG
PGL33CT502 COOLING DUPLEX LUBE OIL CLR O/L TEMP TG
PGL33CT503 COOLING DUPLEX LUBE OIL CLR I/L TEMP TG
PGL33CT504 COOLING DUPLEX LUBE OIL CLR O/L TEMP TG
PGL34CP501 MD-BOOSTER PMP SUCTION PRESS PG
PGL34CP502 MD-BOOSTER PMP DISCH PRESS PG
PGL34CT501 MD-BOOSTER PMP I/L TEMP TG
PGL34CT502 MD-BOOSTER PMP O/L TEMP TG
PGL35CP501 MD-BFP SEAL J KT. CLR I/L PRESS PG
PGL35CP502 MD-BFP SEAL J KT. CLR O/L PRESS PG
PGL35CT501 MD-BFP SEAL J KT. CLR I/L TEMP TG
PGL35CT502 MD-BFP SEAL J KT. CLR O/L TEMP TG
PGL41CP501 CEP-C I/L PRESS PG
PGL41CP502 CEP-C O/L PRESS PG
PGL41CT501 CEP-C I/L TEMP TG
PGL41CT502 CEP-C O/L TEMP TG
PGL42CP501 CEP-B I/L PRESS PG
PGL42CP502 CEP-B O/L PRESS PG
PGL42CT501 CEP-B I/L TEMP TG
PGL42CT502 CEP-B O/L TEMP TG
PGL43CP501 CEP-A I/L PRESS PG
PGL43CP502 CEP-A O/L PRESS PG
PGL43CT501 CEP-A I/L TEMP TG
PGL43CT502 CEP-A O/L TEMP TG
DRAI NI NG AND MAKEUP SYS OF LUB OI L RESERVI ORS
MTV90AP005 BFPDT-A DRAIN OIL PUMP LT
MTV91AP005 BFPDT-B DRAIN OIL PUMP LT
EXTRACTI ON STEAM SYS FOR BFP TURBI NE
LBG60AA201 BFPDT-A AUX STM BLK VLV MOV
LBG60CT103 AUX STM TEMP TO TBFP-A TE
LBG61AA201 BFPDT-B AUX STM BLK VLV MOV
LBG61CT103 AUX STM TEMP TO TBFP-B TE
LBQ72AA201 BFPDT-A CRH STM BLK VLV MOV
LBQ72AA202 BFPDT-A AUX CV WARMUP VLV MOV
LBQ73AA201 BFPDT-B CRH STM BLK VLV MOV
LBQ73AA202 BFPDT-B AUX CV WARMUP VLV MOV
LBS42AA201 EXT-4 STM TO BFPDT-A & B BLK VLV MOV
LBS42CP101 IPT EXHAUST PRESS TO COM I/L OF BFP PT
LBS42CT101 IPT EXHAUST TEMP TO COM I/L OF BFP TE
LBS42CT301 IPT EXHAUST TEMP TO COM I/L OF BFP TG
LBS43AA201 BFPDT-A VENT VLV U/S OF ESV MOV
LBS43CF101 STM FLOW TO TBFP-A FT
LBS43CF102 STM FLOW TO TBFP-A FT
LBS43CP151 BFP-A I/L PRESS PT
LBS43CP351 BFP-A I/L PRESS PG
LBS43CT151 BFP-A I/L TEMP TE
LBS43CT152 BFP-A I/L TEMP TE
LBS43CT351 BFP-A I/L TEMP TG
LBS44AA201 BFPDT-B VENT VLV U/S OF ESV MOV
LBS44CF151 STM FLOW TO TBFP-B FT
LBS44CF152 STM FLOW TO TBFP-B FT
LBS44CP151 BFP-B I/L PRESS PT
LBS44CP351 BFP-B I/L PRESS PG
LBS44CT151 BFP-B I/L TEMP TE
LBS44CT152 BFP-B I/L TEMP TE
LBS44CT351 BFP-B I/L TEMP TG
LBS45AA201 BFPDT-A EXHAUST STM VALVE TO COND MOV
LBS45CP158 BFP-A O/L PRESS PT
LBS45CP356 BFP-A O/L PRESS PG
LBS45CT157 BFP-A O/L TEMP TE
LBS45CT354 BFP-A O/L TEMP TG
LBS46AA201 BFPDT-B EXHAUST STM VALVE TO COND MOV
LBS46CP158 BFP-B O/L PRESS PT
LBS46CP356 BFP-B O/L PRESS PG
LBS46CT157 BFP-B O/L TEMP TE
LBS46CT354 BFP-B O/L TEMP TG
MTA01CT160 BFP-A TEMP TE
MTA01CT161 BFP-A TEMP TE
MTA02CT160 BFP-B TEMP TE
MTA02CT161 BFP-B TEMP TE
EXTRACTI ON STEAM SYS FOR HEATERS
LAA01CP011 DEA PRESS PT
LAA01CP012 DEA PRESS PT
LAA01CP501 DEA PRESS PG
LAA01CT503 FEED STR TNK TEMP TG
LAA01CT504 FEED STR TNK TEMP TG
LAA01CT505 DEA SHELL TEMP TG
LAD01CP501 HPH-6A PRESS PG
LAD02CP501 HPH-6B PRESS PG
LBG40CP501 DESUPERHEATER TO MAIN TURBINE PRESS PG
LBG40CT001 DESUPERHEATER TO MAIN TURBINE TEMP TE
LBG40CT002 DESUPERHEATER TO MAIN TURBINE TEMP TE
LBG40CT501 DESUPERHEATER TO MAIN TURBINE TEMP TG
LBG51AA101 AUX STEAM TO D/A PEGG CV CLCS
LBG52AA201 AUX STEAM TO D/A PEGG BYP VLV MOVI
LBG53AA201 AUX STM TO D/A INITIAL HEATING VLV MOVI
LBG58AA101 CRH TO TURBINE GLAND SEAL ISO VLV MOV
LBQ10CP011 CRH LINE PRESS PT
LBQ10CT011 CRH LINE TEMP TE
LBQ11AA101 CRH STM TO D/A PEGG CV CLCS
LBQ12AA201 CRH STM TO D/A PEGG BYP VLV MOVI
LBQ50CP001 HPH-6A & 6B I/L PRESS PT
LBQ50CP511 HPH-6A I/L PRESS PG
LBQ50CT001 HPH-6A & 6B I/L TEMP TE
LBQ50CT511 HPH-6A I/L TEMP TG
LBQ51AA202 EXTN STM TO HPH-5A ISO VLV MOV
LBQ51CP011 HPH-6A I/L PRESS PT
LBQ51CT011 HPH-6A I/L TEMP TE
LBQ52AA202 EXTN STM TO HPH-5B ISO VLV MOV
LBQ52CP011 HPH-6B I/L PRESS PT
LBQ52CP511 HPH-6B I/L PRESS PG
LBQ52CT011 HPH-6B I/L TEMP TE
LBQ52CT501 HPH-6B I/L TEMP TG
LBS11CP011 LPH-2 I/L STM PRESS PT
LBS11CP021 LPH-1 I/L PRESS PT
LBS11CP501 LPH-2 PRESS PG
LBS11CP512 LPH-2 I/L STM PRESS PG
LBS11CT011 LPH-2 I/L STM TEMP TE
LBS11CT512 LPH-2 I/L STM TEMP TG
LBS21AA201 EXTN STM TO LPH-2 ISO VLV MOV
LBS22CP001 LP EXT STM TO LPH-2 PRESS PT
LBS22CT001 LP EXT STM TO LPH-2 TEMP TE
LBS31AA201 EXTN STM TO LPH-3 ISO VLV MOV
LBS32CP001 LP EXT STM TO LPH-3 PRESS PT
LBS32CT001 LP EXT STM TO LPH-3 TEMP TE
LBS40CP001 IP EXT STM TO DEA PRESS-1 PT
LBS40CP002 IP EXT STM TO DEA PRESS-2 PT
LBS40CT001 IP EXT STM TEMP TE
LBS40CT501 IP TURBINE EXT STEAM TEMP TG
LBS41AA201 EXTN STM TO D/A ISO VLV MOV
LBS41CF011 STM FLOW TO DEA FT
LBS41CF012 STM FLOW TO DEA FT
LBS41CP002 DIFF PRESS ACROSS EXV-6 DPT
LBS41CP011 DEAERTOR I/L PRESS PT
LBS41CP511 DEAERTOR I/L PRESS PG
LBS41CP511 DEAERTOR I/L PRESS PG
LBS41CT011 STM TEMP TO DEA TE
LBS41CT511 STM TEMP TO DEA TG
LBS42CP511 BFP TURBINES I/L PRESS PG
LCC01CP002 LP HEATER-1 SHELL press. PT
LCC01CP531 LPH-1 PRESS PG
LCC01CT521 LPH-1 SHELL TEMP TG
LCM50CL501 FW HTR SV DISCH FT LVL LG
LCM50CT501 FW HTR SV DFT TEMP TG
FEED WATER SYS
LAB10CF011 BFP-A SUCTION FLOW FT
LAB10CP011 BP-A SUCTION PRESS PT
LAB10CP020 BP-A STAINER DIFF PRESS DPT
LAB10CP021 BFP-A SUCTION PRESS PT
LAB10CP021 CONICAL STRAINER BP-A DISCHARGE DIFF PRESS DPT
LAB10CP022 BFP-A SUCTION PRESS PT
LAB10CP023 BFP-A DISCHARGE PRESS PT
LAB10CP024 BFP-A DISCHARGE PRESS PT
LAB10CP501 BP-A SUCTION PRESS PG
LAB10CP502 BP-A DISCHARGE PRESS PG
LAB10CP503 BFP-A SUCTION PRESS PG
LAB10CP504 BFP-A DISCHARGE PRESS PG
LAB10CP520 BP-A STAINER DIFF PRESS DPG
LAB10CP521 CONICAL STRAINER BP-A DISCHARGE DIFF PRESS DPG
LAB10CQ012 DISSOLVED O2 AT DEA O/L DOT
LAB10CQ013 pH AT DEA O/L pH
LAB10CT011 BP-A SUCTION TEMP TE
LAB10CT012 BP-A SUCTION TEMP
LAB10CT013 BP-A DISCHARGE TEMP TE
LAB10CT020 BFP-A SUCTION TEMP TE
LAB10CT023 BFP-A DISCHARGE TEMP TE
LAB10CT520 BFP-A SUCTION TEMP TG
LAB10CT521 BFP-A DISCHARGE TEMP TG
LAB11AA201 AMMONIA DOSING AT BFP A SUC VLV MOV
LAB11AA202 HYDRAZINE DOSING AT BFP A SUC VLV MOV
LAB11AA203 O2 DOSING AT BFP D SUC VLV MOV
LAB11AA203 O2 DOSING AT BFP A SUC VLV MOV
LAB12AA201 AMMONIA DOSING AT BFP B SUC VLV MOV
LAB12AA202 HYDRAZINE DOSING AT BFP B SUC VLV MOV
LAB12AA203 O2 DOSING AT BFP B SUC VLV MOV
LAB13AA201 AMMONIA DOSING AT BFP C SUC VLV MOV
LAB13AA202 HYDRAZINE DOSING AT BFP C SUC VLV MOV
LAB13AA203 O2 DOSING AT BFP C SUC VLV MOV
LAB14AA201 AMMONIA DOSING AT BFP D SUC VLV MOV
LAB14AA202 HYDRAZINE DOSING AT BFP D SUC VLV MOV
LAB20CF011 BFP-B SUCTION FLOW FT
LAB20CP011 BP-B SUCTION PRESS PT
LAB20CP020 BP-B STAINER DIFF PRESS DPT
LAB20CP021 CONICAL STRAINER BP-B DISCHARGE DIFF PRESS DPT
LAB20CP021 BFP-B SUCTION PRESS PT
LAB20CP022 BFP-B SUCTION PRESS PT
LAB20CP023 BFP-B DISCHARGE PRESS PT
LAB20CP024 BFP-B DISCHARGE PRESS PT
LAB20CP501 BP-B SUCTION PRESS PG
LAB20CP502 BP-B DISCHARGE PRESS PG
LAB20CP503 BFP-B SUCTION PRESS PG
LAB20CP504 BFP-B DISCHARGE PRESS PG
LAB20CP520 BP-B STAINER DIFF PRESS DPG
LAB20CP521 CONICAL STRAINER BP-B DISCHARGE DIFF PRESS DPG
LAB20CT011 BP-B SUCTION TEMP TE
LAB20CT012 BP-B SUCTION TEMP
LAB20CT013 BP-B DISCHARGE TEMP TE
LAB20CT020 BFP-B SUCTION TEMP TE
LAB20CT023 BFP-B DISCHARGE TEMP TE
LAB20CT520 BFP-B SUCTION TEMP TG
LAB20CT521 BFP-B DISCHARGE TEMP TG
LAB21AA201 TDBFP-A DIS VLV MOV
LAB21AA202 TDBFP-A MIN RECIRC VLV SOV/O/L
LAB21AA211 TDBFP-A DIS VLV-IBV MOV
LAB22AA201 TDBFP-B DIS VLV MOV
LAB22AA202 TDBFP-B MIN RECIRC VLV SOV/O/L
LAB22AA211 TDBFP-B DIS VLV-IBV MOV
LAB23AA201 MDBFP-C DIS VLV-MAIN MOV
LAB23AA202 MDBFP-C MIN REC VLV SOV/O/L
LAB23AA211 MDBFP-C DIS VLV-IBV MOV
LAB24AA201 MDBFP-D DIS VLV-MAIN MOV
LAB24AA202 MDBFP-D MIN REC VLV SOV/O/L
LAB24AA211 MDBFP-D DIS VLV-IBV MOV
LAB24CP101 TO RH SPRAY PRESS PT
LAB24CT101 RH SPRAY LIME TEMP TE
LAB30AA101 FW TO HPH (30% CAP LINE) MAIN CV CLCS
LAB30AA102 FW TO HPH (30% CAP LINE) ISO VLV U/S OF CV MOV
LAB30AA103 FW TO HPH (30% CAP LINE) ISO VLV D/S OF CV MOV
LAB30AA112 FW TO HPH (30% CAP LINE) ISO VLV U/S OF CV-IBV MOV
LAB30AA113 FW TO HPH (30% CAP LINE) ISO VLV D/S OF CV-IBV MOV
LAB30AA201 FW TO HPH (50% CAP LINE 1) ISO VLV MOV
LAB30AA201 FW TO HPH (50% CAP LINE 2) ISO VLV MOV
LAB30AA211 FW TO HPH (50% CAP LINE 1) ISO VLV-IBV MOV
LAB30AA212 FW TO HPH (50% CAP LINE 2) ISO VLV-IBV MOV
LAB30CF011 BFP-C SUCTION FLOW FT
LAB30CP011 DIFF PRESS ACROSS FDV14 DPT
LAB30CP014 FW DISCHARGE HDR PRESS PT
LAB30CP020 BP-C STAINER DIFF PRESS DPT
LAB30CP021 BFP-C SUCTION PRESS PT
LAB30CP021 CONICAL STRAINER BP-C DISCHARGE DIFF PRESS DPT
LAB30CP022 BFP-C SUCTION PRESS PT
LAB30CP023 BFP-C DISCHARGE PRESS PT
LAB30CP024 BFP-C DISCHARGE PRESS PT
LAB30CP501 BP-C SUCTION PRESS PG
LAB30CP502 BP-C DISCHARGE PRESS PG
LAB30CP503 BFP-C SUCTION PRESS PG
LAB30CP504 BFP-C DISCHARGE PRESS PG
LAB30CP511 FW DISCHARGE HDR PRESS PG
LAB30CP520 BP-C STAINER DIFF PRESS DPG
LAB30CP521 CONICAL STRAINER BP-C DISCHARGE DIFF PRESS DPG
LAB30CQ011 FW DISCHARGE pH pH
LAB30CT011 BP-C SUCTION TEMP TE
LAB30CT012 BP-C SUCTION TEMP TE
LAB30CT013 BP-C DISCHARGE TEMP TE
LAB30CT014 FW DISCHARGE HDR TEMP TE
LAB30CT020 BFP-C SUCTION TEMP TE
LAB30CT023 BFP-C DISCHARGE TEMP TE
LAB30CT520 BFP-C SUCTION TEMP TG
LAB30CT521 BFP-C DISCHARGE TEMP TG
LAB31AA201 HPH-5A I/L ISO VLV MOV
LAB31AA202 HPH-7A O/L ISO VLV MOV
LAB31AA211 HPH-5A I/L ISO VLV-IBV MOV
LAB31AA212 HPH-7A O/L ISO VLV-IBV MOV
LAB32AA201 HPH-5B I/L ISO VLV MOV
LAB32AA202 HPH-7B O/L ISO VLV MOV
LAB32AA211 HPH-5B I/L ISO VLV-IBV MOV
LAB32AA212 HPH-7B O/L ISO VLV-IBV MOV
LAB33AA201 HPH FW 50% BYP VLV MOV
LAB33AA211 HPH FW 50% BYP IBV MOV
LAB34AA201 HPH FW 50% BYP VLV MOV
LAB34AA211 HPH FW 50% BYP-IBV MOV
LAB41AA101 LOW LOAD FEED CNTRL STATION VLV CLCS
LAB41AA201 LOW LOAD FEED CNTRL STN I/L ISO VLV MOV
LAB41AA202 LOW LOAD FEED CNTRL STN O/L ISO VLV MOV
LAB41AA211 LOW LOAD FEED CNTRL STN I/L ISO-IBV MOV
LAB41AA212 LOW LOAD FEED CNTRL STN O/L ISO-IBV MOV
LAB41CP011 I/L PRESS. OF HP HEATER 6A PT
LAB41CT011 I/L TEMP. OF HP HEATER 6A TE
LAB41CT511 I/L TEMP. OF HP HEATER 6A TG
LAB42AA201 FEED CNTRL STN MAIN VLV MOV
LAB42AA211 FEED CNTRL STN MAIN VLV-IBV MOV
LAB42CP011 I/L PRESS OF HP HEATER 7A PT
LAB42CP511 I/L PRESS OF HP HEATER 7A PG
LAB43CP011 I/L PRESS OF HP HEATER 8A PT
LAB43CP511 I/L PRESS OF HP HEATER 8A PG
LAB44CP011 O/L PRESS OF HP HEATER 8A PT
LAB44CP511 O/L PRESS OF HP HEATER 8A PG
LAB44CT011 O/L TEMP. OF HP HEATER 8A TE
LAB44CT511 O/L TEMP. OF HP HEATER 8A TG
LAB45CP011 I/L PRESS OF HP HEATER 6B PT
LAB45CT011 I/L TEMP. OF HP HEATER 6B TE
LAB45CT511 I/L TEMP. OF HP HEATER 6B TG
LAB46CP511 I/L PRESS OF HP HEATER 7B PG
LAB47CP511 I/L PRESS OF HP HEATER 8B PG
LAB48CP011 O/L PRESS OF HP HEATER 8B PT
LAB48CP511 O/L PRESS OF HP HEATER 8B PG
LAB48CT011 O/L TEMP. OF HP HEATER 8B TE
LAB48CT511 O/L TEMP. OF HP HEATER 8B TG
LAB50AA101 FW TO S/H SPRAY I/C VLV MOV
LAB50AA102 BFP CMN DISCH TO S/H SPRAY I/C VLV MOV
LAB60CF011 ECO I/L FLOW FT
LAB60CP501 ECO I/L FLOW PRESS PG
LAB60CP512 ECO I/L FLOW PRESS PG
LAB60CT011 ECO I/L TEMP TE
LAC03AP001 MDBFP-C HT
LAC04AP001 MDBFP-D HT
LAC10CP001 BFP-A LEAK OFF PRESS PT
LAC10CP505 BFP-A LEAK OFF PRESS PG
LAC20CP001 BFP-B LEAK OFF PRESS PT
LAC20CP505 BFP-B LEAK OFF PRESS PG
LAC30CP001 BFP-C LEAK OFF PRESS PT
LAC30CP505 BFP-C LEAK OFF PRESS PG
GOVERNI NG SCHEME FOR BFPDT
LAC21AP001 TDBFP-A SPEED CLCS
LAC22AP001 TDBFP-B SPEED CLCS
XAV43AA011 BFPDT-A TRIP SOLENOID-1 SOV/O/L
XAV43AA012 BFPDT-A TRIP SOLENOID-2 SOV/O/L
XAV43AA013 BFPDT-A REMOTE ENGAGE SOLENOID SOV/O/L
XAV46AA011 BFPDT-B TRIP SOLENOID-1 SOV/O/L
XAV46AA012 BFPDT-B TRIP SOLENOID-2 SOV/O/L
XAV46AA013 BFPDT-B REMOTE ENGAGE SOLENOID SOV/O/L
HEATER DRAI NS & VENT SYS
LAA01AA202 D/A VENT TO ATMOSPHERE VLV MOV
LAD01AA201 HPH-5A VENT TO HPDFT VLV MOV
LAD02AA201 HPH-5B VENT TO HPDFT VLV MOV
LAD12CL011 HPH-6A LEVEL MEASUREMENT LT
LAD12CL511 HPH-6A LEVEL MEASUREMENT LG
LAD22CL011 HPH-6B LEVEL MEASUREMENT LT
LAD22CL511 HPH-6B LEVEL MEASUREMENT LG
LCC01AA201 LPH-1 VENT TO CONDENSER VLV MOV
LCC01CL131 LPH-1 LEVEL MEASUREMENT LT
LCC11CL531 LPH-1 LEVEL MEASUREMENT LG
LCC21CL011 LPL-2LEVEL MEASUREMENT LT
LCC21CL012 LPL-2 LEVEL MEASUREMENT LT
LCC21CL013 LPL-2LEVEL MEASUREMENT LT
LCH10CF011 HPH-6A DRAIN FLOW TO DEA FT
LCH10CF012 HPH-6A DRAIN FLOW TO DEA FT
LCH10CT011 HPH-6A O/L TEMP TE
LCH10CT511 HPH-6A O/L TEMP TG
LCH11AA101 HPH-5A DRN TO D/A CV CLCS
LCH12AA101 HPH-5A DRN TO HPD F/T CV CLCS
LCH13AA101 HPH-5B DRN TO D/A CV CLCS
LCH14AA101 HPH-5B DRN TO HP F/T CV CLCS
LCH15AA101 HPH-6A DRN TO HPH-5A CV CLCS
LCH15CT001 EMER DRAIN FRM HPH-6A TEMP TE
LCH16AA101 HPH-6A DRN TO HPD F/T CV CLCS
LCH17AA101 HPH-6B DRN TO HPH-5B CV CLCS
LCH18AA101 HPH-6B DRN TO HPD F/T CV CLCS
LCH19AA101 HPH-7A DRN TO HPH-6A CV CLCS
LCH20AA101 HPH-7A DRN TO HPDFT CV CLCS
LCH20CF011 HPH-6B DRAIN FLOW TO DEA FT
LCH20CF012 HPH-6B DRAIN FLOW TO DEA FT
LCH20CT011 HPH-6B O/L TEMP TE
LCH20CT511 HPH-6B O/L TEMP TG
LCH21AA101 HPH-7B DRN TO HPH-6B CV CLCS
LCH22AA101 HPH-7B DRN TO HPDFT CV CLCS
LCH25CT001 EMER DRAIN FRM HPH-6B TEMP TE
LCJ 10CT031 LPH-1 SHELL TEMP TE
LCJ 10CT512 DRN CLR I/L TEMP TG
LCJ 10CT531 LPH-1 TEMP TG
LCJ 12AA101 LPH-2 DRN TO LPH-1 CV CLCS
LCJ 13AA101 LPH-2 DRN TO LPD F/T CV CLCS
LCJ 14AA101 LPH-3 DRN TO LPH-2 CV CLCS
LCJ 15AA101 LPH-3 DRN TO LPD F/T CV CLCS
LCJ 20CT002 LP DRN FT I/L TEMP TE
LCJ 20CT011 LPH-2 O/L TEMP TE
LCJ 20CT511 LPH-2 O/L TEMP TG
LCJ 21CT002 LP DRN FT I/L TEMP TE
LCJ 30CT012 LPH-2 I/L TEMP TE
LCJ 30CT512 LPH-2 I/L TEMP TG
LCJ 31CT002 LP DRN FT I/L TEMP LPH-4 TE
LCJ 40CT012 LPH-3 I/L TEMP TE
LCJ 40CT512 LPH-3 I/L TEMP TG
LCJ 50CP511 DRAIN COOLER PRESS PG
LCJ 50CT011 DRAIN COOLER O/L TEMP TE
LCJ 50CT511 DRAIN COOLER O/L TEMP TG
LCL20CT011 LPH-3 O/L TEMP TE
LCM30CL501 HP DRAIN FLASH TNK LVL LG
LCM30CT015 HP DRN-FT SHELL TEMP TE
LCM30CT501 HP DRN-FT SHELL TEMP TG
LCM40CL501 LP DRN FT LVL LG
LCM40CT015 LP DFT TEMP TE
LCM40CT501 LP DRN FT TEMP TG
HP/LP BYPASS SYS
LAE30CT301 SPRAY WTR FRM BFP DICSH TEMP TG
LBA01CP101 MS LINE PRESS PT
LBA01CP102 MS LINE PRESS PT
LBF10CF101 BPV-1 I/L FLOW FT
LBF10CT101 BPV-1 I/L TEMP TE
LBF10CT301 BPV-1 I/L TEMP TG
LBF11CT101 BPV-1 O/L TEMP TE
LBF11CT301 BPV-1 O/L TEMP TG
LBF12AA201 HP BP WARM UP LINE VLV MOVI
LBF20CT101 BPV-2 I/L TEMP TE
LBF20CT301 BPV-2 I/L TEMP TG
LBF21CT301 BPV-2 O/L TEMP TG
LBF22AA201 HP BP WARM UP LINE VLV MOVI
HYDRAZENE DOSI NG SYS
QCA01AA101 HYDRAZINE DOSING PUMP-1 STROKE CTL CLCS
QCA01AP001 HYDRAZINE DOSING PUMP-1 LT
QCA02AA101 HYDRAZINE DOSING PUMP-2 STROKE CTL CLCS
QCA02AP001 HYDRAZINE DOSING PUMP-2 LT
QCA02AP201 HYDRAZINE MIX/STRG TANK AGITATOR LT
J ACKI NG OI L SYS FOR BFPDT
MTV70AP004 BFPDT-A J ACKING OIL PUMP LT
MTV71AP004 BFPDT-B J ACKING OIL PUMP LT
LUB & WORKI NG OI L SYS OF MDBFP
LAC23AP001 MDBFP-C SCOOP CLCS
LAC23AP002 MDBFP-C AOP LT
LUBE OI L SYS-BFPDT
MTV10AN001 BFPDT-A OIL VAPOR EXTRACTOR-FAN-A LT
MTV10AN002 BFPDT-A OIL VAPOR EXTRACTOR-FAN-B LT
MTV10AP001 BFPDT-A LUB OIL PUMP-A LT
MTV10AP002 BFPDT-A LUB OIL PUMP-B LT
MTV11AN001 BFPDT-B OIL VAPOR EXTRACTOR-FAN-A LT
MTV11AN002 BFPDT-B OIL VAPOR EXTRACTOR-FAN-B LT
MTV11AP001 BFPDT-B LUB OIL PUMP-A LT
MTV11AP002 BFPDT-B LUB OIL PUMP-B LT
MTV45AP003 BFPDT-A EMERG OIL PUMP LT-DC
MTV46AP003 BFPDT-B EMERG OIL PUMP LT-DC
MTV50AA201 BFPDT-A LUB OIL TO TURNING GEAR V/V MOV
MTV51AA201 BFPDT-B LUB OIL TO TURNING GEAR V/V MOV
MDBFP I NSTRUMENTATI ON SCHEME
LAC23AA201 MDBFP-C RAPID START UP DEV SOV SOV/O/L
LAC23AA202 MDBFP-C RAPID START UP DEV SOV SOV/O/L
NAOH DOSI NG SYS
QCH01AP201 NAOH MIX/STRG TANK (SG) STIR LT
QCH02AP201 LP DOS-TG (NAOH) STR MTR LT
STEAM AND DRAI N SYS FOR BFPDT
MTA01AA301 BFPDT-A EXHAUST HOOD SPRAY VLV SOV/O/L
MTA02AA301 BFPDT-B EXHAUST HOOD SPRAY VLV SOV/O/L
MTL01AA254 BFPDT-A CASING DRAIN MOV
MTL02AA255 BFPDT-A DRAIN MOV
MTL03AA256 BFPDT-A G/S HDR DRN VLV TO LPDFT (AFT GS PR CV) MOV
MTL04AA257 BFPDT-A GS DUMP LINE DRAIN MOV
MTL06AA254 BFPDT-B CASING DRAIN MOV
MTL07AA255 BFPDT-B CASING CROSS DRAIN VLV MOV
MTL08AA256 BFPDT-B G/S HDR DRN VLV TO LPDFT (AFT GS PR CV) MOV
MTL09AA257 BFPDT-B GS DUMP LINE DRAIN MOV
MTW60AA251 BFPDT-A BEF GS I/L DRN VLV MOV
MTW61AA251 BFPDT-B BEF GS I/L DRN VLV MOV
STEAM DRAI NS SYS
LBC10CL201 CRH DRAIN POT LEVEL LS
LBC10CL202 CRH DRAIN POT LEVEL LS
LCM10CT101 HPBP WL DRN TO UFT TMP TE
LCM10CT102 HPBP WL DRN TO UFT TMP TE
LCM10CT109 UNIT FLASH TANK TEMP TE
LCM10CT301 UNIT FLASH TANK TEMP TG
LCM20CL301 STM DRN FLASH TANK LEVEL LG
LCM20CT101 CRH LINE DRN TO SDFT TMP TE
LCM20CT112 STM DRN FLASH TANK TEMP TE
LCM20CT301 STM DRN FLASH TANK TEMP TG
LCM30AA201 CRH TO D/A PEGG LN DRIN TO HPDFT MOV
LCM30AA202 BFPDT-A CRH DRN TO HPDFT VLV MOV
LCM30AA203 BFPDT-B CRH DRN TO HPDFT VLV MOV
LCM30AA204 EXTN TO HPH-6A LN DRN TO HPDFT VLV MOV
LCM30AA205 EXTN TO HPH-6B LN DRN TO HPDFT VLV MOV
LCM30AA208 BFPDT-A AUX STM DRN BEF BLK VLV MOV
LCM30AA209 BFPDT-B AUX STM DRN BEF BLK VLV MOV
LCM30AA210 BFPDT-A AUX CV D/S DRN TO HPDFT VLV MOV
LCM30AA211 BFPDT-A ESV U/S DRN TO HPDFT VLV MOV
LCM30AA212 BFPDT-B AUX CV D/S DRN TO HPDFT VLV MOV
LCM30AA213 DRN VLV U/S OF BFPDT-B ESV MOV
LCM30AA214 EXTN TO HPH-5A/5B LINE DRN TO HPDFT VLV MOV
LCM30CT101 CRH TO D/A PEGGING DRN LINE TE
LCM30CT102 CRH STM TO BFPT-A LINE DRN TE
LCM30CT103 CRH STM TO BFPT-B LINE DRN TE
LCM30CT104 HPH-7A EXT DRN TMP TE
LCM30CT105 HPH-7B EXT DRN TMP TE
LCM30CT106 HPH-8 EXT DRN LINE TEMP TE
LCM30CT107 HPH-8B EXT DRN LINE TEMP TE
LCM30CT108 AUX STM TO BFPT-A LINE DRN TE
LCM30CT109 AUX STM TO BFPT-B LINE DRN TE
LCM30CT110 CRH STM TO BFPT-A D/S OF CV LINE DRN TE
LCM30CT111 CRH STM TO BFPT-A D/S OF CV LINE DRN TE
LCM30CT112 CRH STM TO BFPT-B D/S OF CV LINE DRN TE
LCM30CT113 CRH STM TO BFPT-B D/S OF CV LINE DRN TE
LCM30CT114 HPH-8A EXT DRN LINE TEMP TE
LCM30CT115 HPH-6A/B COM EXT DRN LINE TEMP TE
LCM40AA201 CRH TO D/A PEGG D/S CONT STN LN DRN TO LPDFT VLV MOV
LCM40AA202 EXTN TO BFPDT A&B LINE DRN TO LPDFT VLV MOV
LCM40AA203 EXTN TO D/A LN DRN TO LPDFT VLV MOV
LCM40AA204 EXTN TO LPH-3 LINE DRN TO LPDFT VLV MOV
LCM40AA205 EXTN TO LPH-2 LINE DRN TO LPDFT VLV MOV
LCM40CT101 CRH TO D/A PEGGING D/S LINE TEMP TE
LCM40CT102 EXT TO BFPT-A&B LINE TEMP TE
LCM40CT103 EXTN TO D/A LINE TEMP TE
LCM40CT104 LPH-4 EXT DRN LINE TEMP TE
MAW10AA011 TURB GLD SEALING LINE DRN TO HPD F/T VLV MOV
MAW10CT101 TURB GLAND SEAL DRN TEMP TE
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STAGE-II (2X660 MW)
P PP PPAR AR AR AR ART - G T - G T - G T - G T - G
SECTION - VI
TECHNICAL DATA SHEETS
FOR
STAGE-II (2X660 MW)
P PP PPAR AR AR AR ART - G T - G T - G T - G T - G
SECTION - VI
FOR
SECTION-VI
TABLE OF CONTENTS
A Project Synopsis
A A-1 Provenness
A Essential Data
A A-2 General
A A-7 (NOT USED)
A D-1 Civil Works
A Spares
MECHANICAL
B A-2 Layout
SECTION-VI
B A-7 (NOT USED)
ELECTRICAL
B B-2 Motors
B B-7 Lighting
(DDCMIS)
SECTION-VI
CIVIL
B D-1 Civil Works
B E-10 (NOT USED)
B E-16 Motors
SECTION-VI
B E-20 Cabling
B E-21 Lighting
E TENDER DRAWING
F NOT USED
SECTION-VI
PART - G
STAGE-II (2X660 MW)
STAGE-II (2X660 MW)
SECTION - VI
PART - G
CONSISTS OF :
MODULE : I - MECHANICAL
MODULE : II - ELECTRICAL
MODULE : III - C&I
SECTION-VI
PART - G
STAGE-II (2X660 MW)
SECTION - VI
PART - G
MODULE - I
MECHANICAL
SECTION-VI
PART - G
STAGE-II (2X660 MW)
MECHANICAL SECTION
MODULE - I DA1 : General Requirement
DA2 : Steam Turbine & Auxiliaries
DA3 : Compressed Air System (Not Used)
DA4 : Hydrogen Generation Plant
DA5 : Equpiment Cooling Water System
DA6 : Power Cycle Piping
DA7 : Low Pressure Piping
DA8 : Layout Requirement
DA9 : Elevators
DA10 : Other Cranes & Hoist
DA11 : CPU
SECTION-VI
PART - G
STAGE-II (2X660 MW)
SUB-SECTION-DA1
GENERAL REQUIREMENT
CLAUSE
NO.
BIDDER'S NAME .......
TECHNICAL DATA SHEET
SECTION-VI
PART - G
PAGE
1 OF 2 DA1
STAGE-II (2X660 MW)
1.01.00 INSTRUCTIONS TO BIDDERS
1.01.01 Part-G describes the technical information and data to be submitted by the Bidder alongwith
the proposal for the equipment and services described in Section-VI.
1.01.02 The Bidder shall ensure that all information, data, performance curves, technical literature
(catalogues) and drawings furnished with the proposal fully describe all equipment/systems
covered under this proposal and fully meet the requirements of the technical specifications.
1.01.03 The Bidder shall use one of the following responses while filling the questionnaire and
proposal and fully meet the requirements of the technical specifications.
a) The Section No. and Page No. of the proposal where the required information/
data has been furnished by the Bidder.
b) An answer (data or narrative description).
c) A Not-Applicable statement (N.A.)
1.01.04 Bids not meeting the above requirement or not containing full description/data/technical
literature/details regarding past experience for similar application for the proposed equipment
may be treated as non responsive and this will be considered as an adequate reason
for rejection of the concerned Bid.
1.01.05 The Employer reserves the right to ask for further details regarding technical features,
application particulars, performance, past experience for similar applications or any other
information as may be required to fully satisfy himself regarding suitability, quality, reliability
and full compliance with this specification for all equipment and systems offered by the
Bidder.
1.01.06 Bidder shall furnish with his proposal the original Technical Data Sheets completely filled
in and five photostat Copies of the data sheets (photocopies of the original). In no case,
the Bidder shall retype/redraft these data sheets.
1.01.07 It may be noted that this technical data sheets section is for Bidding purpose only. During
detailed engineering, the Bidder shall be required to furnish all additional data about the
equipment/system being supplied, even if such details are not asked for in this section.
1.01.08 a) Bidder should legibly fill in all the data asked for in these sheets either by hand
in black ink or preferably by typing the matter. All the filled in data sheets should
be duly returned with the bid.
b) Continuation sheets may be suitably attached whenever the need arises. These
pages may be suitably numbered accordingly.
c) Corrections should be avoided. However, whenever it is imperative to carry out
correction, this should be done neatly and should be initiated by the authorised
signatory.
CLAUSE
NO.
SECTION-VI
PART - G
PAGE
2 OF 2 DA1
STAGE-II (2X660 MW)
d) Each page of the data sheet should be initiated by the authorised signatory &
should bear the legal stamp of the company.
e) Bidder should indicate his name on each sheet.
1.01.09 In case the BIDDER proposes to take any deviations/execeptions to the tender requirements,
the same shall be listed in an orderly manner under Schedule of technical deviations of
Bid Forms. Each page of the filled schedule shall be signed & duly stamped by the
BIDDER.
1.01.10 BIDDER is required to ensure that no contradictions will be brought out on the information/
data/writeup/drg. provided with the bid. In the event of any contradictions, views of the
Employer will be final.
SECTION-VI
PART - G
STAGE-II (2X660 MW)
SUB-SECTION-DA2
STEAM TURBINE & AUXILIARIES
SECTION-VI
PART - G
STAGE-II (2X660 MW)
CHAPTER-I
ESSENTIAL DATA SHEETS
CLAUSE NO.
BIDDERS NAME

STAGE-II (2X660 MW)
SECTION - VI
PART-G

DA 2(I)
ESSENTIAL DATA
PAGE
1 OF 12

The information in this chapter has been identified by the Employer as the essential,
which is to be provided by the bidders along with the bid necessarily. The
information provided by the bidder shall be the basis for Employer to design the
balance facilities of the project. Incase bidder does not fill these information, their bid
may be considered as non responsive.
Sl.N0. Description Data to be filled by Bidder
SYSTEM INTERFACE DATA
1. Steam Generator output corresponding
to BMCR flow under rated steam
condition, turbine under VWO
operation, condenser pressure of 77
mmHg (abs), 0% make up. Difference
of BMCR flow and VWO steam flow
through turbine shall be assumed to be
drawn off from Main steam line. Same
quantity of flow to be added to
condenser as additional make up.
2. 105% of rated load under rated steam
3. 660 MW output under rated steam
CLAUSE NO.
BIDDERS NAME

STAGE-II (2X660 MW)
SECTION - VI
PART-G

DA 2(I)
ESSENTIAL DATA
PAGE
2 OF 12

8. 660 MW output with all HP heaters out
of service under rated steam
9. Turbine Startup Curves for Cold, Warm
and Hot startup.
Start up Curve
10. Cooling water flow across Main Steam
Turbine Condenser at design point of
Condenser (Cu m/Hr )

Main Steam Turbine Condenser at
design point of Condenser (Deg C)

terminal points across Main Steam
Turbine Condenser.(MWC)

13. Cooling water flow across BFP Drive
Turbine Condenser (if separate) at
design point of Condenser

BFP Drive Turbine Condenser (if
separate) design point of Condenser

terminal points across BFP Drive
Turbine Condenser (if separate)

16. Auxiliary Cooling Water(ACW) pump
design flow

POWER CYCLE PIPING DATA
A. HP TURBINE INLET
1. No. & Size (ID/OD x thk) of HP turbine
steam inlet nozzles

CLAUSE NO.
BIDDERS NAME

STAGE-II (2X660 MW)
SECTION - VI
PART-G

DA 2(I)
ESSENTIAL DATA
PAGE
3 OF 12

2. Material of HP turbine steam inlet
nozzles

Turbine nozzles (material) at site or
shop welding is required as per
supplier.

B. HP TURBINE OUTLET
1. No. & size (ID/OD x thk) of HP turbine
exhaust nozzle

2. Material for HP turbine exhaust nozzle
siteor shop welding is required as per
supplier.

4. HP turbine exhaust maximum
temperature (Deg.C)

C. ESV / HP STEAM STOP VALVE &
CONTROL VALVE

1. No. of ESV/ HP steam stop valve
2. No. of HP steam control valve
nozzles of ESV

nozzles of HP control valve


CLAUSE NO.
BIDDERS NAME

STAGE-II (2X660 MW)
SECTION - VI
PART-G

DA 2(I)
ESSENTIAL DATA
PAGE
4 OF 12

supplier.
6. Pressure drop in MS strainer
D. IP TURBINE
1. No. & Size (ID/OD x thk) of IP turbine
steam inlet nozzles

2. Material of IP turbine steam inlet
nozzles

directly welded to the above IP Turbine
supplier.

E. IV/IP STOP VALVE & IP CONTROL
VALVE.

1. No. of IV/ IP steam stop valve
2. No. of IP steam control valve
nozzles of IV

nozzles of IP control valve

supplier.

6. Pressure drop in HRH strainer
CLAUSE NO.
BIDDERS NAME

STAGE-II (2X660 MW)
SECTION - VI
PART-G

DA 2(I)
ESSENTIAL DATA
PAGE
5 OF 12

F. CRH NRV
1. No. ,Size & Body material of CRH NRV
site or shop welding is required as per
supplier.

3. Pressure drop in CRH NRV
G. HP BYPASS VALVE
1. No. of HP Bypass valve/unit
2. Inlet & outlet nozzle material of HP
Bypass valve

Bypass valve nozzles (material) at site
or shop welding is required as per
supplier.

H. LP BYPASS VALVE
1. No. of LP Bypass valve/unit
2. Inlet & outlet nozzle material of LP
Bypass valve

3. Whether piping of material A335
Gr.P91 or X20 or P22 can be directly
welded to the above LP Bypass
nozzles (inlet & outlet) at site or shop
supplier.

CLAUSE NO.
BIDDERS NAME

STAGE-II (2X660 MW)
SECTION - VI
PART-G

DA 2(I)
ESSENTIAL DATA
PAGE
6 OF 12

I. No. & size of dump steam(LP Bypass)
inlet nozzles on condenser

J . Location of Spray arrangement in LP
Bypass down stream path.

K. Max. permissible dump steam pressure
& temperature at inlet to condenser
dump steam inlet nozzles.

LAYOUT AND CIVIL DATA
1. A-B and B-C bay width for TG building,
2. Elevation of CW pit in TG building,
3. TG hall EOT crane rail elevation,
4. TG hall EOT crane clearance diagram,
5. TG hall EOT crane capacity
6. Deaerator centerline elevation,
7. TG building column spacing
8. TG top deck size and elevation
9. TG foundation GA & Loading details of
deck. Design criteria for TG deck and
suggestive location of TG columns.

10. CW Pit Loading details & Layout of
pipes

11. CEP pit GA & loading details
12. Equipment layout Drawings for various
floors of Main plant building.
i) Floor Plan
ii) Loading drawing
iii) Bracing location

CLAUSE NO.
BIDDERS NAME

STAGE-II (2X660 MW)
SECTION - VI
PART-G

DA 2(I)
ESSENTIAL DATA
PAGE
7 OF 12

ELECTRICAL DATA
1. Generation Voltage
2. BFP Motor Rating.
Station Piping Package:
S.
N
Item Qty.
(m
3
/hr)
T.P.
Location &
Elev.
T.P.
Pressure /
Temp.
Pipe size
OD x
thickness
Material
1 Instrument air
consumption for
TG & Auxiliaries

2 Plant air (service
air) consumption
for cleaning of
instruments /
equipment.

3 Demineralised
water for
condenser
normal make-up
& ECW O/H
tank M/U.

4 Demineralised
water for
condenser
emergency
make-up.

5 Service water
for cleaning /
washing of
equipment (if
any).

6 Circulating water
to & from
condenser

CLAUSE NO.
BIDDERS NAME

STAGE-II (2X660 MW)
SECTION - VI
PART-G

DA 2(I)
ESSENTIAL DATA
PAGE
8 OF 12

C&I DATA
1.00.00 DATA REQUIREMENTS FOR EMPLOYERS STATION-C&I PACKAGE
1.01.00 Bidder to furnish the quantity of drives and Input /outputs for all systems/equipments
in his scope that are being controlled through employer procured BOP-C&I DDCMIS
control system and as identified under exclusions clause no in Part-A in the below
mentioned format: For understanding the drives type refer tender drawings/ and
other relevant part of specification
1.01.00.01 Drives Table:-
Type of
control
Type of Drive
Quantity
HT
LT (AC+DC)
VARIABLE FREQUENCY DRIVE (OLCS)
MOD/MOV (MODULATING DAMPER/
VALVE)
MOVI/MODI (INCHING VALVE/DAMPER)
DSOV (DUAL SOLENOID VALVE)
OLCS
SSOV (SINGLE SOLENOID VALVE)
WITH GALVANICALLY ISOLATED
FEEDBACK)
WITHOUT GALVANICALLY ISOLATED
FEEDBACK)
CLCS
CLCS-3 (MODULATING VARIABLE
FREQUENCY DRIVE)
ANY OTHER DRIVE
CLAUSE NO.
BIDDERS NAME

STAGE-II (2X660 MW)
SECTION - VI
PART-G

DA 2(I)
ESSENTIAL DATA
PAGE
9 OF 12

1.01.00.02 Input output signals Table:-

Note:
1) The I/O,s per drive shall be as per that indicated in the Appendix-1 to C&I
scope, Part-A
Quantity
Signal Type
AI (4-20mA)
AI (4-20mA) HART COMPATIBLE AI (Control)
AI (4-20mA)
AI (4-20mA) HART COMPATIBLE
AI
(Information)
AO (4-20mA)
AO
AO (4-20mA) Galvanic ISOLATED
DI (COC) CHANGE OVER
CONTACT
DI
DI (NO/NC) NORMALLY OPEN/
NORMALLY CLOSED CONTACT
DO (Contact)
DO
DO (24 VDC)
SEQUENCE OF EVENTS FROM
BIDDERS CONTROL SYSTEM/
EQUIPMENTS
DI-SOE
SEQUENCE OF EVENTS FOR
BIDDERS EQUIPMENTS BEING
CONTROLLED THROUGH
EMPLOYER CONTROL SYSTEM
CLAUSE NO.
BIDDERS NAME

STAGE-II (2X660 MW)
SECTION - VI
PART-G

DA 2(I)
ESSENTIAL DATA
PAGE
10 OF 12

1.02.00 HART SIGNAL MONITORING:-Bidder to furnish the quantity of HART compatible
signals in his scope to be monitored in Employers BOP-C&I control system
Signals Quantity
HART signals connected to BOP-C&I DDCMIS from TG-
C&I

(Note: All the HART compatible signals being connected in TG-C&I control system
shall also be monitored in HART management system being procured under
Employers Station-C&I package. Quantity of such signals shall be indicated in the
above table)
1.03.00 VIBRATION MONITORING SYSTEM:- Bidder to furnish following details for
Vibration Monitoring system to be procured under Employers Station-C&I package,
required for interlock, protection and monitoring of Bidders HT equipment(s)
Sl.
No
Name of
main HT
drive
Type of
Bearing
Type of
Vibration
Sensor
No of
Sensors
Range Remarks

1.04.00 CONTROL PANELS/OTHER PANELs Bidder to furnish details of control
panels/other panels to be placed in control equipment room as per the following
format.
Sl
No
Panel
description
Qty Dimensions Cut-out
dimensions
Heat
load
Remarks

1.05.00 UPS load requirement:- Bidder to furnish total load requirement of 230 V AC supply
for his systems/equipment, to be fed from Employers UPS system. The following
feeders have been considered under employer procured UPS system.

CLAUSE NO.
BIDDERS NAME

STAGE-II (2X660 MW)
SECTION - VI
PART-G

DA 2(I)
ESSENTIAL DATA
PAGE
11 OF 12

Sl.
no
Fdr no. Frm To Feeder Desc. KVA PDB
location
PDB
scope
1 Fdr-1 ACDB-1 PDB-
110-1
HMI Load-1 Prog.
Room
TG
vendor
2 Fdr-2 ACDB-1 PDB-
110-1
HMI Load-2 Prog.
Room
TG
vendor
3 Fdr-3 ACDB-1 PDB-
110-2
TSI & other
Loads
CER TG
vendor
4 Fdr-4 ACDB-1 PDB-
110-3
Miscellaneous
Loads
8.5m TG
vendor
Notes:
half through Feeder-2 to ensure availability of at least 50% of the HMI Loads
in event of any fault in either of the feeders.
1.06.00 SOFT/Hard wired signal exchange:-Bidder to furnish the quantity of soft/hardwired
signal Exchange between TG C&I system and Employers Station C&I system in the
following format:
Sl
No
Syste
m
(from)
System
(to)
Total Database Periodically
transmitted
Unit(U) /
Common
(C)
Soft/
Hardwired
Analog Binary Analog Binary

1.07.00 Measuring instruments:- Bidder to furnish the quantity of following measuring
instruments to be procured under employer supplied station C&I package based on
enclosed tender P&ID and bidders recommendation for the offered systems
/equipments.
CLAUSE NO.
BIDDERS NAME

STAGE-II (2X660 MW)
SECTION - VI
PART-G

DA 2(I)
ESSENTIAL DATA
PAGE
12 OF 12

Sl No Type of Measuring
instrument
Service Process range
1 Pressure Transmitters
2 Differential Pressure
Transmitters

3 Level Transmitters with
type (for ex
rada/ultrasonic etc)

4 Flow Transmitters with
type (DP, any other type)

5 Analytical measurement
like pH, Conductivity,
Silica etc with type

1.08.00 The above information is essentially required to be furnished along with the bid.

SECTION-VI
PART - G
STAGE-II (2X660 MW)
CHAPTER-I
TECHNICAL DATA TO BE
SUBMITTED ALONGWITH THE BID
CLAUSE BIDDER'S NAME
NO.
SECTION-VI
PART - G
PAGE
1 OF 32
DA2(I)
STAGE-II (2X660 MW)
SUB-SECTION - DA 2 (I)
PART - 1
BASIC DATA
1.00.00 STEAM TURBINE AND REFERENCE TO APPENDIX
AUXILIARY SYSTEMS AND DRAWING NO.
1.01.00 Performance Data
1.01.01 Heat Balance Diagrams in
Metric Units as called for
under Clause No. 1.22.01
Sub-Sec-A3, Part-B, Section-VI
of the specification including
the following :
(a) 693MW (i.e. 105% of
rated load) under rated
steam condition at
condenser pressure
77 mm Hg (abs), with
zero make up ....................................................................
(b) 660 MW output under
rated steam conditions
at condenser pressure
of 77 mmHg (abs) with
zero make-up ....................................................................
(c) 528 MW output under
turbine throttle inlet
steam conditions
corresponding to sliding
pressure operation and
rated steam temperature
of 77 mm Hg (abs) with
0% make-up. ....................................................................
(d) 528 MW output under
steam conditions
pressure operation and
rated steam temperature
NO.
SECTION-VI
PART - G
PAGE
2 OF 32
DA2(I)
STAGE-II (2X660 MW)
of 77 mm Hg (abs) with
3% make-up. ....................................................................
(e) 396 MW output under
steam conditions
pressure at condenser
pressure of 77 mm Hg
(abs) with 0%
make-up. ....................................................................
(f) 396 MW output under
steam conditions
pressure at condenser
(abs) with 3%
make-up. ....................................................................
(g) 330 MW output under
turbine throttle inlet steam
conditions corresponding
to sliding pressure
operation at condenser
(abs) with zero make-up. ....................................................................
(h) 660 MW output under
rated steam conditions at
condenser pressure of
77 mm Hg (abs) with
3% make-up. ....................................................................
(i) 660 MW output under
rated steam conditions at
89 mm Hg (abs) with 3%
make-up. ....................................................................
(j) 198 MW output under
steam conditions
pressure operation at
NO.
SECTION-VI
PART - G
PAGE
3 OF 32
DA2(I)
STAGE-II (2X660 MW)
make-up. ....................................................................
(k) 198 MW output under
steam conditions
pressure operation at
77 mm Hg (abs) with
3% make-up. ....................................................................
(l) VWO with over
pressurisation
corresponding to boiler
capability at condenser
(abs) with 3% make-up
(If applicable). ....................................................................
(m) VWO output under rated
steam conditions at
89 mm Hg (abs) with
3% make-up. ....................................................................
(n) VWO output under rated
steam conditions at
77 mm Hg (abs) with
0% makeup ....................................................................
(o) VWO output under rated
steam conditions at
77 mm Hg (abs) with
3% makeup ....................................................................
(p) HP heaters out of service
(One string and both
strings) under rated
steam conditions at
condenser pressure
of 77 mm Hg (abs) and
89 mm Hg (abs) with
0% make up maximum
continuous output ....................................................................
NO.
SECTION-VI
PART - G
PAGE
4 OF 32
DA2(I)
STAGE-II (2X660 MW)
(q) HP heaters out of service
(One string and both
strings) under rated
steam conditions at
condenser pressure
of 77 mm Hg (abs) and
89 mm Hg (abs) with
3% make up maximum
continuous output ....................................................................
(r) All HP heaters out of
service under rated
steam conditions at
77 mm Hg (abs) and
89 mm Hg (abs) with
0% percent make up
and maximum continuous
output ....................................................................
(s) All HP heaters out of
service under rated
steam conditions at
77 mm Hg (abs) and
89 mm Hg (abs) with
3% percent make up.
and rated output ....................................................................
(t) 660 MW output under
sliding pressure conditions
at condenser pressure of
77 mm Hg (abs) with
0% percent make-up. ....................................................................
(u) 660 MW output under
sliding pressure conditions
77 mm Hg (abs) with
3% percent make-up ....................................................................
(v) HP-LP bypass operation
under rated steam
condtions with bypass
valves open to full
capacity and turbine on
house load operation. ....................................................................
NO.
SECTION-VI
PART - G
PAGE
5 OF 32
DA2(I)
STAGE-II (2X660 MW)
(w) HP-LP bypass operation
under rated steam
conditions with steam
generator output of 65%
of BMCR. ....................................................................
(s) 60% unit load with one
pass of condenser(s) in
isolated condition. ....................................................................
(y) Steam generator output
corresponding to BMCR
flow under rated steam
conditions, turbine in
parallel operation with
HP-LP bypass with by
pass open to full capacity. ....................................................................
(z) 462 MW output under
sliding pressure operation
makeup. ....................................................................
(aa) 462 MW output under
77 mm Hg (abs) with
3% makeup. ....................................................................
(bb) Steam Generator output
condition, turbine under
VWO operation,
77 mmHg, 0% make up. ....................................................................
(cc) Steam Generator output
condition, turbine under
VWO operation,
77 mmHg, 3% make up. ....................................................................
NO.
SECTION-VI
PART - G
PAGE
6 OF 32
DA2(I)
STAGE-II (2X660 MW)
(dd) Turbine operation at 40%
rated pressure at
77mmHg, 0% make up,
under sliding pressure
operation. ....................................................................
(ee) Turbine operation at 40%
rated pressure at
77mmHg, 3% make up,
operation. ....................................................................
(ff) 65% unit rated output
(abs) with 0% make up. ....................................................................
(gg) 65% unit rated output
(abs) with 3% make up. ....................................................................
1.01.02 Turbine expansion lines/dia-
grams as called in Sub-Section-A-3,
Part-B, Section-VI of specification
clearly marking pressure,
temperature, mass flow, specific
volume and enthalpy at various
points including the following points: .......................................................................
a) Inlet and outlet of main
steam stop valves
b) Inlet and outlet of M.S.
control valves
c) Inlet of HP turbine first
stage & after first stage
d) Exhaust of H.P. turbine
e) Inlet of reheat stop valves
NO.
SECTION-VI
PART - G
PAGE
7 OF 32
DA2(I)
STAGE-II (2X660 MW)
f) Inlet of reheat control
valves
g) Inlet of I. P. turbine
h) Exhaust of I. P. turbine
i) Inlet of L. P. turbine
j) L. P. Turbine last stage
k) Inlet of condenser
l) At each extraction point
The expansion lines are to be
furnished for the following
operating conditions:
i) 660 MW output under
of 77 mm Hg (abs) &
0% make up .......................................................................
ii) 528 MW output under
steam condition corr-
esponding hrottle steam
pressure of 230 Kg/cm
2
(abs) and rated steam
temperature at condenser
pressure of 77mm Hg (abs)
and 0% makeup .......................................................................
iii) 396 MW output under
steam conditions
corresponding to modified
77mm Hg (abs) and
0% make up .....................................................................
iv) 330 MW output under
steam conditions
corresponding to modified
NO.
SECTION-VI
PART - G
PAGE
8 OF 32
DA2(I)
STAGE-II (2X660 MW)
77mm Hg (abs) and
0% make up ....................................................................
v) 660 MW output under
of 77 mm Hg (abs) &
3% make up .....................................................................
vi) 660 MW output under
of 89 mm Hg (abs) &
3% make up .....................................................................
vii) VWO output under
rated steam conditions,
of 77 mm Hg (abs) &
3% make up ....................................................................
viii) VWO output under
of 89 mm Hg (abs) &
3% make up ....................................................................
ix) VWO with maximum
allowable over pressuri-
sation at condenser
(abs) & 3% make up .....................................................................
(if applicable)
x) 660 MW output under
sliding pressure condi-
tions with 0% throttle
reserve at condenser
(abs) & 0% make up ....................................................................
xi) 528 MW output under
pure sliding pressure
(abs) & 0% make up ....................................................................
NO.
SECTION-VI
PART - G
PAGE
9 OF 32
DA2(I)
STAGE-II (2X660 MW)
xii) 396 MW output under
(abs) & 0% make up ....................................................................
xiii) 330 MW output under
(abs) & 0% make up .....................................................................
xiv) 198 MW output under
(abs) & 0% make up ......................................................................
1.02.00 Correction curves for Perfor-
mance Guarantee. Furnish
justification with necessary
calculations to substantiate
the correction curves. .....................................................................
1.02.01 Correction curves for variation
in heat rate and load for per-
formance guarantee under rated
steam pressure operation for
660 MWand throttle steam pressure
of 230 Kg/cm
2
(abs) and rated
steam temperature for 528 MW
guarantee load conditions as
called for under clause 1.22.03
Sub-Section-A-3, Part-B,
Section-VI of specification. .....................................................................

i) Correction curves for
throttle steam pressure
variation .....................................................................
ii) Correction curves for
throttle steam temperature
variation ......................................................................
iii) Correction curves for
reheat steam temperature
variation ......................................................................
NO.
SECTION-VI
PART - G
PAGE
10 OF 32
DA2(I)
STAGE-II (2X660 MW)
iv) Correction curves for
reheat circuit pressure drop
variation ......................................................................
v) Correction curves for
SH spray flow variation
(applicable as indicated in
spcification) ....................................................................
vi) Correction curves for
RH spray flow variation ......................................................................
vii) Correction curves for
feed water pressure variation
at inlet to economiser NRV
i.e. at bidder's terminal point ......................................................................
viii) Correction curves for
condenser pressure
variation ......................................................................
ix) Correction curves for
BFP DT condenser pressure
variation (if separate
condenser offered for BFP
drive turbine) ..................................................................
v) Correction curves for
variation in power factor,
frequency, generator
hydrogen pressure
and voltage ......................................................................
vi) Correction curves for
variation in system
water storage ......................................................................
1.02.02 Correction curves showing the
changes in the guaranteed
output of 3% make up and
89 mm Hg (abs) with conden-
ser pressure variation at rated
inlet steam condition ......................................................................
1.02.03 Condenser performance /
correction curves showing
pressure Vs. heat load to
the condenser under various
NO.
SECTION-VI
PART - G
PAGE
11 OF 32
DA2(I)
STAGE-II (2X660 MW)
CW flows, fouling factors,
and CW inlet temperatures
(from 15 deg C to 40 deg.C
in steps of 5.0 deg C). Also
indicate the design point (Ref.
clause 1.22.03, Sub-Section-A-3,
Part-B, Section-VI of
specification.) ......................................................................
1.02.04 Curves showing change in
output with condenser inlet CW
temperature at rated inlet steam
conditions, VWO conditions &
over pressure conditions ......................................................................
1.03.00 Characteristic Curves
1.03.01 Throttle flow Vs. megawatt load ......................................................................
1.03.02 Heat rate Vs.megawatt load (Also
identify valve points) ......................................................................
1.03.03 Turbine cooling curves ......................................................................
1.03.04 Start up curves for turbine gene-
rator set for hot, warm and cold
conditions for both constant
pressure & sliding pressure
operations. ......................................................................
1.03.05 Specific steam consumption Vs.
flow .......................................................................
1.03.06 High pressure section exhaust
pressure and end point enthalpy
Vs. megawatt load ......................................................................
1.03.07 Cross over enthalpy and pressure
Vs. megawatt load ......................................................................
1.03.08 Efficiency Vs. output and flow for
each Turbine cylinder (indicating
the group stage efficiency points
for each steam extraction) ......................................................................
1.03.09 Last stage efficiency curves ....................................................................
NO.
SECTION-VI
PART - G
PAGE
12 OF 32
DA2(I)
STAGE-II (2X660 MW)
1.03.10 Expansion line end point Vs.
throttle flow for HP and reheat
section ......................................................................
1.03.11 Condenser flow (as percent of
throttle flow) Vs. megawatt load .....................................................................
1.03.12 Exhaust loss curves (variation
in exhaust loss Vs total volu-
metric flow of steam leaving the
last stage of LP turbine.) ......................................................................
1.03.13 Turbine and Generator losses
Vs. output .....................................................................
1.03.14 Extraction stage pressure Vs.
flow to the succeeding stages
through turbine ......................................................................
1.03.15 HP-LP bypass capacity Vs.
main steam pressure ......................................................................
1.03.16 Sealing steam leak off curves
Vs. main steam pressure ......................................................................
1.03.17 Sealing steam distribution
curves and diagrams ......................................................................
1.03.18 Gland leakages from various
points and their corresponding
enthalpy at various loads and
throttle flows ......................................................................
1.03.19 Boiler feed pump set efficiency
Vs. throttle flow ......................................................................
1.03.20 a) For throttle governed machines
i) Pressure drop in Kgf/
cm
2
in M.S. control
valve Vs total steam
flow in T/hr through
the control valve .....................................................................
b) For nozzle governed
machines
i) Valve stroke % and
steam flow in T/hr.
NO.
SECTION-VI
PART - G
PAGE
13 OF 32
DA2(I)
STAGE-II (2X660 MW)
through each valve
and total steam flow
in T/hr Vs MW load. .....................................................................
ii) Pressure drop in
Kgf/cm
2
across each
control valve Vs MW
load. .....................................................................
1.03.21 Condenser air evacuation pumps
performance characteristic curves .....................................................................
1.03.22 Performance characteristics for
oil centrifuge including .....................................................................
a) Percentage impurity in lube
oil system Vs. through put
capacity of centrifuge ......................................................................
b) Viscosity Vs. temperature
of lube oil .....................................................................
c) Impurity level in purified oil
Vs. temperature of lube oil
to centrifuge ......................................................................
1.03.23 First stage pressure Vs. MW load
& steam flow for constant pres-
sure and variable pressure
regimes ......................................................................
1.03.24 Output Vs. C.W. inlet temperature ......................................................................
1.03.25 Characteristic Curves for
Condensate Pumps
i) Characteristic curves for
head, NPSHR at 3% head
drop and 40,000 hours
erosion life, NPSHR at 1%
head break down, power
consumption, efficiency
against pump flow for the
condensate extraction
pumps. .....................................................................
ii) Speed Vs Torque characte-
ristic curves of condensate
pump .....................................................................
NO.
SECTION-VI
PART - G
PAGE
14 OF 32
DA2(I)
STAGE-II (2X660 MW)
iii) Speed Vs Torque characte-
ristic curves of condensate
pump motor. ......................................................................
1.03.26 Performance Curves for
Heaters & Deaerator
a) Performance curves for the
load ranges from 25% to
150% of the flow through
the heaters with regard to
the following parameters.
i) Terminal temperature
difference. .....................................................................
ii) Drain cooler approach
temperature difference .....................................................................
iii) Feed water pressure
drop across nozzle. .....................................................................
iv) Pressure drop of
steam/condensate,
shell side. ......................................................................
v) Loss of steam through
venting ......................................................................
b) Performance curves for the
load range from no load
to VWO conditions of the
flow through deaerator with
regard to the following
parameters:
i) Oxygen content in
feed water at deae-
rator outlet. .....................................................................
ii) Loss of steam
through venting ......................................................................
iii) Pressure decay
characteristic ....................................................................
NO.
SECTION-VI
PART - G
PAGE
15 OF 32
DA2(I)
STAGE-II (2X660 MW)
1.03.27 Characteristic Curves for
Boiler Feed Pumps .....................................................................
i) Characteristic curves for
discharges head, inter-stage
bleed pressure, kicker stage
(if applicable), power con-
sumption, NPSHR at 3%
head break-down and for
40,000 hours erosion life,
NPSHR at 1% head break-
down, efficiency against
pump flow for Boiler feed
pump. .....................................................................
ii) Total dynamic head, NPSHR
at 3% head break down
and for 40,000 hours erosion
life, NPSHR at 1% head
break-down, efficiency
against pump flow power
consumption for the BFP
booster pumps. .....................................................................
The characteristics curves
shall be submitted at the
rated speed, maximum
speed, minimum speed and
over the range of intervals
660 rpm. The run out-
condition and also the
emergency condition shall
be clearly marked on the
characteristic curves. The
minimum flow time at vari-
ous speed shall also be
marked.
iii) Speed Vs Torque charac-
teristics for BFP .....................................................................
iv) Speed Vs. Torque chara-
cteristics of BFP motor. .....................................................................
v) Speed Vs. Torque charac-
teristics for the step down
gear box ......................................................................
vi) Torque Vs.slip charact-
eristics and losses Vs
speed characteristics for
the hydraulic coupling .....................................................................
NO.
SECTION-VI
PART - G
PAGE
16 OF 32
DA2(I)
STAGE-II (2X660 MW)
PART - 2
SUPPLEMENTARY DATA
1.01.00 Thermal kit data for heat
balance computation ................................................................
1.02.00 Broad procedure for perfor-
mance guarantee test proposed
for this project indicating the
code, primary flow measure-
ment, type and accuracy class
of all instrumentation etc. ..................................................................
1.03.00 True copies (signed) for the
performance guarantee test
reports on the turbine generator
sets rated for 660 MW and
above supplied by the Bidder
indicating the complete details
of the performance actually
realised for the machine.
Indicate the rated conditions,
actual test conditions, guara-
nteed parameters, test codes
adopted, list of instruments and
their accuracies, actual meas-
urements taken for various para
meters needed for computation
of the performance and calcul-
ations of heat rate (Ref. clause
1.22.02 Sub-Section-A-3, Part-B,
Section-VI of the specification) .............................................................
1.04.00 Write up on special design
features, if any provided in
respect of the heat rate figures
quoted ..................................................................
1.05.00 Campbell diagrams (typical)
for blading proposed, clearly
indicating the resonant points
and the operating frequency
range (Ref. clause 1.06.00 (f),
Sub-Section-A-3, Part-B, Section-VI ..................................................................
NO.
SECTION-VI
PART - G
PAGE
17 OF 32
DA2(I)
STAGE-II (2X660 MW)
1.06.00 a) Schedule of valves giving
service type, make, size,
body, trim materials, location
and details of actuators ..................................................................
b) Schedule of control valves
as above .................................................................
1.07.00 Write-up on Online Automatic
Turbine Testing System including
the features of selection of each
test ..................................................................
1.08.00 Write-up on HP-LP bypass
system with necessary process
& control scheme and arrange-
ments provided for operation of
HP-LP bypass system under
variable pressure and constant
pressure modes of operation and
with sufficient details to establish
the provenness (Ref. Sub-Section-
PROVENNESS, Part-A, Section-VI) ..................................................................
1.09.00 Write-up on ARTS, turbine gover-
ning system, turbine supervisory
system, turbine control system,
gland seal steam control system,
fire protection system design for
oil leaks etc. with necessary
diagrams and typical logics for
ATRS. ..................................................................
1.10.00 Write up on the suggested
control schemes for lube oil
system, control oil system, seal
oil system, generator gas system,
stator water cooling system etc. .................................................................
1.11.00 Write-up on suggested generator
supervisory system like ..................................................................
a) Core monitoring system ..................................................................
b) End winding vibration
monitoring system ..................................................................
NO.
SECTION-VI
PART - G
PAGE
18 OF 32
DA2(I)
STAGE-II (2X660 MW)
c) Active shaft grounding
system ..................................................................
d) On-line radio frequency
monitoring system for arc
detection inside generator .................................................................
e) Alkaliser unit and on line
oxygen monitoring system ..................................................................
f) On-line temperature
monitoring of water in
stator winding bars .................................................................
g) Power system stabiliser .................................................................
h) TG shaft torsional
oscillation monitoring
system .................................................................
1.12.00 Write-up on interlock and
protection for turbine and
generator alongwith functional
requirements .................................................................
1.13.00 Detailed write-up on start up
and shut down procedure for
steam turbine generator set
(Enclose start up curves) ..................................................................
1.14.00 The turbine generator unit
shall be suitable for two shift
and cyclic operation at an early
date in its life and will be
required to participate in
automatic load frequency
control system. Bidder
to furnish the following data
(Also refer clause 1.01.04
& clause 1.21.00 Sub-Section-A-3,
Part-B, Section-VI
for additional details) ..................................................................
a) Design Criteria ..................................................................
b) Limits of thermal stresses .................................................................
NO.
SECTION-VI
PART - G
PAGE
19 OF 32
DA2(I)
STAGE-II (2X660 MW)
c) Critically stressed compo-
nents/locations and cycle life
expended for each of the
following: ..................................................................
i) Cold startup .................................................................
ii) Warm overnight startup .................................................................
iii) Warm week end startup ..................................................................
iv) hot startup .................................................................
v) Cyclic load variations .................................................................
d) Instruments provided for
monitoring critical parameters .................................................................
e) Write-up, data and start up
curves .................................................................
f) Permissible variation of load
under various regimes .................................................................
g) Controls provided to limit the
requirements of the start up
curves .................................................................
h) List of units supplied which
are in operation in two shift
and cyclic mode (Design
criteria to be elaborated, and
operating cycle, steam para-
meters, start-up time after
8 hours shut down and 32
hours shut down, date of
commercial operation and
cumulated number of start
ups till date to be indicated) ..................................................................
1.15.00 Write up on variable pressure
mode of operation of TG set with
output Vs. main steam pressure,
M.S. temp & HRH temp curves,
for pure and modified sliding operation and
possibility of running units in constant
pressure mode of operation etc.
NO.
SECTION-VI
PART - G
PAGE
20 OF 32
DA2(I)
STAGE-II (2X660 MW)
1.16.00 Write-up on turbine water
damage protection as per
ASME-TDP-1-1985 (Refer
clause 1.01.02 (xiii),
Sub-Section-A-3,
Part-B, Section-VI) ....................................................................................
1.17.00 Write-up on corrosion protection
of turbine during long shutdown
(turbine preservation system)
including schematic & GA
drawings and details of system
provided) (Ref. clause 1.03.00
(iii), Sub-Section-A-3,
Part-B, Section-VI) .......................................................................................
1.18.00 Sizing calculations for conden-
ser air evacuation pump (Refer
clause 2.06.00 Sub-Section-A-3,
Part-B, Section-VI .......................................................................................
1.19.00 Thermal, hydraulic and mecha-
nical design calculations for
condenser (Ref. clause 2.00.00,
Sub-Section-A-3, Part-B, Section-VI) .......................................................................................
1.20.00 Gland steam condenser
thermal design calculations .................................................................
1.21.00 Sizing calculations for flash
tanks ..................................................................
1.22.00 Thermal design of all heat
exchangers ..................................................................
1.23.00 Sizing criteria for vapour
exhausters for gland steam
condenser and lube oil system .......................................................................................
1.24.00 Life expenditure curves for TG set .......................................................................................
1.25.00 Recommended wet steam washing
procedure (indicating the list of equip-
ments required, steam parameters
etc.) (Ref. Clause 1.03.00,
Sub-Section-A-3, Part-B, Section-VI) .......................................................................................
NO.
SECTION-VI
PART - G
PAGE
21 OF 32
DA2(I)
STAGE-II (2X660 MW)
1.26.00 Temporary speed rise values (To be duly
supported by detailed calculations bringing
out clearly all the input data correlation
considered and results) .................................................................
1.27.00 Write up on criteria for back end loading
of the turbine. Also furnish complete tec-
hnical data alongwith LP exhaust
area, Last stage blade height, max. steam
flow under VWO condition through LP
annulus area, actual back end loading,
design back end loading etc (Refer
clause 1.06.00 (h), Sub-
Section-A-3, Part-B, Section-VI) ..................................................................
1.28.00 Write-up on selection basis of the proven
turbine modules proposed, backed up with ..................................................................
i) No. and name of units in operation
with year of commercial operation .................................................................
ii) Design details and dimensional
arrangement drawings of each
module .................................................................
iii) Variation, if any, in the modules
proposed for this project from
those modules already manufactured
and supplied and which are in suc-
cessful operation. (Bring out all major
variations like the changes in blade
profile, blade height & any other
details). .......................................................................................
iv) Operational availability records from
utilities with exact information on the
unavailability, type of failure/break
down, corrective action taken etc. .................................................................
1.29.00 Boiler Feed Pumps and Condensate
Extraction Pumps
i) Complete write-up and control
schemes for condensate extraction
pumps and all internals. ..................................................................
ii) Complete write-up and control
schemes for Boiler feed pumps
including its booster pump and
all internals. .................................................................
NO.
SECTION-VI
PART - G
PAGE
22 OF 32
DA2(I)
STAGE-II (2X660 MW)
iii) Complete write-up on the hydraulic
coupling including all accessories. .................................................................
iv) Write-up on cartridge removal
system for BFP .................................................................
v) Data on special features incorpo-
rated in the feed and condensate
pumps so as to ensure a high
degree of reliability .................................................................
1.30.00 Heaters and Deaerator
i) All the necessary technical write-
ups and any special features
incorporated for the following: .................................................................
a) Methods of separating the
various heat exchange
zones and means of prote-
cting the tubes and other
internal parts from imping-
ement and erosion. .................................................................
b) Methods of providing adeq-
uate venting of non-con-
densable gases with
minimum loss of steam
taking into account the
variation in water level,
accompanying load changes. ..................................................................
ii) Illustrative literatures and catal-
ogues covering design and
construction of the heaters and
deaerator. .................................................................
iii) Catalogues for the standard
equipment like level gauges,
sentinel valves and relief valves. .................................................................
iv) Procedure for cladding of tube
sheet. ..................................................................
v) Procedure for rolling tubes into
the tube sheet. .................................................................
vi) Procedure for welding tubes to
the tube sheet. .................................................................
NO.
SECTION-VI
PART - G
PAGE
23 OF 32
DA2(I)
STAGE-II (2X660 MW)
vii) Procedure for leak testing of
tube to tube sheet joint,
hydraulic testing and drying. ..................................................................
viii) Detailed procedure for over-
hauling, maintenance and
operation of the equipment
and method of protecting the
heaters and deaerator during
transportation/erection/storage/
commissioning. ..................................................................
ix) Detailed procedure of the
plugging and information reg-
arding number of tubes that
can be plugged during operation
without affecting the performance. ..................................................................
x) Procedure for measurement of
dissolved oxygen and carbon
dioxide content at the deaerator
outlet and details of the test kit
for measuring the dissolved
oxygen content. ..................................................................
xi) Complete thermal design cal-
culation for each feed water
heater clearly bringing out the
calculation, curves etc. for
determining the heat transfer
coefficient of various zones. .................................................................
1.31.00 List of Turbine Generator Unit asse-
mblies/sub-assemblies/components
and other components / systems
covered in this package .................................................................
1.31.01 Items of above list proposed to be
manufactured at
i) Bidder's works .................................................................
ii) Collaborator's works .................................................................
iii) Sub-Vendor's works (Also
identify name of sub-vendor/works) .................................................................
NO.
SECTION-VI
PART - G
PAGE
24 OF 32
DA2(I)
STAGE-II (2X660 MW)
1.31.02 Experience in respect of above list
(other than TG modules) indicating
Name of utility, Name of Power station,
Number of units, type of unit (fossil
fuel fired/nuclear) Unit size, capacity
of the equipment/component/system
type of equipment, date of commissi-
oning of the unit. .................................................................
1.32.00 Allowable forces, moments and move-
ments if any on the turbine, main steam
and reheat stop and control valves,
steam inlet, outlet and extraction piping,
HP-LP bypass valves and condenser
under cold and hot conditions .................................................................
1.33.00 i) Components requiring
a) replacement .................................................................
b) repairs during life cycle of
the plant .................................................................
ii) Mean time between failures. .................................................................
iii) List of tasks to be carried out
during major overhauls. .................................................................
1.34.00 Write-up on criteria & details of studies
carried out for selection of Turbine
Generator Combination offered. .................................................................
1.35.00 Technical information and exchange
capacity curves of the resins of
condensate polishing unit for stator
water coolant. .......................................................................................
1.36.00 Write -up on condenser on -load
tube cleaning system including list of
supply under tube cleaning system
(Refer clause 3.00.00, Sub-Section-A-3,
Part-B, Section-VI) ...................................................................
1.37.00 Complete technical literature including
characteristic curves, data sheets, sizing
calculations etc. for all control valves,
process valves and flow measuring
devices in steam, condensate and
feedwater ...................................................................
NO.
SECTION-VI
PART - G
PAGE
25 OF 32
DA2(I)
STAGE-II (2X660 MW)
1.38.00 Characteristic curves of all the actuators
in respect of valves ....................................................................
1.39.00 Compressed air (station & Instrument)
requirements stating the quantity and
quality etc. for the various equipment
and actuators forming part of this
specification. ...................................................................
1.40.00 i) Cooling water requirements equip-
mentwise, stating the quantity,
quality, pressure etc. at Bidder's
terminal point alongwith the scheme ....................................................................
ii) Details of arrangement provided (if
any) to meet the pressure and temp-
rature requirements. ....................................................................
1.41.00 Auxiliary steam requirement
a) Pressure (Kg/cm
2
) .......................................................................................
b) Temperature (deg C) .......................................................................................
c) Quantity (T/hr) .......................................................................................
1.42.00 a) Complete list of maintenance tools
and tackles included in the offer .......................................................................................
b) Complete list of special calibration,
testing & maintenance instruments
included in the offer .................................................................
c) Maintenance facilities provided
for assembly, disassembly and
alignment work of Turbine
Generator components .......................................................................................
1.43.00 Details of forced cooling of the turbine
indicating the provisions made,
equipments provided/required, turbine life
expended when force cooled. (ref clause
1.03.00, Sub-Section-A-3, Part-B, Section-VI) ........................................................
1.44.00 Write-up on Gland Type & Gland Steam
Sealing System ........................................................
1.45.00 Calculation for Steam requirement for
starting TDBFP using Aux. Steam or any
NO.
SECTION-VI
PART - G
PAGE
26 OF 32
DA2(I)
STAGE-II (2X660 MW)
other alternate source considered for
Start up of the unit in Cold, Warm &
Hot condition ........................................................
1.46.00 Write-up on BFPDT including its Control
arrangement, steam washing lube oil,
control oil, protection etc. ........................................................
PART - 3
DRAWINGS
1.01.00 Schematic diagrams with instrumen-
tation and control for turbine lube oil
and control oil system, gland sealing
system, turbine drainage system, con-
densate spray system HP-LP bypass
system clearly indicating the scope of
supply. ..................................................................
1.02.00 Schematic diagram for turbine and BFP drive
turbine governing system ..................................................................
1.03.00 Layout drawing showing the preferred
location of the equipment covered in
the proposal ..................................................................
1.04.00 Drawing showing loading and location
of all columns around T. G. Platform ..................................................................
1.05.00 Drawing showing details of sub zero
pits, pipe trenches with sizes and levels .................................................................
1.06.00 Drawing showing details of structural
steel arrangement around T.G. pedestal
and the restrictions on number and sizes. ..................................................................
1.07.00 Drawing showing the details of fixtures,
embedded parts, foundation plates .................................................................
1.08.00 Recommended foundation drawings
adopting reinforced concrete foun-
dations for all the equipment covered
under this specification including
various static and dynamic loads
coming at different points with location
and direction and the embedment
requirements. ..................................................................
NO.
SECTION-VI
PART - G
PAGE
27 OF 32
DA2(I)
STAGE-II (2X660 MW)
1.09.00 General arrangement giving dimensions,
weights (empty, operating & flooded),
nozzle connections, orientation with
respect to main plant axes, mounting
and support details of each equipment
and assembly including but not limited
to ..................................................................
a) Turbine ..................................................................
b) Condenser .................................................................
c) i) Condensate Extraction System
ii) Drip pumps (if offered) .................................................................
d) Boiler Feed Pump and its Booster
Pump, drive turbine, gear box etc. .................................................................
e) LP heater (in condenser neck)
(with limiting dimensions if any) .................................................................
f) Other LP Heaters .................................................................
g) Water box handling arrangement ..................................................................
h) Lube oil tank (unit & central) ..................................................................
i) Lube oil coolers, control fluid
coolers and control fluid tank ..................................................................
j) Gland steam condensers .................................................................
k) Deaerator ..................................................................
l) Condensate flow nozzle for PG test .................................................................
m) HP Heaters. .................................................................
n) Generator .......................................................................................
o) Exciter .......................................................................................
p) Seal oil coolers .......................................................................................
q) Stator water coolers .......................................................................................
r) Hydrogen cooler .......................................................................................
s) HP and LP bypass valves .......................................................................................
NO.
SECTION-VI
PART - G
PAGE
28 OF 32
DA2(I)
STAGE-II (2X660 MW)
t) Steam throw off device .......................................................................................
u) Main steam & reheat stop & control
valves with strainers ..................................................................
v) Flash tanks ..................................................................
w) Condenser air evacuation pp ..................................................................
x) COLTCS system including its
components .................................................................
y) Lube oil purification system (unit
& central) .................................................................
z) GSC vapour exhauster .................................................................
1.10.00 Sectional drawings (dimensioned) of all
equipment including but not limited to
a) Turbine .................................................................
b) Condenser ..................................................................
c) i) Condensate Extraction pump .................................................................
ii) Drip Pumps (if offered)
d) Boiler Feed Pump and Mechanical
Seal, gear box, BFP drive turbine etc. .................................................................
e) BFP Booster Pump and Mechanical
Seal ..................................................................
f) Hydraulic Coupling .................................................................
g) Generator and Exciter ..................................................................
h) Main steam & reheat stop and control
valves ..................................................................
i) PG test primary flow nozzle assembly .................................................................
j) LP & HP Heaters .................................................................
k) Deaerator .................................................................
l) Centrifuge .................................................................
m) Oil pumps .................................................................
n) J OP .................................................................
NO.
SECTION-VI
PART - G
PAGE
29 OF 32
DA2(I)
STAGE-II (2X660 MW)
1.10.01 Drawing showing suggestive layout below
the T.G. deck for MS, CRH, HRH, LP bypass
together with extraction lines, heater drain lines ..................................................................
1.11.00 Schematic diagram indicating terminal points
and instrumentation for the following:
i) BFP and booster pumps including
sealing arrangement. ..................................................................
ii) Condensate pumps including sealing
arrangement. .................................................................
iii) Lubricating oil system for motor
driven pumps. ...............................................................
iv) Lube oil and control oil system for ...............................................................
turbine drive BFP
v) Auxiliary cooling water supply &
return for TDBFP and MDBFP ..................................................................
1.12.00 a) Preliminary static and dynamic loads
to be considered for design of TDBFP/
MDBFP, booster pump and condensate
extraction pump foundations, indicating
the point of application of loads. ..................................................................
b) Individual cross sectional drawing
for the following: ..................................................................
i) First stage impeller of feed pump. .................................................................
ii) First stage impeller of condensate
pump. ..................................................................
iii) Booster pump impeller. ..................................................................
c) Drawing showing the hydraulic
balancing device and the proc-
edure of fixing it to the shaft. ..................................................................
d) Preliminary drawing of BFP and
CEP shafts indicating the diameters
at various stages. ..................................................................
e) Drawing clearly indicating the various
internal clearances for each of the
following: ..................................................................
NO.
SECTION-VI
PART - G
PAGE
30 OF 32
DA2(I)
STAGE-II (2X660 MW)
i. Boiler feed pump .................................................................
ii. Booster pump ..................................................................
iii. Condensate pump .................................................................
iv. Drip Pumps (if offered)
v. BFP drive turbine .................................................................
f) Drawing indicating the clearances
at the feed pump glands ..................................................................
g) Drawing indicating all the terminal
connections. ..................................................................
h) Drawing of strainers for each of the
following:
i) Gland sealing line of BFP turbine ..................................................................
ii) Booster Pump ..................................................................
iii) From booster pump discharge
to BFP suction. ..................................................................
iv) CEP ....................................................................
i) Drawing indicating the maximum forces
and moments that can be permitted on
the following nozzles from the connecting
piping. .................................................................
i) Booster pump suction and discharge. ..................................................................
ii) BFP suction and discharge. ..................................................................
iii) CEP suction and discharge. ..................................................................
iv) BFP drive turbine .....................................................................
v) Drip Pump suction and discharge. ..................................................................
(if offered)
j) Drawing indicating the initial movements
at BFP booster pump suction and disch-
arge, BFP suction and discharge, CEP
suction and discharge and BFP drive
turbine .................................................................
NO.
SECTION-VI
PART - G
PAGE
31 OF 32
DA2(I)
STAGE-II (2X660 MW)
1.13.00 Drawing showing the laydown space
requirements ..................................................................
1.14.00 Overall length, width and height of TG
set in the rotor withdrawal space
requirement ..................................................................
1.15.00 Drawing indicating generator stator kept
on a well type rail wagon indicating all
dimensions. ..................................................................
1.16.00 Locations and sizes of steam inlet
connections .................................................................
1.17.00 Bearing spans and coupling locations ................................................................
1.18.00 Shaft centre line to operating floor
dimension .................................................................
1.19.00 Generator rotor widthdrawal clearance ..................................................................
1.20.00 Temperature control diagram .................................................................
1.21.00 Erection assembly drawings. .................................................................
1.22.00 Details of torsional oscillation frequen-
cies of the TG shaft sections and their
torsional mode shapes ..................................................................
1.23.00 Drawings indicating the final loading
data, and fixing details of the equipment ..................................................................
1.24.00 Integral piping diagrams including com-
plete piping schemes, layouts, location
and loading ..................................................................
1.25.00 Dimensional drawing showing the
suggested routing of main steam, Hot
Reheat piping between strainer/stop
valves & turbine. ..................................................................
1.26.00 Atmospheric relief diaphragm ..................................................................
1.27.00 Drawing showing the edge preparation
details of terminals for welding to the
contractor's equipment alongwith
allowable forces, moments and
movements ..................................................................
NO.
SECTION-VI
PART - G
PAGE
32 OF 32
DA2(I)
STAGE-II (2X660 MW)
1.28.00 Drawing showing the bolt (casing) loading
and strains and indicating the estimated
period in which retightening or replace-
ment of bolts is required alongwith the
instructions. ..................................................................
1.29.00 Erection assembly drawings as
detailed below .................................................................
1.29.01 Turbine including casings, rotors,
nozzles, exhaust connections, emer-
gency stop valve, interceptor valves,
non-return valves, nozzle valves, turning
gear arrangement etc ................................................................
1.29.02 Condensing plant including condenser,
vacuum pumps, circulating water valves
and expansion joints, vacuum breaker
system etc. .................................................................
1.29.03 Governing system .................................................................
1.29.04 Turbine lube oil tanks ..................................................................
1.29.05 HP and LP bypass valves .................................................................
1.29.06 Butterfly valves ..................................................................
1.29.07 Pumps including emergency oil pump,
auxiliary oil pump and jacking oil pump ..................................................................
1.29.08 Drawing indicating the preferred location
of L.P. heater(s) in condenser neck
(with the limiting dimensions & location
of nozzles etc.) ..................................................................
1.30.00 Turbine clearance diagram indicating ..................................................................
values for radial & axial clearances and
leakage rate at EMCR load & worst
operating condition.
1.31.00 Condenser tube layout including withdrawal
space of the condenser necessary for tube
banks,steam laying arrangement inside the
condenser,condenser hotwell and deaerating
section layout ..................................................................
SECTION-VI
PART - G
STAGE-II (2X660 MW)
CHAPTER-II
NO.
SECTION-VI
PART - G
PAGE
1 OF 149
DA2(II)
STAGE-II (2X660 MW)
SUB-SECTION - DA2 (II)
PART - 1
STEAM TURBINE AND ACCESSORIES
1.00.00 RATING AND CAPABILITIES
1.01.00 Rated output MW ........................................
1.02.00 a) Maximum continuous Rating
under rated steam conditions at
89 mm Hg (abs) Condenser pressure
and 3% make up MW .........................................
b) Maximum continuous output the
machine can deliver (indicate the
operating conditions and furnish
heat balance diagram) MW ...........................................
1.03.00 a) Economic Maximum Continuous
Rating (EMCR) (corresponding to
77 mm Hg (abs) and 3% make-up
and rated steam conditions) MW ........................................
b) Main steam flow rate under EMCR
condition T/hr ...........................................
1.04.00 Peak capability
a) Peak load MW ...........................................
b) Time limitation if any Sec ...........................................
c) Operating condition(s)
(with heat Balance) ...........................................
d) Limiting factor (indicate whether it is
turbine flow path/blade stressing/
generator capability / any other
factor) ...........................................
1.05.00 a) Is the turbine designed for over
pressure operation Yes/No
b) Indicate the % over-pressure
capability of the turbine generator
under VWO condition and the
corresponding continuous output
and steam flow with rated steam
temperature & 77 mm Hg Condenser
pressure
(Furnish Heat Balance Diagram) % ...........................................
NO.
SECTION-VI
PART - G
PAGE
2 OF 149
DA2(II)
STAGE-II (2X660 MW)
1.06.00 a) Flow through turbine under V.W.O.
conditions (with rated steam inlet
pressure and temperature) T/hr ............................................
b) VWO output at rated steam
conditions 77 mm Hg (abs)
Condenser pressure & 3% make up MW ............................................
c) VWO output at rated steam
conditions, 89 mm Hg (abs)
Condenser pressure & 3% make up MW ............................................
d) VWO output at rated steam
conditions, all HP heaters out of
service 77 mm Hg (abs) Condenser
pressure at 0% and 3% make up
(furnish HBDs) MW ............................................
1.07.00 Indicate maximum continuous output the
unit is capable of delivering under rated
steam conditions at 77 mm Hg (abs) and
89 mm Hg (abs) Condenser pressure & 3%
as well as 0% make up with. .............................................
a) i) Both strings of HP Heaters out MW ............................................
with 0% make up
ii) Both strings of HP Heaters out MW ............................................
with 3% make up
b) i) One string of HP heaters out MW ............................................
with 0% make up
ii) One string of HP heaters out MW ............................................
with 3% make up
c) Capacity of TG set as per Clause MW ............................................
1.01.04 (i), Sub-Section-A-3, Part-B
of Section-VI
1.08.00 Maximum flow through LP turbine (Indicate
pressure, Temp. & Wetness & condition of
operation) T/hr ............................................
1.09.00 Design back-pressure for above mm Hg
rating (EMCR) (abs) ............................................
1.10.00 Number of uncontrolled extraction points ..........................................
NO.
SECTION-VI
PART - G
PAGE
3 OF 149
DA2(II)
STAGE-II (2X660 MW)
1.11.00 Final feed water temperature .........................................
a) Under heat rate guarantee point deg C ..........................................
b) Under EMCR conditions deg C ..........................................
1.12.00 Rated speed of the turbine rpm ..........................................
1.13.00 a) Operating frequency range
for turbine Hz ............................................
b) Limitations on number of hours
of operation if any at frequency
beyond this range ..........................................
1.14.00 Is the turbine capable of two shift
and cyclic operation Yes/No ..........................................
1.15.00 Is the turbine primarily designed for
constant pressure mode of operation Yes/No ..........................................
1.16.00 Is the turbine capable of sliding
pressure mode of operation Yes/No ..........................................
1.17.00 Rated throttle steam pressure ata ..........................................
1.18.00 Rated throttle steam temperature deg. C ..........................................
1.19.00 Reheat steam inlet temperature deg. C ..........................................
1.20.00 Is the acceptable variation from rated
steam pressure and temperature as
per IEC-45 ..........................................
a) Under normal pressure condition Yes/no ..........................................
b) Under over pressure condition Yes/No ..........................................
1.21.00 Maximum vibration level on any of the
bearings of TG set Microns ..........................................
1.22.00 Maximum noise level of
i) Main TG set Decibels ..........................................
ii) Auxiliaries including HP/LP
bypass system Decibels ..........................................
NO.
SECTION-VI
PART - G
PAGE
4 OF 149
DA2(II)
STAGE-II (2X660 MW)
1.23.00 a) i) Is the turbine generator
suitable for installation on
conventional framed
foundation Yes/No ..........................................
ii) Experience list for framed
foundation above ..........................................
b) i) Is the turbine generator
suitable for installation on
vibration isolation system
consisting of helical springs
and viscous dampers Yes/No
ii) Experience list for (b), above i) ....................................
ii) ....................................
2.00.00 DESIGN AND OPERATION DATA
2.01.00 Make .........................................
2.02.00 Type of blading (Impulse /Reaction) .........................................
2.03.00 Type of governing (throttle/nozzle/
combined with auto change over
facility) ..........................................
2.04.00 Number of turbine cylinders ..........................................
a) HP ..........................................
b) IP ..........................................
c) Combined HP-IP (if applicable) ..........................................
d) LP ..........................................
e) Total ..........................................
f) Tandem/cross compound ..........................................
2.05.00 Module number and details (attach
dimensioned drawings, experience
details, operational feed back etc.)
a) HP ..........................................
b) IP ..........................................
d) LP ..........................................
e) Generator ..........................................
NO.
SECTION-VI
PART - G
PAGE
5 OF 149
DA2(II)
STAGE-II (2X660 MW)
2.06.00 Installation (Indoor/Outdoor) ..........................................
2.07.00 Mode of operation (constant/
variable/both) pressure ..........................................
2.08.00 Maximum allowable throttle Kg/Cm
2
steam pressure (abs) ..........................................
2.09.00 Maximum allowable throttle steam
temperaturedeg C ..........................................
2.10.00 Maximum allowable reheat turbine
inlet temperature deg C ..........................................
2.11.00 Maximum HP exhaust pressure
(under transients)
a) expected Kg/Cm
2
..........................................
(abs)
b) allowable Kg/Cm
2
..........................................
(abs)
2.12.00 Maximum permissible steam metal
temperature differential during
a) Cold start-up (after more than 36
hrs shut down) deg C ..........................................
b) Warm start-up (between 36 hrs
and 8 hours shut down) deg C ..........................................
c) Hot start up (less than 8 hrs
shut down) deg C ..........................................
d) Loading/unloading and shut
down deg C ..........................................
e) Normal operation deg C ..........................................
2.13.00 Maximum reheat steam pressure at
intermediate pressure turbine Kg/cm
2
inlet (abs) ..........................................
2.14.00 Steam pressure drop in the reheater % of HP
circuit turbine
exhaust
pressure ..........................................
NO.
SECTION-VI
PART - G
PAGE
6 OF 149
DA2(II)
STAGE-II (2X660 MW)
2.15.00 Turbine exhaust pressure Kg/cm
2
..........................................
(abs)
2.16.00 No-load steam flow through turbine T/hr ..........................................
2.17.00 Make-up to heat cycle (at condenser
hotwell) ..........................................
a) Under heat rate guarantee % of M.S.
conditions flow ..........................................
b) Normal operating conditions % of M.S ..........................................
2.18.00 Exhaust steam parameters to condenser
(at condenser design conditions)
2.18.01 Flow T/hr. ..........................................
2.18.02 Enthalpy at turbine exhaust Kcal/kg ..........................................
2.18.03 Dryness fraction ..........................................
2.18.04 Maximum allowed dryness fraction ..........................................
2.19.00 Design conditions for Extraction steam
at Turbine Extraction point.
Note: 1) The steam parameters for
various steam extractions
to be filled under this clause
must correspond to the
turbine extraction nozzles /
turbine outlet.
2) Figures must be
furnished for 100% Heat rate
guarantee conditions. Separate
figures for 80%, 60% and 50%
Load conditions.
2.19.01 Extraction Steam to Low Pressure Feed
Water Heater(s) in condenser neck
a) Flow T/hr ..........................................
b) Enthalpy kcal/kg ..........................................
c) Temperature (Dryness fraction) deg C ..........................................
d) Pressure Kg/cm
2
..........................................
NO.
SECTION-VI
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7 OF 149
DA2(II)
STAGE-II (2X660 MW)
(abs)
Water Heater No. 2
a) Flow T/hr ..........................................
c) Temperature deg C ..........................................
d) Pressure Kg/cm
2
..........................................
(abs)
Water Heater No. 3
a) Flow T/hr ..........................................
d) Pressure Kg/cm
2
(abs) ..........................................
2.19.04 Extraction Steam to Deaerating
Pressure Feed Water Heater at
Deaerator
a) Flow T/hr ..........................................
d) Pressure Kg/cm
2
..........................................
(abs)
2.19.05 Extraction Steam from Turbine
to Boiler feed pump turbine drives at
BFPT
a) Flow T/hr ..........................................
d) Pressure Kg/cm
2
..........................................
NO.
SECTION-VI
PART - G
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8 OF 149
DA2(II)
STAGE-II (2X660 MW)
2.19.06 Extraction Steam to High Pressure Feed
Water Heater No. 5 A/5B
a) Flow T/hr ..........................................
d) Pressure Kg/cm
2
..........................................
(abs)
2.19.07 Extraction Steam from Cold
Reheat Line to High Pressure Feed
Water Heater No. 6A/6B
a) Flow T/hr ..........................................
d) Pressure Kg/cm
2
..........................................
(abs)
Reheat Line to High Pressure Feed
Water Heater No. 7A/7B
a) Flow T/hr ..........................................
d) Pressure Kg/cm
2
..........................................
(abs)
Reheat Line to Boiler Feed
pump drive turbine at low load
a) Flow T/hr .........................................
b) Enthalpy kcal/kg .........................................
c) Temperature deg C .........................................
d) Pressure Kg/cm
2
.........................................
(abs)
NO.
SECTION-VI
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DA2(II)
STAGE-II (2X660 MW)
2.19.10 LP turbine exhaust before mixing with
BFPT exhaust steam
a) Flow T/hr .........................................
b) Enthalpy kcal/kg .........................................
c) Temperature deg C .........................................
d) Pressure Kg/cm
2
.........................................
(abs)
2.20.00 Change over of steam source
from IP-LP cross over to alternate
steam source for boiler feed
pump drive turbine during normal
plant operation. % EMCR .........................................
2.21.00 Critical speeds for turbine bladed
rotors (State for individual rotors
& for combined rotor) RPM .........................................
2.22.00 Combined critical speeds of TG set RPM .........................................
2.23.00 Does any turbine rotor pass through
critical speed coming up to rated
speed? If so, what shaft and at
what speed? RPM .........................................
2.24.00 Combined critical speed studies
for offered TG sets Yes/No ..........................................
Furnished at ......................................
2.25.00 Type of turning gear (Hydraulic/
Motorised) .........................................
2.25.01 KW rating of motor (if motorised turning
gear is used) KW .........................................
2.25.02 Turning speed RPM .........................................
2.26.00 Is the turbine designed for full
arc admission during start-up? Yes/No .........................................
2.27.00 Moisture at LP last stage under
normal steam conditions and with
all extractions open for boiler
feed pump drive turbines % .........................................
NO.
SECTION-VI
PART - G
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10 OF 149
DA2(II)
STAGE-II (2X660 MW)
2.28.00 Maximum allowable temperature at LP
turbine exhaust hood deg C .........................................
2.29.00 Temperature of exhaust hood at
which spray will be initiated deg C .........................................
2.30.00 Is spray water required at
i) Low load operation Yes/no .........................................
ii) House load operation Yes/no .........................................
iii) No load operation Yes/No .........................................
iv) HP-LP bypass operation Yes/No .........................................
2.31.00 Minimum stable load for
operation of TG set:
a) Continuous without exhaust
hood spray MW .........................................
b) With time limitation MW .........................................
c) Continuous with exhaust hood
spray MW .........................................
2.32.00 Coast - down time to turning gear
speed standstill condition after
Turbine Trip-out .........................................
2.32.01 with Vacuum Minutes .........................................
2.32.02 With Vacuum broken Minutes .........................................
2.33.00 Total quantity of spray water required
a) For Exhaust Hood Spray T/hr .........................................
b) Other flash Boxes T/hr .........................................
NO.
SECTION-VI
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11 OF 149
DA2(II)
STAGE-II (2X660 MW)
2.34.00 Thermal Kit Data
2.34.01 Turbine internal efficiencies For 660 For 528
considered in guarantee heat MW MW
balance diagrams Guarantee Guarantee
heat heat
balance balance
a) Efficiency of each stage of HP turbine % ............ ......... ............ ............
b) Group stage efficiency upto first
extraction (i.e. of HP turbine) % ............ ......... ............ ............
c) Weighted efficiency of HP module % ............ ......... ............ ............
d) Efficiency of each stage of IP turbine % ............ ......... ............ ............
e) Group stage efficiencies for stages
between each extraction point in IP
turbine % ............ ......... ............ ............
f) Weighted efficiency of IP Module % ............ ......... ............ ............
g) Efficiency of each stage of
LP turbine % .......... ......... ......... ......... ............
h) Group stage efficiencies for
stages between each extraction
point in LP turbine % .......... ......... ......... ......... ............
i) Weighted efficiency of LP
module % .......... ......... ......... .....................
NO.
SECTION-VI
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DA2(II)
STAGE-II (2X660 MW)
2.34.02 Losses considered in heat bal-
ance computations
VWO 660 528 396 330
3% mu MW MW MW MW
& HR HR 0% mu 0% mu
design guar guar modified sliding
conden- antee antee & &
ser point point
press- & &
ure design design design design
cond- cond- cond- cond-
enser enser enser enser
pres- pres pres pres
sure sure sure sure
a) Turbine mechanical loss
including bearing friction
but excluding power
consumed by shaft driven
driven MOP KW .......... ........ ......... ......... ........ .........
b) Turbine windage losses KW .......... ........ ......... ......... ........ .........
c) Turbine Exhaust losses Kcal/Kg .......... ........ ......... ......... ........ .........
KW
d) Generator losses KW .......... ........ ......... ......... ........ .........
e) Generator mechanical
losses (including
bearing friction losses) KW .......... ........ ......... ......... ........ .........
f) Power consumed
by main oil pump KW .......... ........ ......... ......... ........ .........
g) Power consumed by
other integral auxiliary
services for the turbine
generator (with list of
auxiliaries) KW ....... ........ ......... ......... ......... .........
h) Total losses and power
consumption considered for
arriving at Pg for guaranteed
heat rate consumption (Also
indicate if all the items at
serial numbers (a) to (g)
considered for computation) KW ........ ......... ......... ........ ......... .........
NO.
SECTION-VI
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DA2(II)
STAGE-II (2X660 MW)
2.34.03 Main steam pressure at inlet to Kg/cm
2
strainer (abs) ...........................................
2.34.04 Main steam pressure at inlet
to stop valve Kg/cm
2
...........................................
(abs)
2.34.05 Main steam pressure at inlet to Kg/cm
2
1st stage of HP turbine (abs) ...........................................
2.34.06 Pressure drops (in kg/cm
2
(abs)/percentage) VWO 660 528 396 330 396
3% mu MW MW MW MW MW
& HR HR 0% mu 0% 0% mu
design guar guar modi- mo- &
cond- antee antee fied slid design
enser point point pres- back press-
press- & de- & de- sure & & de- ure
ure sign sign design sign
cond- cond- cond- cond-
enser enser enser enser
pres- pres pres pres
sure sure sure sure
a) Main steam strainer ......... ........ ......... ......... ........ .........
b) Main steam stop valve ......... ........ ......... ......... ........ .........
c) Main steam control valve ......... ........ ......... ......... ........ .........
d) Hot reheat strainer ......... ........ ......... ......... ........ .........
e) Reheat stop valve ......... ........ ......... ......... ........ .........
f) Reheat control valve ......... ........ ......... ......... ........ .........
g) Extraction lines to HPH7A/B
if applicable
(including the part of CRH line) ......... ........ ......... ......... ........ .........
h) Extraction lines to HPH6A/B
(including the part of CRHline) ......... ........ ......... ......... ........ .........
i) Extraction lines to HPH-5A & 5B ......... ........ ......... ......... ........ .........
i) From stage outlet
to turbine flange.
ii) From turbine flange to
heater inlet
NO.
SECTION-VI
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14 OF 149
DA2(II)
STAGE-II (2X660 MW)
j) Extraction line to deaerator ......... ........ ......... ......... ........ .........
to turbine flange.
deaerator inlet
k) Extraction line to LPH-3 ......... ........ ......... ......... ........ .........
to turbine flange.
heater inlet
l) Extraction line to LPP-2 ......... ........ ......... ......... ........ .........
to turbine flange.
heater inlet
m) Extraction line to LP Heater(s) ......... ........ ......... ......... ........ .........
& Condenser neck
to turbine flange.
heater inlet
n) M.S. line from strainer to stop ......... ........ ......... ......... ........ .........
valve/control valve
o) H.R.H. line from strainer to stop
valve ......... ........ ......... ......... ........ .........
p) M.S. line from control
valve to HP turbine inlet ......... ........ ......... ......... ........ .........
q) H.R.H. line from control
valve to IP turbine inlet ......... ........ ......... ......... ........ .........
r) Reheater circuit ......... ........ ......... ......... ........ .........
s) Exhaust hood ......... ........ ......... ......... ........ .........
NO.
SECTION-VI
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DA2(II)
STAGE-II (2X660 MW)
t) Condensate/feedwater side of ......... ........ ......... ......... ........ .........
I) HPH 7A & 7B ......... ........ ......... ......... ........ .........
ii) HPH 6A & 6B ......... ........ ......... ......... ........ .........
iii) HPH 5A & 6B ......... ........ ......... ......... ........ .........
iv) LPH 3 ......... ........ ......... ......... ........ .........
v) LPH 2 ......... ........ ......... ......... ........ .........
vi) LP heater(s) in condenser neck ......... ........ ......... ......... ........ .........
vii) Gland steam condenser ......... ........ ......... ......... ........ .........
Note: All pressure drop figures for items
under Sl. No. a) to s) of the clause
2.34.06 above must be filled in
Kgf/cm
2
2.34.07 Gland leakage coefficients
a) Stop and control valves ..........................................
b) HP front ..........................................
c) HP rear ..........................................
d) Reheat stop & control valve ..........................................
e) IP front ..........................................
f) IP rear ..........................................
2.34.08 Efficiency of boiler feed pump
considered % ........................................
2.34.09 Enthalpy rise across Boiler feed pump Kcal/kg ..........................................
2.34.10 Enthalpy rise across condensate
extraction pump Kcal/kg ..........................................
2.35.00 Temporary speed rise of turbine ..........................................
a) Volume of steam entrained
between main steam control
valves and inlet to first stage M
3
..........................................
to HP turbine
NO.
SECTION-VI
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DA2(II)
STAGE-II (2X660 MW)
b) Volume of steam entrained
between re-heat control valves
and inlet to IP turbine M
3
..........................................
c) Volume of steam entrained
between first stage to last
stage of HP turbine M
3
..........................................
d) Volume of steam entrained
between last stage of HP
turbine and NRVs on CRH
lines M
3
..........................................
e) Volume of steam entrained
in IP turbine M
3
..........................................
f) Volume of steam in IP-LP
cross over pipe M
3
..........................................
g) Volume of steam in LP turbine M
3
..........................................
h) Volume of steam entrained
in the extraction lines between
the turbine and NRVs on
i) extraction to HPH 7A & 7B M
3
..........................................
ii) extraction to HPH 6A & 6B M
3
..........................................
iii) extraction to HPH 5A & 5B M
3
..........................................
iv) extraction to deaerator M
3
..........................................
v) extraction to LPH 3 M
3
..........................................
vi) extraction to LPH 2 M
3
..........................................
i) Steam parameters at extraction
points
Stage number Steam Parameter
Pressure Enthalpy
Kg/cm
2
Kcal/Kg
(abs)
Extraction to HPH 7 A & 7B
Extraction to HPH 5 A & 5B
NO.
SECTION-VI
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DA2(II)
STAGE-II (2X660 MW)
extraction to deaerator
extraction to LPH 3
extraction to LPH 2
extraction to LP heater(s) in
condenser neck
j) Stored energy in
i) Main steam line Kcal ..........................................
ii) HRH line Kcal ..........................................
iii) HP turbine Kcal ..........................................
iv) CRH line Kcal ..........................................
v) IP turbine Kcal ..........................................
vi) Cross over pipe Kcal ..........................................
vii) LP turbine Kcal ..........................................
viii) Extraction lines Kcal ..........................................
k) Tripping lag for
i) main steam stop valve sec ..........................................
ii) Reheat stop valve sec ..........................................
2.36.00 Performance guarantee test
2.36.01 Test code for guarantee heat rate test ..........................................
2.36.02 Type of primary flow measuring device
(furnish the drawing) ..........................................
2.36.03 Method of calibration of flow
measuring device and institute of
calibration ..........................................
2.36.04 Type of instrumentation for
temperature measurement and
accuracy class ..........................................
NO.
SECTION-VI
PART - G
PAGE
18 OF 149
DA2(II)
STAGE-II (2X660 MW)
2.36.05 Type instrumentation for
pressure measurement and
their accuracy class ..........................................
2.36.06 Test code for condenser performance ..........................................
2.37.00 Turbine governing system
2.37.01 Mode of governing (Nozzle/Throttle ..........................................
combined)
2.37.02 Type ..........................................
2.37.03 Make ..........................................
2.37.04 Model No. ..........................................
2.37.05 Mechanical-Hydraulic back-up provided Yes/No ..........................................
2.37.06 Electro-hydraulic back-up provided Yes/No ..........................................
2.37.07 Dead band of the governor % ..........................................
2.37.08 Percentage regulation and its range
of adjustability % ..........................................
2.37.09 Method of sensing speed changes ..........................................
2.37.10 a) What is the time delay of the
system between speed signal
and governor valve initiation? Sec ..........................................
b) For opening through full travel? Sec ..........................................
c) For closing through full travel? Sec .........................................
2.37.11 On-full load throw-off:
a) Temporary speed rise (TSR) % ..........................................
b) Permanent speed rise % ..........................................
c) Time taken to reach steady
state Sec ..........................................
d) Over all response time of the
governor from the moment of
full load throw off to the moment
of full closing of HP and Interceptor
governor valves Sec ..........................................
NO.
SECTION-VI
PART - G
PAGE
19 OF 149
DA2(II)
STAGE-II (2X660 MW)
2.37.12 Range of adjustability of speeder gear % ..........................................
2.38.00 Other components of governing
system
2.38.01 Recommended type of control fluid
and make ..........................................
2.38.02 Specific gravity of control fluid ..........................................
2.38.03 Specification of control fluid ..........................................
2.38.04 Degree of cleanliness to be
maintained for the control fluid
for satisfactory operation of the
system.
a) Permissible suspended
particle size Micron ..........................................
b) Permissible water-content
in fluid by volume % ..........................................
2.38.05 If fire resistant fluid is used as
the control fluid, what are the
specific features provided in the
design to avoid contamination of
control fluid with lube oil during
normal operation? ..........................................
2.38.06 If mineral oil is used as the control
fluid, is extensive protection provided
for oil piping around high temperature
areas against fire hazard? If so, give
details. ..........................................
2.38.07 Total system fluid capacity Lt ..........................................
2.38.08 Fluid reservoir capacity Lt ..........................................
2.38.09 Fluid in piping Lt ..........................................
2.38.10 Fluid flow through the system Lt/min ..........................................
2.38.11 Normal operating fluid pressure Kg/cm
2
(g) ..........................................
2.38.12 a) Number of fluid pumps Nos & ..........................................
furnished make
NO.
SECTION-VI
PART - G
PAGE
20 OF 149
DA2(II)
STAGE-II (2X660 MW)
b) Material of pump
components ..........................................
2.38.13 Capacity and discharge pressure Lt/min ..........................................
Kg/cm
2
(g)
2.38.14 Fluid pump motor rating KW ..........................................
2.38.15 Heaters (if provided)
a) Type and Number ..........................................
b) Rating KW ..........................................
c) Design temperature deg C ..........................................
d) Thermostatic control range
and type ..........................................
2.38.16 Filters/strainers
a) Type of filter ..........................................
b) Make ..........................................
c) Number of filters ..........................................
d) Pressure drop across filter Kg/cm
2
..........................................
e) Material of filter ..........................................
f) Mesh size ..........................................
g) Indicate whether the mesh Yes/No ..........................................
size provided is Bidder's
standard practice
2.38.17 Piping, Valves & Fittings
a) Material ..........................................
b) Design Code ..........................................
2.38.18 Is fluid conditioning equipment
furnished Yes/No ..........................................
2.38.19 If fluid conditioning equipment
provided, furnish following data:
a) Type of conditioner ..........................................
NO.
SECTION-VI
PART - G
PAGE
21 OF 149
DA2(II)
STAGE-II (2X660 MW)
b) Make & Model ..........................................
c) Mode of operation ..........................................
d) Capacity of unit ..........................................
e) Description of system with
literature/catalogues ..........................................
f) Materials ..........................................
g) Design Code, if any ..........................................
h) No. of circulating pumps
working/stand-by ..........................................
i) Capacity of each circulating
pump (m
3
/hr) ..........................................
j) Material of circulating water
pumps ..........................................
2.38.20 Fluid Coolers
a) Number of coolers in
service ..........................................
b) Number of standby coolers ..........................................
c) Type of heat exchanger
and make ..........................................
d) Design Code ..........................................
e) Capacity of each cooler Lt/min ..........................................
f) Cooling water requirements ..........................................
i) Flow Lt/min ..........................................
ii) Pressure Kg/cm
2
(g) ..........................................
iii) Temperature deg C ..........................................
iv) Quality ..........................................
g) Velocity of water through the
tubes m/sec ..........................................
NO.
SECTION-VI
PART - G
PAGE
22 OF 149
DA2(II)
STAGE-II (2X660 MW)
h) Water side pressure drop of
each cooler kg/cm
2
(g) ..........................................
i) Tube O.D. and thickness mm & mm ..........................................
j) Material of ..........................................
i) Cooler tubes ..........................................
ii) Cooler shell ..........................................
iii) Cooler waterbox ..........................................
k) Fluid inlet temperature deg C ..........................................
l) Fluid outlet temperature deg C ..........................................
m) Cooling water outlet
temperature deg C ..........................................
n) LMTD deg C ..........................................
o) Fluid pressure drop across
each cooler Kg/cm
2
(g) ..........................................
p) Heat load Kcal/hr ..........................................
q) Heat transfer coefficient Kcal/hr.
m
2
degC ..........................................
r) Heat transfer area required
for rated load condition m
2
..........................................
s) Heat transfer area provided m
2
..........................................
t) Pressure of control fluid
at inlet to cooler Kg/cm
2
(g) ..........................................
u) Shell design/test pressure Kg/cm
2
..........................................
v) Tube & Water box design
pr./test pr. Kg/cm
2
(g) ..........................................
w) Tube to tube sheet joint
(welded/expanded/any other ..........................................
x) Facility provided for changeover ..........................................
of coolers.
NO.
SECTION-VI
PART - G
PAGE
23 OF 149
DA2(II)
STAGE-II (2X660 MW)
2.39.00 Lubricating Oil System
2.39.01 Recommended type of turbine
oil and specification of oil including
a) Absolute viscosity Centipoise ..........................................
b) Kinematic viscosity Centistokes ..........................................
c) Specific gravity ..........................................
d) Specific heat Kcal/kg
0
C ..........................................
e) Flash point (by Cleveland
open cup method) deg C ..........................................
f) Fire point (by Cleveland open
cup method) deg C ..........................................
2.39.02 Oil requirement per bearing M
3
/hr ..........................................
2.39.03 Total oil system capacity Lit ..........................................
2.39.04 Number of oil changes per hour ..........................................
2.39.05 Oil tank capacity
a) Upto normal operating temp Lit ..........................................
b) Total volume of tank Lit ..........................................
2.39.06 Material of oil tank ..........................................
2.39.07 Oil in piping and bearings Lit ..........................................
2.39.08 Normal lube oil pressure Kg/cm
2
..........................................
(g)
2.39.09 Oil requirement for
lubrication system Lit/min ..........................................
2.39.10 Oil requirement for seal
oil system under emergency Lit/min ..........................................
2.39.11 Degree of cleanliness to be
maintained for the lube oil at
inlet to bearings ..........................................
a) Permissible suspended
particle size Microns ..........................................
NO.
SECTION-VI
PART - G
PAGE
24 OF 149
DA2(II)
STAGE-II (2X660 MW)
b) Permissible water content in
oil by volume % ..........................................
2.39.12 Oil temperature
a) At inlet to the bearings
i) normal deg C ..........................................
ii) maximum deg C ..........................................
b) At outlet from the bearings
i) Normal deg C ..........................................
ii) maximum deg C ..........................................
2.39.13 Main oil pump
a) Capacity Lit/min ..........................................
b) Discharge pressure Kg/cm
2
(g) ..........................................
c) Normal operating flow Lit/min ..........................................
d) Material of pump components ..........................................
e) Make ..........................................
f) Type ..........................................
2.39.14 Main oil pump drive ..........................................
2.39.15 Method of providing positive suction
pressure to main oil pump ..........................................
2.39.16 A. C. Motor Driven Auxiliary oil Pumps
a) Number of pumps in service ..........................................
b) Number of stand by pumps ..........................................
c) Make ..........................................
d) Type ..........................................
e) Capacity of each pump Lit/min .........................................
NO.
SECTION-VI
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DA2(II)
STAGE-II (2X660 MW)
f) Discharge pressure Kg/cm
2
(g) ..........................................
g) Motor rating KW ..........................................
2.39.17 A.C. Motor Driven Turning Gear oil pump
(If provided)
a) Number in service / Stand by ..........................................
b) Make ..........................................
c) Type ..........................................
d) Capacity of pump Lit/min ..........................................
e) Discharge pressure Kg/cm
2
(g) ..........................................
f) Motor rating KW ..........................................
2.39.18 D.C. Motor Driven emergency
Oil Pump
a) Number ..........................................
b) Make ..........................................
c) Type ..........................................
d) Capacity of pump Lit/min ..........................................
2
(g) ..........................................
f) Motor rating KW ..........................................
2.39.19 AC motor driven jacking oil pump
a) Number ..........................................
b) Make ..........................................
c) Type ..........................................
d) Capacity Lit/min ..........................................
2
(g) ..........................................
f) Motor rating KW ..........................................
NO.
SECTION-VI
PART - G
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26 OF 149
DA2(II)
STAGE-II (2X660 MW)
2.39.20 DC Motor driven jacking oil pump
a) Number ..........................................
b) Make ..........................................
c) Type ..........................................
2
(g) ..........................................
f) Motor rating KW ..........................................
2.39.21 Filter/Strainer on common lube
oil supply line.
a) Type of Filter ..........................................
b) Make ..........................................
c) Number of filters ..........................................
d) Pressure drop across filters Kg/cm
2
(g) ..........................................
e) Material of filter element ..........................................
f) Size of filter NB mm ..........................................
g) Mesh size mm ..........................................
2.39.22 Piping
a) Material ..........................................
b) Design Code ..........................................
b) Arrangement provided to prevent
fire hazards due to oil leakage ..........................................
2.39.23 Oil Cooler
a) Design Code ..........................................
b) Number of oil Coolers working
furnished /standby ..........................................
c) Type of oil cooler ..........................................
NO.
SECTION-VI
PART - G
PAGE
27 OF 149
DA2(II)
STAGE-II (2X660 MW)
e) Cooling water requirement
(at inlet to the cooler) ..........................................
i) Flow Lit/min ..........................................
ii) Quality ..........................................
iii) Pressure Kg/cm
2
(g) ..........................................
iv) Temperature deg C ..........................................
f) Water side pressure drop Kg/cm
2
..........................................
g) Tube (OD & Thickness) mm & mm ..........................................
h) Material of
i) Cooler tubes ..........................................
ii) Cooler sheet ..........................................
iii) Cooler waterbox ..........................................
i) Oil inlet temp. deg C ..........................................
j) Oil outlet temp. deg C ..........................................
k) Water outlet temp. deg C ..........................................
l) Cooling water velocity
through the tubes m/sec ..........................................
m) Oil pressure drop in cooler kg/cm
2
..........................................
n) Heat Load on the Cooler Kcal/hr ..........................................
o) Heat transfer coefficient kcal/hr/ ..........................................
m
2
degC
p) LMTD degC ..........................................
q) Heat transfer area required for
rated load conditions m
2
..........................................
r) Heat transfer area provided m
2
..........................................
s) Pressure of oil at kg/cm
2
..........................................
inlet to cooler (g)
t) Shell design pr/Test pressure kg/cm
2
......................................
(g)
NO.
SECTION-VI
PART - G
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28 OF 149
DA2(II)
STAGE-II (2X660 MW)
u) Tube & Water box kg/cm
2
..........................................
design pr/Test pr (g)
v) Tube to Tube sheet joint
(welded/expanded/any other) ..........................................
w) Facility provided for
changeover of coolers ..........................................
2.39.24 Vapour Extractor
a) Number of vapour extreactors
furnished Nos. .........................................
b) Capacity Nm
3
/hr .........................................
c) Motor rating KW .........................................
2.40.00 Unit Lube Oil Purifier
2.40.01 Type .........................................
2.40.02 Make & model .........................................
2.40.03 Number .........................................
2.40.04 Capacity Lit/Hr .........................................
2.40.05 Optimum throughput capacity .........................................
(percentage of max. through put capactiy) % .........................................
2.40.06 Max. particle size in oil at outlet a) microns .........................................
b) ISO desig
nation .........................................
2.40.08 Materials of rotating parts & bowl .........................................
2.40.09 Centrifuge motor rating KW .........................................
2.40.10 Heater capacity & no. of steps Kw/No. .........................................
2.40.11 Material of various components .........................................
2.41.00 Details of the central lube oil storage
and purification system given at
2.41.01 Central lube oil purifier
a) Number .........................................
NO.
SECTION-VI
PART - G
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29 OF 149
DA2(II)
STAGE-II (2X660 MW)
b) Capacity Lit/min. .........................................
c) Make & model .........................................
d) Type .........................................
e) Oil purity level at outlet of centrifuge .........................................
i) microns .........................................
ii) ISC designation .........................................
f) Moisture content in oil at outlet % .........................................
of centrifuge
g) Material of rotating parts and bowl .........................................
h) Centrifuge motor rating KW .........................................
2.41.02 Oil storage tanks
a) Capacity of clean oil tank M
3
.........................................
b) Capacity of dirty oil tank M
3
.........................................
c) Material of oil tank .........................................
2.41.03 Oil transfer pumps
a) No. of pumps provided .........................................
b) Capacity of each pump LIt/hr .........................................
c) Head (MWC) .........................................
d) Motor rating KW .........................................
2.42.00 Gland seal System .........................................
2.42.01 Source of gland sealing steam .........................................
a) During normal operation .........................................
b) During low load operation .........................................
(indicate the load range)
2.42.02 Quantity of sealing steam required T/hr .........................................
2.42.03 Sealing steam pressure at turbine glands Kg/cm
2
....................................
(abs)
NO.
SECTION-VI
PART - G
PAGE
30 OF 149
DA2(II)
STAGE-II (2X660 MW)
2.42.04 Sealing steam temperature at turbine glands deg C .........................................
2.42.05 Minimum steam pressure required for Kg/cm
2
.........................................
operating steam seal system at start-up (abs)
2.42.06 Pressure and temperature of gland steam
supply header during
Pressure Temperature
Kg/cm
2
(abs) deg C
a) Initial start -up ............... ................
b) Normal operation .............. .................
c) Transient operation .............. .................
2.42.08 Type of gland steam condenser .........................................
(indicate whether shell & tube type
or any other type and whether straight
tube or U tube type)
2.42.09 Arrangement of gland steam .........................................
condenser bypass as per
specification (Furnish Drawing)
2.42.10 Minimum cooling condensate
flow through gland steam condenser T/hr .........................................
required
2.42.11 Design condensate flow through T/hr .........................................
gland steam condenser
2.42.12 Pressure drop across gland steam condenser
a) Condenser side Kg/cm
2
.........................................
b) Steam side Kg/cm
2
.........................................
NO.
SECTION-VI
PART - G
PAGE
31 OF 149
DA2(II)
STAGE-II (2X660 MW)
2.42.13 Capacity of gland steam condenser T/hr .........................................
2.42.14 Material of .........................................
i) Tubes .........................................
ii) Shell .........................................
iii) Water box .........................................
2.42.15 Heat exchange surface area M2 .........................................
2.42.16 Blower rating KW .........................................
2.42.17 No. of blowers provided in service/standby .........................................
2.42.18 Gland steam condenser (GSC) details : .........................................
a) Tube length m .........................................
b) Heat transfer coefficient Kcal/hr/M
2
/
deg C .........................................
c) Total heat considered Kcal/hr .........................................
d) LMTD deg C .........................................
e) Temp. of condensate entering the GSC deg C .........................................
f) Temp. of condensate at outlet of GSC deg C .........................................
2.43.00 HP/LP Steam turbine bypass system
2.43.01 HP bypass station
a) Make & Model (Furnish experience
details for specified capacity & service
with operating feed back) .........................................
b) Capacity T/hr .........................................
c) Type of actuation .......................................
d) Number of hydraulic oil
supply units provided on oil
system .........................................
NO.
SECTION-VI
PART - G
PAGE
32 OF 149
DA2(II)
STAGE-II (2X660 MW)
e) Number of pumps provided In service/
in each hydraulic oil supply stand by
unit .........................................
f) Capacity of the above pumps Lit/min .........................................
g) Number of accumulators
provided in each hydraulic
oil supply unit .........................................
h) Number of tanks in each
hydraulic oil supply unit .........................................
i) Capacity of accumulators in Number
each hydraulic oil supply unit of valve
strokings .........................................
j) Is fully redundant safety
channel provided Yes/No .........................................
k) Details of hydraulic actuation
system Drg. No. .........................................
l) Number of valves on steam
side and their location .........................................
m) Capacity of each valve on
steam side with corresponding
up stream pressure and
temp. T/hr/ata/deg.C .........................................
n) Design pressure of above
valves Kg/cm
2
(g) .........................................
o) Design temperature of above
valves deg. C .........................................
p) Number of valves on spray
water side .........................................
q) Capacity of each valve on
spray water side T/hr .........................................
r) Design pressure of valves
on spray water side Kg/cm
2
(g) ..........................................
s) Design temperature of valves
on spray water side deg C .........................................
NO.
SECTION-VI
PART - G
PAGE
33 OF 149
DA2(II)
STAGE-II (2X660 MW)
t) Stroking time (from full open
to full close position) of steam
pressure reducing valve .........................................
i) Under quick action sec .........................................
ii) Under modulating mode sec .........................................
2.43.02 LP Bypass Station
a) Make & Model (Furnish
experience details for
specified capacity &
service with operating
feed back) ..........................................
b) Is the hydraulic oil supply
system independent of the
turbine control oil system Yes/No .........................................
c) Capacity T/hr .........................................
d) Type of actuation .........................................
e) Number of hydraulic oil
supply units provided on oil
system .........................................
f) Number of pumps provided In service/
in each hydraulic oil supply stand by
unit .........................................
g) Capacity of the above pumps Lit/min .........................................
h) Number of accumulators
provided in each hydraulic
oil supply unit .........................................
i) Number of tanks in each
hydraulic oil supply unit .........................................
j) Capacity of accumulators in Number
each hydraulic oil supply unit of valve
strokings .........................................
k) Is fully redundant safety
channel provided Yes/No .........................................
l) Details of hydraulic actuation
system Drg. No. .........................................
NO.
SECTION-VI
PART - G
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34 OF 149
DA2(II)
STAGE-II (2X660 MW)
m) Number of valves on steam
side and their location .........................................
n) Capacity of above valves
with corresponding up
stream pressure and
temperature T/hr/ata/deg.C .........................................
o) Design pressure of above
valves Kg/cm
2
(g) .........................................
p) Design temperature of above
valves deg. C .........................................
q) Number of valves on spray
water side .........................................
r) Capacity of valves on
spray water side T/hr .........................................
s) Design pressure of valves
on spray water side Kg/cm
2
(g) .........................................
t) Design temperature of valves
on spray water side deg C .........................................
u) Stroking time (from full open
to full close position) of steam
pressure reducing valve .........................................
i) Under quick action sec .........................................
ii) Under modulating mode sec .........................................
2.43.03 Minimum temperature of spray
water required for
a) HP Bypass Station deg. C .........................................
b) LP Bypass Station deg. C .........................................
2.43.04 a) LP exhaust hood
temperature during HP-LP
Bypass operation. deg. C .........................................
b) Condenser pressure during
HP-LP Bypass operation with
C.W. inlet temperature of. .........................................
i) 33 deg.C mm of Hg(abs) .........................................
ii) 36 deg C mm of Hg(abs) .........................................
NO.
SECTION-VI
PART - G
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DA2(II)
STAGE-II (2X660 MW)
2.44.00 Whether Low initial Pressure
Unloading is provided Yes/No ........................................
(Furnish details)
2.45.00 Whether Low Vacuum Unloading
gear is provided (Furnish backup information
on standard proven practice) Yes/No .........................................
a) Give operating Condenser pressure mm Hg (abs) .........................................
b) Furnish details .........................................
2.46.00 Condenser
2.46.01 Is drive turbine condenser is separate Yes/No
(If drive turbine condenser is separate,
separate data for drive turbine condenser
also to be provided as indicated below)
Steam Surface Condenser
i) Design, manufacture and testing ............................................
(a) Whether own design or
Collaborator's design ............................................
(b) Name of the design agency ............................................
(c) Desin, manufacture and
testin code ............................................
ii) Number of passes ............................................
iii) Heat load considered for design
(with reference of corresponding heat
balance diagram) ............................................
iv) Whether Condenser centre line is
parallel or perpendicular to TG centre
line? ............................................
v) Design circulating water quantity with
inlet temp. of 33 de. C and 36 Deg C. ............................................
vi) Vacuum in the condenser with inlet mm
water temp. of 33 deg. C and 36 Deg. C. Hg (abs) ............................................
vii) Tube length betwen tue plates mm ............................................
viii) Total number of tues ............................................
NO.
SECTION-VI
PART - G
PAGE
36 OF 149
DA2(II)
STAGE-II (2X660 MW)
ix) Tube outside diameter and thickness mmxmm ..........................................
x) Tube material ..........................................
a) Top rows of tubes ..........................................
b) condensing zone ..........................................
c) Air cooling zone ..........................................
xi) No. of water passes ............................................
xii) Water box material ............................................
xiii) Water box design pressure Kg/cm2 ............................................
(gauge)
xiv) Water box test pressure Kg/cm2 ...........................................
xv) Water box material thickness mm ..........................................
xvi) Corrosion allowance for mm
water box ..........................................
xvii) Shell material ..........................................
xviii) Single shell or double shell ..........................................
xix) Shell thickness mm ..........................................
xx) Corrosion allowance mm ..........................................
xxi) Shell design pressure Kg/cm2 ..........................................
(abs)
xxii) Shell test pressure Kg/cm2 ..........................................
(abs)
xxiii) Tube plate thickness mm ..........................................
xxiv) Corrosion allowance for tube mm ..........................................
plate
xxv) Tube plate material ..........................................
xxvi) No. of tube support plates ..........................................
xxvii) Tube support plate thickness mm ..........................................
NO.
SECTION-VI
PART - G
PAGE
37 OF 149
DA2(II)
STAGE-II (2X660 MW)
xxviii) Material of the support plate ..........................................
xxix) Design velocity through tubes m/sec ..........................................
xxx) Head loss under design
CW flow and CW inlet temp.
through ..........................................
a) Condenser (between
inlet & outlet flanges
of water box) mwc ..........................................
b) Butterfly valves on CW
side mwc ..........................................
c) Expansion joints on mwc ..........................................
CW side
d) CW duct in Bidder's mwc ..........................................
scope
e) CW system between
Bidder\s terminal mwc ..........................................
points (total)
xxxi) Pressure drop across tube
bundle of condenser on
steam side mwc ..........................................
(Furnish back-up calculations
& data on provenness).
xxxii) Design cleanliness factor ..........................................
a) Steam side ..........................................
b) Cooling water side ..........................................
xxxiii) Total heat transfer surface
area m2 ..........................................
xxxiv) Overall heat transfer Kcal/hr/
coefficient m2/deg C ..........................................
xxxv) Number of tubes which
can be plugged without
affecting condenser
performance ..........................................
NO.
SECTION-VI
PART - G
PAGE
38 OF 149
DA2(II)
STAGE-II (2X660 MW)
xxxvi) Rated terminal temperature
difference with design steam
and C.W. flows and with circulating
water inlet temperature of ..........................................
a) Design value deg C ..........................................
b) 36 deg. C deg C ..........................................
xxxvii)Temp. rise of cooling water deg C ..........................................
xxxviii)Weight of condenser (without ..........................................
LP heater)
a) Empty Tonnes ..........................................
b) Flooded Tonnes ..........................................
xxxix) Limiting weight of LP heaters ..........................................
in condenser neck
a) Empty Tonnes ..........................................
b) Flooded Tonnes ..........................................
c) Weight of Tubes Tonnes ..........................................
xL) Method of supporting the
condenser ..........................................
xLi) Type of condenser neck to LP ..........................................
turbine casing joint
xLii) Material of expansion
piece (if used in the condenser
neck) ..........................................
xLiii) Provision for compensation
of differential expansion between
shell & tube ..........................................
xLiv) Provision for expansion of
condenser as per specification ..........................................
xLv) Type of water box Removable/ ..........................................
Non-removable
NO.
SECTION-VI
PART - G
PAGE
39 OF 149
DA2(II)
STAGE-II (2X660 MW)
xLvi) Maximum oxygen content in the
condensate leaving the hotwell
(Furnish write-up on how deaeration
of make up water is done) ..........................................
a) under normal condition ..........................................
b) under abnormal condition ..........................................
xLvii) Condenser hotwell storage capacity
between the normal water level
and low water level m3 ..........................................
xLviii) Condenser pressure during Kg/cm2
bypass operation (abs) ..........................................
xLix) Arrangement for protecting
top row of condenser tubes ..........................................
L) Steam throw off device
a) Capacity T/hr ..........................................
b) Number of nozzles ..........................................
c) Total no. of devices ..........................................
(per condenser)
Li) Tube density (No. of tubes per m2
of tube sheet surface area) (furnish
backup information on provenness)
Lii) Dome angle (Condenser dome wall
inclination to the vertical) (furnish
backup data on provenness for
effective steam distribution over
entire tube nest)
Liii) T.G. output with one half of the
condenser isolated, C.W. flow limited
to half the design flow, 3% make-up
to the cycle and CW inlet temp.
of 33 deg. C ..........................................
2.46.02 Expansion joints on C.W. connections to
Condenser
a) Make ..........................................
b) Design Standard ..........................................
NO.
SECTION-VI
PART - G
PAGE
40 OF 149
DA2(II)
STAGE-II (2X660 MW)
c) Size (Nominal dia) mm ..........................................
d) Design Pressure Kg/cm2 (g) ..........................................
e) Design Vacuum mmHg ..........................................
f) Pressure drop across
expansion joint mwc ..........................................
g) Design Temperature deg C ..........................................
h) Test pressure Kg cm2 (g) ..........................................
i) Arrangement for preventing collapse ..........................................
j) Materials ..........................................
k) Are the expansion joints of
pressure balance type Yes/No ..........................................
2.46.03 Circulating Water Butterfly valves ..........................................
a) Make ..........................................
b) Design Standard ..........................................
c) No. offered ..........................................
d) Flow rate (normal) m3/hr (g) ..........................................
e) Flow rate (maximum) m3/hr ..........................................
f) Design Pressure Kg/cm2 (g) ..........................................
g) Test Pressure Kg/cm2 (g) ..........................................
h) Pr. drop across valve Kg/cm2 ..........................................
i) Max. design temperature deg. C ..........................................
j) Connecting flange size/rating ..........................................
k) Type of bonnet ..........................................
l) Time for full opening and sec ..........................................
closing of valve
NO.
SECTION-VI
PART - G
PAGE
41 OF 149
DA2(II)
STAGE-II (2X660 MW)
m) Materials
i) Body ..........................................
ii) Disc ..........................................
iii) Shaft ..........................................
iv) Dowels ..........................................
v) Bearing ..........................................
vi) Seal ..........................................
vii) Seat ..........................................
viii) Seating ..........................................
ix) Gland Packing ..........................................
n) Are the butterfly valves of Yes/No ..........................................
pressure balance type?
o) Size (Nominal dia) mm ..........................................
2.46.04 Condenser Air evacuation system
(vacuum pumps) for Main Drive turbine
Condenser Condenser
(if offered)
a) Make & Model ..........................................
b) Number offered ..........................................
c) Number working ..........................................
d) Size and type ..........................................
e) Design code ..........................................
f) Capacity in free air delivered
at standard conditions with pump
operating at saturated inlet
condition of 25.4 mm Hg (abs) &
at design condenser pressure & sub-
cooled by 4.17 deg. C below
temperature corresponding to the
absolute suction pressure scfm i) .....................................
( at 25.4 mm Hg (abs))
ii) ....................................
(at Design condenser pressure)
NO.
SECTION-VI
PART - G
PAGE
42 OF 149
DA2(II)
STAGE-II (2X660 MW)
g) Capacity of each pump during hogging
operation at 10" (254 mm) Hg (abs)
suction pressure scfm .........................................
h) Suction Pressure mm Hg ..........................................
(abs)
i) Suction temperature at ..........................................
i) 25.4 mm Hg (abs)
suction pressure deg C ..........................................
ii) 77 mm Hg (abs) suction
pressure deg C ..........................................
j) Suction line pressure drop mm Hg ..........................................
k) Power required at pump ..........................................
i) 25.4 mm Hg condenser pressure kW ..........................................
ii) Condenser design pressure kW ..........................................
l) Sealing water for vacuum pump and
Cooling water required for sealant
heat exchanger m
3
/hr ..........................................
m) Design ITD (Saturation temperature-
cooling water inlet temp.) deg. C ..........................................
n) Design TTD of heat exchanger deg C ..........................................
o) Volume of condenser and turbine
steam spaces to be evacuated
as a basis of pump design m
3
..........................................
p) Time to evacuate the above volume
under standard conditions
(21.1 deg C & 1.033 (abs) minutes ..........................................
q) Whether air ejector is provided Yes/no ..........................................
r) Number of stages ..........................................
s) Compression ratio of each stage ..........................................
t) Cooling water pressure at inlet
to heat exchanger ..........................................
NO.
SECTION-VI
PART - G
PAGE
43 OF 149
DA2(II)
STAGE-II (2X660 MW)
u) Blank off suction pressure
(at 36 deg. C cooling water
inlet temp.) mmHg ..........................................
v) Motor
i) Make ..........................................
ii) Rating kW ..........................................
iii) Rated voltage kV ..........................................
w) Weight of each pump motor unit Tonnes ..........................................
x) Material of pump
i) Casing ..........................................
ii) Shaft ..........................................
iii) Impeller ..........................................
iv) Shaft Sleeves ..........................................
v) Cooler tubes ..........................................
y) Characteristic/Performance curves
(without air ejector and with air
ejector, if applicable) :
i) Inlet air capacity in free
dry air vs. suction pressure
for ITD values of 10 deg. C,
11 deg C, 13 deg C,
15 deg. C & 16 deg. C ..........................................
ii) Power consumption
vs. suction pressure ..........................................
iii) Suction pressure vs. sealant
temp./ITD showing air ejector
cutting in and cutting off
(if applicable) ..........................................
iv) Pump performance with
and without air ejector
(if applicable) for different
back pressures and
condenser heat loads ..........................................
NO.
SECTION-VI
PART - G
PAGE
44 OF 149
DA2(II)
STAGE-II (2X660 MW)
v) Air evacuation time
(hogging time) vs. pump
suction pressure with one
pump in operation and two
pumps in operation. ..........................................
vi) Design Air leakage into the
condenser considered for
sizing the condenser air
evacuation system ..........................................
2.46.05 Condenser on Load Tube Cleaning system
a) Name of Manufacturer ..........................................
b) Model No. & Design ..........................................
c) List of item/assemblies
sub assemblies enclosed? Yes/No ..........................................
d) Materials of various components ..........................................
e) Average life of sponge
rubber ball ..........................................
f) No. of sponge rubber balls
i) For single charge ..........................................
ii) For 3 years of
continuous operation ..........................................
iii) Lost during 1000 hrs.
of plant operation ..........................................
g) No. of Abrasive coated balls provided ..........................................
h) Arrangement provided on
CW side to prevent loss
of balls during
Conden Conden
ser inlet ser outlet
i) Normal operation .............. ................
ii) CW pumps trip .............. ..................
i) Pressure drop across the ball
collecting strainer in the C.W.
circuit mwc ............... .................
NO.
SECTION-VI
PART - G
PAGE
45 OF 149
DA2(II)
STAGE-II (2X660 MW)
i) Under clean condition
(normal operating) ..........................................
ii) under 50% clogged
condition ..........................................
iii) When strainer back
washing is indicated ..........................................
j) Whether complete descriptive
write up of the system and individual
equipment and explaining control
& instruments provided. Enclosed? Yes/No ..........................................
k) Whether schematic of the system,
layout drawing & drawings of all
components enclosed? Yes/No ..........................................
l) Duration of operation per day ..........................................
m) Number of ball circulation pump
provided for each TG unit ..........................................
n) Number of ball collecting vessels
for each TG unit ..........................................
o) Number of ball oversize monitors for
each TG unit ..........................................
p) Number of ball recirculation
monitors for each TG unit ..........................................
q) Number of ball strainers for
each TG unit ..........................................
r) Number of ball ejector nozzles ..........................................
s) Type of ball sorter Automatic/ ..........................................
Manual
t) No. of ball sorters ..........................................
u) Diff. pressure measurement Yes/No ..........................................
across ball collection strainers
provided or not
v) Flushing arrangement of Diff.
pressure impulse line ..........................................
NO.
SECTION-VI
PART - G
PAGE
46 OF 149
DA2(II)
STAGE-II (2X660 MW)
2.47.00 Turbine Protection System
2.47.01 Emergency overspeed trip of governor % of rated
speed ..........................................
2.47.02 Low lubircating oil pressure trip Kg/cm2 ..........................................
(gauge)
2.47.03 High exhaust-hood temperature trip deg C ..........................................
2.47.04 Low initial steam pressure unloading
operation (range, setting) Kg/cm2 ..........................................
(gauge)
2.47.05 Low initial steam pressure trip Kg/cm2 ..........................................
(gauge)
2.47.06 Low vacuum unloading operation Kg/cm2 ..........................................
(range, setting) (gauge)
2.47.07 Low vacuum trip Kg/cm2 ..........................................
(abs)
2.47.08 Thrust bearing excessive wear trip +/- mm ..........................................
2.47.09 Pressure relief diaphragm setting Kg/cm2 ..........................................
(abs)
2.48.00 State load limitations, in percent of rated
load, if any, for testing full closure of
2.48.01 Main stop valves % ..........................................
2.48.02 HP governor valves % ..........................................
2.48.03 Reheat stop valves % ..........................................
2.48.04 Interceptor valves % ..........................................
2.49.00 Quantity of first fill and one year topping
requirement of lube oil Tonnes ..........................................
2.50.00 Quantity of first fill and one year topping
requirement of control oil Tonnes ..........................................
3.00.00 MATERIAL OF CONSTRUCTION
Indicate ASTM designations whenever
possible. Otherwise furnish details like
applicable standards, casting/forging,
chemical composition, etc.
NO.
SECTION-VI
PART - G
PAGE
47 OF 149
DA2(II)
STAGE-II (2X660 MW)
3.01.00 Turbine Casings
3.01.01 HP outer casing ..........................................
3.01.02 HP blade carrier/casings ..........................................
3.01.03 IP outer casing ..........................................
3.01.04 IP inner casing ..........................................
3.01.05 LP inner casing (s) ..........................................
3.01.06 LP outer casing ..........................................
3.02.00 Turbine shaft
3.01.01 HP shaft ..........................................
3.02.02 IP shaft ..........................................
3.02.03 LP shaft ..........................................
3.03.00 Turbine Disc (if shrunk on)
3.03.01 HP Turbine ..........................................
3.03.02 IP Turbine ..........................................
3.03.03 LP Turbine ..........................................
3.04.00 Moving Blades
3.04.01 HP Turbine first stage ..........................................
3.04.02 HP Turbine other stages ..........................................
3.04.03 IP Turbine first stage ..........................................
3.04.04 IP Turbine other stages ..........................................
3.04.05 LP Turbine last stage ..........................................
3.04.06 LP Turbine other stages ..........................................
3.05.00 Fixed Blades
3.05.01 HP Turbine first stage ..........................................
3.05.02 HP Turbine other stages ..........................................
NO.
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DA2(II)
STAGE-II (2X660 MW)
3.05.03 IP Turbine first stage ..........................................
3.05.04 IP Turbine other stages ..........................................
3.05.05 LP Turbine first stage ..........................................
3.05.06 LP Turbine other stages ..........................................
3.06.00 Casing Joint Bolts
3.06.01 HP cylinder ..........................................
3.06.02 IP cylinder ..........................................
3.06.03 LP cylinder ..........................................
3.07.00 Shaft Couplings ..........................................
3.08.00 IP/LP Crossover/cross around piping ..........................................
3.09.00 Main steam chest ..........................................
3.10.00 Main steam strainer ..........................................
3.11.00 MS stop valves ..........................................
3.11.01 Valve body ..........................................
3.11.02 Valve Spindle ..........................................
3.11.03 Valve Seat ..........................................
3.12.00 Main Steam Control valves ..........................................
3.12.01 Valve body ..........................................
3.12.02 Valve spindle ..........................................
3.12.03 Valve seat ..........................................
3.13.00 Hot Reheat Strainer ..........................................
3.14.00 Reheat stop valves ..........................................
3.14.01 Valve body ..........................................
3.14.02 Valve spindle ..........................................
3.14.03 Valve seat ..........................................
NO.
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DA2(II)
STAGE-II (2X660 MW)
3.15.00 Reheat Control valves ..........................................
3.15.01 Valve body ..........................................
3.15.02 Valve spindle ..........................................
3.15.03 Valve seat ..........................................
3.16.00 Main steam piping from strainer to
turbine nozzle
3.17.00 HRH piping from strainer to turbine
nozzle ..........................................
3.18.00 LP turbine extraction piping inside
condenser neck ..........................................
3.19.00 Labyrinth Seals
(a) HP ..........................................
(b) IP ..........................................
(c) LP ..........................................
3.20.00 Whether all of the above materials Yes/No ..........................................
are field proven for the rated
parameters
3.21.00 Indicate Materials used for various ..........................................
components covered under Clause
3.00.00 above, for two separate
stations for rated steam parameters
4.00.00 CONSTRUCTION FEATURES AND
OTHER DATA
4.01.01 Main TG
4.01.01 Number of cylinders ..........................................
a) HP ..........................................
b) IP ..........................................
d) LP ..........................................
NO.
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PART - G
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DA2(II)
STAGE-II (2X660 MW)
4.01.02 Type of turbine cylinders ..........................................
a) Single flow/double flow ..........................................
i) HP ..........................................
ii) IP ..........................................
iii) HP-IP (if applicable) ..........................................
iv) LP ..........................................
b) Barrel/Horizontally split ..........................................
INNER OUTER
i) HP ................. .................
ii) IP .................. .................
iv) LP ................ ...................
c) Number of Shells ............... ..................
i) HP ............... .................
ii) IP .............. ................
4.01.03 Is the HP outer casing and IP outer ................ ..................
casing separate? Yes/No ..........................................
4.01.04 Number of Stages : ..........................................
a) HP : No of impulse stages ..........................................
No. of reaction stages ..........................................
b) IP : No of impulse stages ..........................................
c) LP : No. of impulse stages ..........................................
NO.
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DA2(II)
STAGE-II (2X660 MW)
4.01.05 Number of rows and blades integrally
shrouded ..........................................
a) HP ..........................................
b) IP ..........................................
c) LP ..........................................
4.01.06 Number of rows of blades unshrouded
(indicate whether free standing or with
lacing wires)
a) IP ..........................................
b) LP ..........................................
4.01.07 First stage diameter mm ..........................................
4.01.08 Length of longest blade mm ..........................................
4.01.09 a) Tip diameter of largest wheel mm ..........................................
b) Pitch circle diameter of largest wheel mm ..........................................
4.01.10 Maximum peripheral velocity of
largest wheel M/sec ..........................................
4.01.11 a) LP turbine last two stages details Last stage Last But
one stage
i) Blade height mm ............... ...................
ii) Root diameter mm ................ ...................
iii) Pitch diameter mm ................ ..................
iv) Tip diameter mm ................ .................
(Furnish velocity triangles clearly
indicating inlet and outlet angles of
blades and various velocity sectors)
b) Modulus of section (Z) for critical
sections including root, pcd & tip
sections ..........................................
c) Steam bending stresses at the
above critical sections kg/cm2 ..........................................
NO.
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DA2(II)
STAGE-II (2X660 MW)
d) Reaction at root, pitch circle diameter
and tip Kgf ..........................................
e) Leaving velocity at the exit of last
stage blades m/sec ..........................................
f) Safe design bending stress of last
stage blades kg/cm2 ..........................................
g) Actual bending stress (duly supported
by detailed calculations bringing out
clearly all input data, correlation
considered and results) kg/cm2 ..........................................
4.01.12 a) Method of vibration test on LP stages ..........................................
b) Furnish details ..........................................
4.01.13 Furnish campbell diagrams (typical) for the
LP blading proposed ..........................................
a) Are LP turbine blading individually
tuned? Yes/No ..........................................
b) Indicate the stages which are
individually tuned ..........................................
4.01.14 LP exhaust annulus area m2 ..........................................
4.01.15 i) Design back end loading T/hr-m2 ..........................................
ii) Back end loading under following
conditions T/hr-m2 ..........................................
a) EMCR ..........................................
b) VWO ..........................................
c) VWO +over pressure ..........................................
d) HP heaters out ..........................................
4.01.16 Method of moisture removal in the last
stage ..........................................
4.01.17 i) Type of blade protection against
moisture erosion ..........................................
ii) Details substantiating the superiority
of the proposed arrangement
(if other than as called for in
specification) ..........................................
NO.
SECTION-VI
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DA2(II)
STAGE-II (2X660 MW)
4.01.18 Number of low pressure stages protected
against moisture erosion ..........................................
4.01.19 Area of blades protected against moisture
erosion mm2 ..........................................
4.01.20 Exhaust area at condenser neck m2 ..........................................
4.01.21 Pressure drop between LP exhaust
and condenser top row tubes mwc ..........................................
4.01.22 Main steam and reheat stop & control
valves
Main Reheat
steam steam
a) No. of : ..........................................
i) Stop valves ..........................................
ii) Control valves ..........................................
b) Type of : ..........................................
i) Stop valves ..........................................
ii) Control valves ..........................................
c) Whether combined or separate
(Furnish details & arrangement
drawing) ..........................................
d) Type of valve support ..........................................
e) Is the external steam chest supported
independent of main casing &
arranged to accept piping forces
during operation without transmitting
to the casing Yes/No ..........................................
f) If no then details of alternate
arrangement justify its superiority ..........................................
4.01.23 Strainers : Main Reheat
steam steam
a) No. of strainers ..........................................
i) Permanent ..........................................
ii) Temporary ..........................................
NO.
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DA2(II)
STAGE-II (2X660 MW)
b) Mesh size ..........................................
c) Strainer element material ..........................................
d) Strainer body material ..........................................
e) Are strainers removable Yes/No ..........................................
4.01.24 Bearings for turbine and generator
(Furnish a diagram indicating the
location of all bearings)
a) Number of journal bearings for turbine ..........................................
b) Number of journal bearings for
generator including exciter
(if applicable) ..........................................
c) Total number of journal bearings ..........................................
d) No. of thrust/thrust cum journal
bearings & their location ..........................................
e) Type of thrust bearing Fixed/ ..........................................
tilting pad
f) Type of journal bearing Fixed/
tilting pad ..........................................
g) Material of bearing shell ..........................................
h) Type of lining (antifriction material) ..........................................
i) Radial clearance for each bearing mm ..........................................
j) Bearing length mm ..........................................
k) Bearing pressure (due to running load) Kg/cm2
(gauge) ..........................................
m) Expected bearing temperature deg. C ..........................................
n) Maximum temperature permissible deg C ..........................................
o) Mean coefficient of friction between
journal and bearing ..........................................
p) Total load on the bearing kg ..........................................
q) Kilowatt loss per bearing kg ..........................................
NO.
SECTION-VI
PART - G
PAGE
55 OF 149
DA2(II)
STAGE-II (2X660 MW)
4.01.25 Shaft gland packing
a) Type ..........................................
b) Method adjustment ..........................................
c) Is packing replaceable Yes/No ..........................................
4.01.26 Method of mounting blades on rotor ..........................................
4.01.27 Method of fastening shroud ..........................................
4.01.28 Method of securing the fixed
blades to the casing ..........................................
4.01.29 Can the glands be examined without lifting
the top half casing? Yes/No ..........................................
4.01.30 Is turbine flange heating envisaged? Yes/No ..........................................
4.01.31 Is bolt heating envisaged? Yes/No ..........................................
4.01.32 Minimum Fixed Blade/moving Blade, Axial
& Radial Clearances (Furnish clearance
diagram & leakage rates as per
specification) ..........................................
Stationary Running
a) HP cylinder mm ..........................................
b) IP cylinder mm ..........................................
c) LP cylinder mm ..........................................
4.01.33 Shaft Glands ..........................................
a) Type of gland ..........................................
b) No. of stages per gland ..........................................
c) Normal running radial clearance ..........................................
d) Normal running axial clearance ..........................................
4.01.34 Overspeed Trip
a) Type ..........................................
b) Number ..........................................
c) Method of varying trip speed setting ..........................................
NO.
SECTION-VI
PART - G
PAGE
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DA2(II)
STAGE-II (2X660 MW)
4.01.35 Type of shaft couplings
a) HP/LP ..........................................
b) IP/LP ..........................................
c) LP/LP (if applicable) ..........................................
d) LP/Generator ..........................................
4.01.36 Turning Gear
a) Type ..........................................
b) Method of engagement ..........................................
4.01.37 Number and size of External Connections NO. Size Type
a) Main steam ..........................................
b) HP outlet for reheating ..........................................
c) Hot reheat return ..........................................
d) Extraction to deaerator ..........................................
e) Extraction to HP heaters
(state individual sizes) ..........................................
f) Extraction to LP heaters
(state individual sizes) ..........................................
g) Extraction to boiler feed pump
drive turbine ..........................................
4.01.38 Maximum allowable forces, moments at
each of the connections listed in 4.01.37
with notations used (Furnish this data in
the form of drawings and state drawing
numbers) ..........................................
4.01.39 For foundations design, furnish the
following in the form of drawings and
indicate drawing number :-
Loading data static and dynamic
values-including weights of rotating parts,
loading at base of bearings, short
circuit moments loads, loads from pipes,
dynamic out of balance forces
(two directional) ..........................................
NO.
SECTION-VI
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DA2(II)
STAGE-II (2X660 MW)
4.01.40 No. and location of water detection
thermocouples provided in the turbine
casing and drain lines
(furnish drg. indicating locations) ..........................................
4.01.41 LP turbine bursting diaphragms
a) Number ..........................................
b) Diameter mm ..........................................
c) Diaphragm material ..........................................
d) Area provided to pass the steam m2 ..........................................
e) Internal pressure at ..........................................
which the diaphragm is kg/cm
2
designed to rupture (abs) ..........................................
f) Time taken from the point of loss of
vacuum & turbine trip to the
diaphragm bursting sec ..........................................
g) Relieving capacity m/Sec. ..........................................
4.01.42 a) Are the cylinder horizontal joint bolts
heat tightened Yes/No ..........................................
b) Design feature incorporated to
prevent the seizure of the nuts and
studs. ..........................................
CLAUSE
NO.
(Bidder's Name...........................................................)
SECTION-VI
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PAGE
58 OF 149
DA2(II)
STAGE-II (2X660 MW)
4.02.00 Extraction line non-return valves
i) Ordinary Power operated Make Type Rating Material Bore Seat Pressure Valve Valve
(nos.) (indicate type & swing Lb class size dia. drop across closing opening
of actuation Design check/ the valve time time
i.e. power oil Code tilting disc/
or pneumatic) piston check mm mm ata sec sec
Extraction to
HP Heater 7A/7B
CRH line
Extraction to
HP Heater 6A/6B
Extraction to
HP Heater 5 A/5B
Extraction to Deaerator
Extraction to BFP
drive turbine
Extraction to LP Heater 3
Extraction to LP Heater 2
Extraction to LP heater no. 1
(if located outside the
condenser neck)
Others (for additional
extraction if any)
ii) Experience list of the valves of each size, type & rating offered indicating Name of manufacturer, utility, plants, unit size, Type, Size, rating,
service
NO.
SECTION-VI
PART - G
PAGE
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DA2(II)
STAGE-II (2X660 MW)
4.03.00 Vacuum Breaker Valve
a) Number ............... ..................
b) Make ............... ..................
c) Type of actuator ................ .................
d) Type of seat & gland sealing
(Furnish arrangement drawing) ............... .................
4.04.00 Insulation for turbine and
other equipment
Turbine Other Equip-
ment
a) Supplier ............ ..................
b) Insulating material ............ ..................
c) Type of application ............ ..................
d) Density of insulation ............ ..................
e) Thickness of insulation mm ............ ..................
f) Max. continuous temperature at
which the material is guaranteed
free from deterioration deg. C. ............ ...................
g) Thermal conductivity of
insulation at different
temperatures ............ .................
h) Surface temperature of
insulation (at 45 deg. C
ambient temperature) deg.C ............ ................
i) Total quantity of insulation
material envisaged ............... ................
j) Design Codes & standards ............... ................
k) Sheathing materials .............. ................
l) Thickness of sheathing ............... ..................
m) Cladding material & details ............... ..................
NO.
SECTION-VI
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DA2(II)
STAGE-II (2X660 MW)
4.05.00 Arrangement for noise
reduction of
a) Turbine .........................................
b) HP/LP Bypass .........................................
c) Others .........................................
(Furnish a write up on the
arrangement provided for noise
reduction of these equipment)
NO.
SECTION-VI
PART - G
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61 OF 149
DA2(II)
STAGE-II (2X660 MW)
PART-2
1.00.00 CONDENSATE EXTRACTION PUMPS
(PER UNIT)
1.01.00 Design flow rate (kg/hr) ..........................................
1.02.00 Design inlet condition .........................................
1.02.01 Inlet temp. (deg.C) .........................................
1.02.02 Specific gravity .........................................
1.02.03 NPSH required at impeller centre line .........................................
a) 3% head breakdown m .........................................
b) 1% head breakdown m .........................................
c) 0% head breakdown m ..........................................
d) 40,000 hrs. erosion life of
first stage impeller m ..........................................
1.03.00 Design discharge conditions
1.03.01 Discharge pressure ata ..........................................
1.03.02 TDH m ..........................................
1.03.03 Shut off head m ..........................................
1.04.00 Pump speed rpm ..........................................
1.05.00 Power Consumption at design Condition ..........................................
1.05.01 Power input to motor at
50 Hz/47.5 Hz kW ..........................................
1.05.02 Loss in motor at
50 Hz/47.5 Hz kW ..........................................
1.05.03 Power input to pump at
50 Hz/47.5 Hz kW ..........................................
1.05.04 Efficiency of pump alone, % ..........................................
1.05.05 Overall efficiency of pump set % ..........................................
NO.
SECTION-VI
PART - G
PAGE
62 OF 149
DA2(II)
STAGE-II (2X660 MW)
1.06.00 Suction Specific speed for first
stage indicating the flow at which US Units
the same is considered ............................................
1.07.00 Cannister losses mwc ............................................
1.08.00 Seal water requirement (flow/pressure/temp.) m
3
/hr./ata/
o
C ............................................
1.09.00 Minimum flow for continuous
stable operation m
3
/hr ............................................
1.10.00 On set recirculation flow m
3
/hr ............................................
1.11.00 Peripheral speed at the eye of
first stage impeller, m/sec ............................................
1.12.00 Maximum thrust, up/down Kgs ............................................
1.13.00 Manufacturer ............................................
1.14.00 Model Number and No. of
pumps ............................................
1.15.00 Number of stages ............................................
1.16.00 Type of first stage impeller ............................................
1.17.00 Impeller outer diameter, mm ............................................
1.18.00 Suction specific speeds US units ............................................
1.19.00 Design pressure of bowl and
discharge components, ata ............................................
1.20.00 Outer casing (can) :
1.20.01 Minimum wall thickness, mm ............................................
1.20.02 Design pressure ata ............................................
1.20.03 Depth below pump mounting flange mm ............................................
1.21.00 Suction connection:
1.21.01 Size/schedule ............................................
1.21.02 Type of connection with piping ............................................
NO.
SECTION-VI
PART - G
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DA2(II)
STAGE-II (2X660 MW)
1.21.03 Depth of centerline below pump
mounting flange mm ..........................................
1.22.00 Discharge connection:
1.22.01 Size/schedule ...........................................
1.22.02 Type of connection with piping ...........................................
1.22.03 Height of centerline above pump
mounting flange mm ...........................................
1.23.00 Critical speeds: ...........................................
1.23.01 First critical speed in water rpm ...........................................
1.23.02 Second critical speed in water rpm ...........................................
1.24.00 GD
2
of rotor including coupling kg-m
2
..........................................
1.25.00 Impeller shaft: ...........................................
1.25.01 Length mm ...........................................
1.25.02 Dia mm ...........................................
1.25.03 Span between bearings, mm ...........................................
1.26.00 Intermediate shafts: ...........................................
1.26.01 Length mm ...........................................
1.26.02 Dia mm ...........................................
1.26.03 Span between bearings (max.) mm ..........................................
1.26.04 Method of coupling with adjacent
shafting. ...........................................
1.27.00 Radial bearings ..........................................
1.27.01 Type & Number ...........................................
1.27.02 Size mm ...........................................
1.28.00 Thrust bearing ..........................................
1.28.01 Located in pump/motor ..........................................
NO.
SECTION-VI
PART - G
PAGE
64 OF 149
DA2(II)
STAGE-II (2X660 MW)
1.28.02 Type & number ..........................................
1.28.03 Design load, kg ...........................................
1.28.04 Max. load kg ...........................................
1.29.00 Bearing lubrication type: ...........................................
1.29.01 Radial bearing ...........................................
1.29.02 Thrust bearing ...........................................
1.29.03 Recommended hole size
of suction strainer ...........................................
1.30.00 First stage details
(Bidder shall necessarily fill up this data)
1.30.01 Impeller eye diameter mm
1.30.02 Hub diameter mm
1.30.03 Inlet angle degrees
1.30.04 Inlet area between vanes normal
to average Meridional velocity mm
2
1.30.05 Eye, peripheral velocity M/sec.
1.30.06 Axial fluid velocity, in eye M/sec.
1.30.07 Discharge angle Degrees
1.30.08 Discharge area between vanes
normal to average meridional
velocity mm
2
1.30.09 Width of impeller water way at
discharge mm
2
1.30.10 Impeller eye area mm
2
1.30.11 Impeller/diffuser width ratio
1.30.12 Number of impeller vanes
1.30.13 Clearance between impeller tip
and diffuser %
NO.
SECTION-VI
PART - G
PAGE
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DA2(II)
STAGE-II (2X660 MW)
1.31.00 Pressure pulsation data (peak-to-peak)
1.31.01 At sunction and discharge nozzle :
- design, flow metres
- b.e.p. metres
- 60% flow metres
- 40% flow metres
- Minimum flow metres
1.31.02 Maximm allowable metres
2.00.00 DRIP PUMPS (IF OFFERED)
(PER UNIT)
2.01.00 Design flow rate (kg/hr) ..........................................
2.02.00 Design inlet condition .........................................
2.02.01 Inlet temp. (deg.C) .........................................
2.02.02 Specific gravity .........................................
2.02.03 NPSH required at impeller centre line .........................................
a) 3% head breakdown m .........................................
b) 1% head breakdown m .........................................
c) 0% head breakdown m ..........................................
d) 40,000 hrs. erosion life of
first stage impeller m ..........................................
2.03.01 Discharge pressure ata ..........................................
2.03.02 TDH m ..........................................
2.03.03 Shut off head m ..........................................
2.04.00 Pump speed rpm ..........................................
NO.
SECTION-VI
PART - G
PAGE
66 OF 149
DA2(II)
STAGE-II (2X660 MW)
2.05.00 Power Consumption at design Condition ..........................................
2.05.01 Power input to motor at
50 Hz/47.5 Hz kW ..........................................
2.05.02 Loss in motor at
50 Hz/47.5 Hz kW ..........................................
2.05.03 Power input to pump at
50 Hz/47.5 Hz kW ..........................................
2.05.04 Efficiency of pump alone, % ..........................................
2.05.05 Overall efficiency of pump set % ..........................................
2.06.00 Suction Specific speed for first
stage indicating the flow at which US Units
the same is considered ...........................................
2.07.00 Cannister losses mwc ..........................................
2.08.00 Seal water requirement (flow/pressure/temp.) m
3
/hr./ata/
o
C ..........................................
2.09.00 Minimum flow for continuous
stable operation m
3
/hr ..........................................
2.10.00 On set recirculation flow m
3
/hr ..........................................
2.11.00 Peripheral speed at the eye of
first stage impeller, m/sec ..........................................
2.12.00 Maximum thrust, up/down Kgs ..........................................
2.13.00 Manufacturer ..........................................
2.14.00 Model Number and No. of
pumps ..........................................
2.15.00 Number of stages ..........................................
2.16.00 Type of first stage impeller ..........................................
2.17.00 Impeller outer diameter, mm ..........................................
2.18.00 Suction specific speeds US units ..........................................
2.19.00 Design pressure of bowl and
discharge components, ata ..........................................
NO.
SECTION-VI
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PAGE
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DA2(II)
STAGE-II (2X660 MW)
2.20.00 Outer casing (can) :
2.20.01 Minimum wall thickness, mm ..........................................
2.20.02 Design pressure ata ..........................................
2.20.03 Depth below pump mounting flange mm ..........................................
2.21.00 Suction connection:
2.21.01 Size/schedule ..........................................
2.21.02 Type of connection with piping ..........................................
2.21.03 Depth of centerline below pump
mounting flange mm ..........................................
2.22.00 Discharge connection:
2.22.01 Size/schedule .........................................
2.22.02 Type of connection with piping .........................................
2.22.03 Height of centerline above pump
mounting flange mm .........................................
2.23.00 Critical speeds: .........................................
2.23.01 First critical speed in water rpm .........................................
2.23.02 Second critical speed in water rpm .........................................
2.24.00 GD
2
of rotor including coupling kg-m
2
..........................................
2.25.00 Impeller shaft: .........................................
2.25.01 Length mm .........................................
2.25.02 Dia mm .........................................
2.25.03 Span between bearings, mm .........................................
2.26.00 Intermediate shafts: .........................................
2.26.01 Length mm .........................................
2.26.02 Dia mm .........................................
NO.
SECTION-VI
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DA2(II)
STAGE-II (2X660 MW)
2.26.03 Span between bearings (max.) mm ..........................................
2.26.04 Method of coupling with adjacent
shafting. .........................................
2.27.00 Radial bearings ..........................................
2.27.01 Type & Number .........................................
2.27.02 Size mm .........................................
2.28.00 Thrust bearing ..........................................
2.28.01 Located in pump/motor ..........................................
2.28.02 Type & number ..........................................
2.28.03 Design load, kg .........................................
2.28.04 Max. load kg ..........................................
2.29.00 Bearing lubrication type: .........................................
2.29.01 Radial bearing .........................................
2.29.02 Thrust bearing .........................................
2.29.03 Recommended hole size
of suction strainer .........................................
2.30.00 First stage details
(Bidder shall necessarily fill up this data)
2.30.03 Inlet angle degrees
to average Meridional velocity mm
2
2.30.05 Eye, peripheral velocity M/sec.
2.30.06 Axial fluid velocity, in eye M/sec.2
NO.
SECTION-VI
PART - G
PAGE
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DA2(II)
STAGE-II (2X660 MW)
velocity mm
2
2.30.09 Width of impeller water way at
discharge mm
2
2
2.30.12 Number of impeller vanes
2.30.13 Clearance between impeller tip
and diffuser %
2.31.00 Pressure pulsation data (peak-to-peak)
2.31.01 At sunction and discharge nozzle :
- design, flow metres
- b.e.p. metres
- 60% flow metres
- 40% flow metres
- Minimum flow metres
2.31.02 Maximm allowable metre
NO.
SECTION-VI
PART - G
PAGE
70 OF 149
DA2(II)
STAGE-II (2X660 MW)
PART - 3
FEED WATER HEATING PLANT
1.00.00 GLAND STEAM CONDENSER
1.01.00 Manufacturer ..........................................
1.02.00 Model number and No. off ..........................................
1.03.00 Type and arrangement ..........................................
1.04.00 Design and construction standard ..........................................
1.05.00 Minimum / Max. condensate flow Kg/hr. ..........................................
1.06.00 Pressure drop through water
tubes corresponding to above
flows. ..........................................
1.07.00 Number of tubes ..........................................
1.08.00 Tube outside dia x thickness mmxmm ..........................................
1.09.00 Tube material ..........................................
1.10.00 Water velocity through tubes m/sec ..........................................
1.11.00 Shell material ..........................................
1.12.00 Overall length of shell m ..........................................
1.13.00 Shell OD mm ..........................................
1.14.00 Shell thickness mm ..........................................
1.15.00 Motor driven vent fan Yes/No ..........................................
provided
1.16.00 No. of vent fans ..........................................
1.17.00 Type of vent fan ..........................................
1.18.00 Power absorbed by vent fan ..........................................
1.19.00 Vent fan motor rating ........................................
NO.
SECTION-VI
PART - G
PAGE
71 OF 149
DA2(II)
STAGE-II (2X660 MW)
1.20.00 Steam supply to gland steam
condenser ejector. .........................................
1.21.00 Quantity Kg/hr .........................................
1.22.00 Pressure (Kg/cm
2
) .........................................
1.23.00 Temperature (deg.C) .........................................
2.00.00 LOW PRESSURE HEATERS & DRAIN
COOLER
LP Heaters Drain
cooler
3 2 1
2.01.00 Manufacturer ........... .......... .......... .................
2.02.00 Model number and No. off ........... .......... .......... .................
2.03.00 Type and arrangement ........... .......... .......... .................
2.04.00 Design and construction standard ........... .......... .......... .................
2.05.00 No. of shell passes ........... .......... .......... .................
2.06.00 No. of tube passes ........... .......... .......... .................
2.07.00 No. of zones ........... .......... .......... .................
2.08.00 Heat transfer surface area
a. Drain cooling zone m
2
..........................................
b. Condensing zone m
2
..........................................
c. Desuperheating zone m
2
..........................................
d. Ineffective area m
2
..........................................
e. Total area m
2
..........................................
f. Total extra surface provided m
2
..........................................
NO.
SECTION-VI
PART - G
PAGE
72 OF 149
DA2(II)
STAGE-II (2X660 MW)
2.09.00 Heat transfer data under design
(guaranteed ) condition:
a. Heat (kcal/Hr.) transferred in
i. Drain cooling zone ..........................................
ii. Condensing zone ..........................................
iii. Desuperheating zone ..........................................
iv. Total heat transferred ..........................................
b) L.M.T.D. (deg C)
i. Drain cooling zone .........................................
ii. Condensing zone .........................................
c) Overall heat transfer co-
efficient (Kcal/Hr-m
2
degC)
d) Tube inside fouling factor
(hr-m
2
-degC/Kcal) as
applied to each heat transfer
zone. ..........................................
e) Outer tube surface fouling
factor (hr-m
2
-degC/Kcal)
for
f) Velocity through tubes m/sec ..........................................
g) Drain level in the Heaters
NO.
SECTION-VI
PART - G
PAGE
73 OF 149
DA2(II)
STAGE-II (2X660 MW)
i. Normal mm ..........................................
ii. Maximum mm ..........................................
iii. Minimum mm ..........................................
iv. Clearance between the
maximum operating
level and the bottom
of the tube bundle ..........................................
2.10.00 Maximum noise level produced during
operating (dBA) ..........................................
2.11.00 Tubes
a) Type of tube provided (welded
or seamless) ..........................................
b) Total no. of U-tubes ..........................................
c) No. of extra tubes provided ..........................................
d) Effective length of U-tubes mm ..........................................
e) Total straight length of one
leg. mm ..........................................
f) Outside diameter mm ..........................................
g) Wall thickness, before
bending mm(BWG) .........................................
h) Minimum thickness at bend
after bending mm(BWG) ..........................................
i) Maximum carbon content in tube ..........................................
j) Design pressure Kgf/cm
2
(g) ..........................................
k) Design temperature deg. C ..........................................
i) Desuperheating zone ..........................................
ii) Other zones ..........................................
l) Hydrostatic test pressure Kgf/cm
2
(g) .........................................
NO.
SECTION-VI
PART - G
PAGE
74 OF 149
DA2(II)
STAGE-II (2X660 MW)
m) Type of tube to tube sheet joint ..........................................
n) Tube pitch mm ..........................................
o) Groove dimensions .........................................
p) Type of tube pattern ..........................................
q) Shell /tube bundle clearance
space (clearance between
outside diameter of tube
bundle and inside diameter
of shell) mm ..........................................
r) Tube withdrawal space required.
(for LP Heater(s) in condenser
neck only). mm .........................................
2.12.00 Shell
a. Outside diameter mm .........................................
b. Wall thickness mm ..........................................
c. Shell skirt outside diameter mm ..........................................
d. Shell skirt length mm ..........................................
e. Shell skirt length mm ..........................................
f. Overall length mm ..........................................
g. Withdrawal length mm ..........................................
h. Type of dished end for shell
cover (Hemispherical/torispherical/
Ellipsoidal or any other) ..........................................
i. Design pressure Kgf/cm
2
(g) ..........................................
j. Length of desuperheating zone mm ..........................................
k. Design temperature deg. C ..........................................
i) Skirt ..........................................
ii) Shell ..........................................
NO.
SECTION-VI
PART - G
PAGE
75 OF 149
DA2(II)
STAGE-II (2X660 MW)
l. Hydraulic test pressure Kgf/cm
2
(g) ..........................................
m. Design vacuum mm of Hg ..........................................
n. Corrosion allowance provided mm ..........................................
o. Type of shell supports for LP Heater
in condenser neck Also indicate the
shell length inside the condenser
neck. ..........................................
p. Dimension of the anti flash
baffle for LP heater in condenser
neck & drain cooler. ..........................................
q. Whether stainless steel liners
are provided in the flashed
drain inlets or not? ..........................................
r. Whether stainless steel band
is provided at the cutting point
s. What type of provision has
been provided for compensating
differential expansion between
shell and tube for drain cooler ..........................................
2.13.00 Impingement Plates
a. Number ..........................................
b. Thickness mm ..........................................
2.14.00 Tube support plate, Tie Rods etc. ..........................................
a. No. of tube support plates in ..........................................
i. Desuperheating zone ..........................................
ii. Drain cooling zone ..........................................
iii. Condensing zone ..........................................
b. Thickness of tube support plates mm ..........................................
NO.
SECTION-VI
PART - G
PAGE
76 OF 149
DA2(II)
STAGE-II (2X660 MW)
c. Spacing of support plates in ..........................................
i. Desuperheating zone ..........................................
ii. Drain cooling zone ..........................................
iii. Condensing zone ..........................................
d. No. of the rods .......................................
e. Diameter of the rods mm .........................................
f. Number of spacers ..........................................
g. Clearance between tube and ..........................................
support plate hole in
i. Desuperheating zone .........................................
ii. Drain cooling zone .........................................
iii) Condensing zone .........................................
2.15.00 Shell side Relief Valves
a. Manufacturer & Model No. .........................................
b. Type .........................................
c. Nos. provided .........................................
d. Size .........................................
e. Capacity of each at 10%
accumulation kg/hr .........................................
f. Set pressure, Kgf/cm
2
(g) .........................................
g. Blow down pressure Kgf/cm
2
(g) .........................................
h. Material .........................................
i. Body and Bonnet/cover .........................................
ii. Disc .........................................
iii. Spring .........................................
iv. Nozzle .........................................
v. Spindle .........................................
vi. Sleeve guide/spindle
guide, bushing .........................................
NO.
SECTION-VI
PART - G
PAGE
77 OF 149
DA2(II)
STAGE-II (2X660 MW)
vii Bolts .........................................
viii. Nuts .........................................
i. Hand lever provided for testing? .........................................
2.16.00 Tube side Relief Valve
b. Type .........................................
c. Nos. provided .........................................
d. Size & type .........................................
e. Set pressure, Kgf/cm
2
(g) .........................................
f. Blow down pressure Kgf/cm
2
(g) .........................................
g. Materials .........................................
i. Body and Bonnet/cover ..........................................
ii. Disc ..........................................
iii. Spring .........................................
iv. Nozzle ..........................................
v. Spindle .........................................
guide, bushing .........................................
vii Bolts .........................................
viii. Nuts .........................................
h. Hand lever provided for testing? .........................................
2.17. 00 Materials of Construction (indicate
ASTM Specification
a. Heater Body ..........................................
i. Skirt ..........................................
ii. Shell .........................................
NO.
SECTION-VI
PART - G
PAGE
78 OF 149
DA2(II)
STAGE-II (2X660 MW)
iii. Head .........................................
b. Water Box and Covers .........................................
i. Skirt .........................................
ii. Shell .........................................
iii. Head .........................................
c. Water Box and Covers .........................................
i. Water box pass partition plate .........................................
ii. Flow diffusers, straighteners .........................................
d. Tubes .........................................
e. Tube sheet (including overlay material) .........................................
f. Baffles & support plates .........................................
g. Impingement plates .........................................
h. Antiflash baffles .........................................
i. Nozzles .........................................
j. Flanges .........................................
k. Tie rods and spacers .........................................
l. Bolts .........................................
m. Nuts .........................................
n. Gaskets .........................................
2.18.00 Nozzles connection size (Indicate
No. Size (mm) & type)
a. Feed water /condensate inlet .........................................
b. Feed water /condensate outlet .........................................
c. Steam inlet .........................................
d. Cascading drain inlet .........................................
NO.
SECTION-VI
PART - G
PAGE
79 OF 149
DA2(II)
STAGE-II (2X660 MW)
e. Cascading drain outlet .........................................
f. Drain cooler bypass (Not
applicable for LP heater-1) .........................................
g. Shell vent (Operating) .........................................
h. Shell drain .........................................
i. Start up vent .........................................
j. Water box drain .........................................
k. Water box vent .........................................
l. Water box relief valve .........................................
m. Shell relief valve .........................................
n. Stand pipes .........................................
2.19.00 Operating Vent Orifice
a. Nos. provided .........................................
b. Design code/standard .........................................
c. Steam flow through each
orifice at heater design
condition Kg/hr .........................................
d. Material of orifice plate
(Indicate ASTM Specification) .........................................
e. Diameter of orifice mm .........................................
f. Diameter of orifice plate mm .........................................
g. Thickness of orifice plate mm .........................................
2.20.00 Start-up Vent Orifice
a. Nos. provided .........................................
c. Steam flow at start-up Kg/hr .........................................
NO.
SECTION-VI
PART - G
PAGE
80 OF 149
DA2(II)
STAGE-II (2X660 MW)
2.21.00 Stand Pipe
a. Material (Indicate ASTM
Specification) .........................................
b. Nominal diameter & thickness mm .........................................
c. Over all length mm .........................................
d. Nos. provided .........................................
e. Drain & isolation valve provided .........................................
2.22.00 Level Gauge Glass
b. Type .........................................
c. Measurement range mm .........................................
d. Isolation, drain, vent & ball
check valves provided? .........................................
e. Number provided .........................................
2.23.00 Weights (Tonnes)
a. Empty .........................................
b. Normal operating ..........................................
c. Hydrostatic test weight flooded .........................................
d. Weight of tube bundle .........................................
e. Weight of shell .........................................
f. Weight of water box .........................................
NO.
SECTION-VI
PART - G
PAGE
81 OF 149
DA2(II)
STAGE-II (2X660 MW)
g. Total shipping weight .........................................
h. Weight of heaviest single piece
during: .........................................
i. Erection .........................................
ii. Maintenance .........................................
2.24.00 Shipping Dimensions (mm) (Indicate
the following for heaviest as well
as largest piece
a. Length .........................................
b. Breadth .........................................
c. Height .........................................
3.00.00 DEAERATOR
3.01.00 Manufacture .........................................
3.02.00 Model No. & Number off .........................................
3.03.00 Type .........................................
3.04.00 Design and construction standard .........................................
3.05.00 Design pressure Kgf/
cm
2
(g) .........................................
3.06.00 Design temperature (deg.C) and design
Vacuum (mm of Hg) .........................................
3.07.00 Hydrostatic test pressure Kgf/
cm
2
(g) .........................................
3.08.00 Shell diameter and thickness mm .........................................
a. Deaerator .........................................
b. Storage tank .........................................
NO.
SECTION-VI
PART - G
PAGE
82 OF 149
DA2(II)
STAGE-II (2X660 MW)
3.09.00 Straight length and overall length
of shell mm .........................................
a. Deaerator .........................................
b. Storage tank .........................................
3.10.00 Type of dished ends and thickness mm .........................................
a. Deaerator .........................................
b. Storage tank .........................................
3.11.00 Type of storage tank supports to
mount the deaerator on floor .........................................
3.12.00 Number of supports on storage tank .........................................
3.13.00 Distance between the supports .........................................
3.14.00 Dimensions of sparger pipe .........................................
3.15.00 Whether antivortex baffle .........................................
provided
3.16.00 Mesh size of the reinforced wide
meshed strainer provided at the
discharge connections from
deaerator storage tank .........................................
3.17.00 Whether the access platform provided
is adequate enough from the
maintenance and operation point
of view? .........................................
3.18.00 Whether the oxygen measuring kit
has been provided? .........................................
3.19.00 Number of sections the storage
tank and deaerator to be split for
shipping it to the site .........................................
3.20.00 Type of manhole provided .........................................
3.21.00 Dimension of manhole .........................................
3.22.00 Number of splash plates provided .........................................
3.23.00 Number of trays provided .........................................
NO.
SECTION-VI
PART - G
PAGE
83 OF 149
DA2(II)
STAGE-II (2X660 MW)
3.24.00 Number of steam distribution
rakes provided .........................................
3.25.00 Corrosion allowance provided
on shells and dished ends mm .........................................
3.26.00 Storage capacity at normal
water level, with a filling factor
of 0.66 of the cross-sectional
area of the storage tank m
3
.........................................
3.27.00 Storage capacity available from
normal level to the low-low level m
3
.........................................
3.28.00 Water level from centre line
of horizontal vessel mm
a. Normal .........................................
b. Low .........................................
c. Low-Low .........................................
d. High .........................................
e. High-High .........................................
3.29.00 Type of integral, vent condenser
provided .........................................
3.30.00 Spray valves
b. Type (Disc Spring or Plunger
type) .........................................
c. Nos. provided .........................................
d. Control range .........................................
e. Pressure drop across the valve Kgf/cm
2
.........................................
f. Material of construction
(Indicate ASTM Standard ) of
body, disc, spring and nozzle). .........................................
NO.
SECTION-VI
PART - G
PAGE
84 OF 149
DA2(II)
STAGE-II (2X660 MW)
g. Residence time .........................................
h. Droplet size .........................................
i. Arrangement of spray
nozzles within deaerator .........................................
3.31.00 Protection against inflow of
condensate in the steam
supply pipe. .........................................
3.32.00 Whether flashed drain inlet is
provided with hardened SS liner. .........................................
3.33.00 Safety Valves
b. Type .........................................
c. Nos. provided .........................................
d. Size .........................................
e. Capacity at 10%
accumulation kg/hr .........................................
2
(g) .........................................
g. Blow down Kgf/cm
2
(g) .........................................
h. Material of construction
(Indicate ASTM St.) .........................................
ii. Disc. .........................................
iii. Spring .........................................
iv. Nozzle .........................................
v. Spindle .........................................
guide, bushing .........................................
vii Bolts .........................................
viii. Nuts .........................................
NO.
SECTION-VI
PART - G
PAGE
85 OF 149
DA2(II)
STAGE-II (2X660 MW)
3.34.00 Stand Pipe
Standard) .........................................
d. Nos. provided .........................................
b. Type .........................................
c. Number provided .........................................
d. Measurement range mm .........................................
e. Isolation, drain, vent & ball
3.36.00 Materials of construction (Indicate
ASTM Standard)
a. Shell and head
i. Deaerator .........................................
ii. Storage tank .........................................
b. Splash plates .........................................
c. Steam distribution rakes .........................................
d. Trays .........................................
e. Baffles (including Antivortex
baffle). .........................................
f. i. Nozzles .........................................
ii. Nozzle liner .........................................
g. Restricting orifices .........................................
h. Vent Pipes .........................................
NO.
SECTION-VI
PART - G
PAGE
86 OF 149
DA2(II)
STAGE-II (2X660 MW)
i. Valves .........................................
j. Bolts .........................................
k. Nuts .........................................
l. Gaskets .........................................
m. Access platform .........................................
n. Strainer .........................................
o. Impingement plate ........................................
3.37.00 Nozzle Connections
Nos. Size Type
a. Condensate inlet .........................................
b. Condensate outlet .........................................
c. Extraction steam inlet .........................................
d. Auxiliary steam inlet .........................................
e. Pressure equalising between
supply pipe and deaerator .........................................
vessel
f. Deaerator overflow .........................................
g. Drain from HP Heaters .........................................
h. Recirculation from BF pumps .........................................
i. Leak-off from BF pumps .........................................
j. Vent .........................................
k. Drain .........................................
l. Safety valve outlet .........................................
m. Thermowell .........................................
a. Nos. provided .........................................
NO.
SECTION-VI
PART - G
PAGE
87 OF 149
DA2(II)
STAGE-II (2X660 MW)
condition Kg/hr .........................................
a. Nos. provided .........................................
condition Kg/hr .........................................
a. Empty .........................................
b. Normal operating .........................................
c. Hydrostatic test condition
(flooded weight) .........................................
d. Total shipping weight .........................................
e. Weight of heaviest single piece
during: .........................................
i. Erection .........................................
ii. Maintenance .........................................
NO.
SECTION-VI
PART - G
PAGE
88 OF 149
DA2(II)
STAGE-II (2X660 MW)
3.41.00 Shipping Dimensions (mm) piece
Heaviest Biggest
piece piece
a. Length .........................................
b. Breadth .........................................
c. Height .........................................
d. No. of pieces complete
deaerator shell be shipped .........................................
4.00.00 HIGH PRESSURE HEATERS
HP Heaters
5A/5B 6A/6B 7A/7B
4.01.00 Manufacturer ..........................................
4.02.00 Model No. and Number off .........................................
4.03.00 Type and arrangement .........................................
404.00 Design and construction standard .........................................
4.05.00 No. of shell passes .........................................
4.06.00 No. of tube passes .........................................
4.07.00 No. of zones .........................................
4.08.00 Heat transfer surface area
a. Drain cooling zone m
2
.........................................
b. Condensing zone m
2
.........................................
c. Desuperheating zone m
2
.........................................
d. Ineffective area m
2
.........................................
e. Total area m
2
.........................................
f. Total extra surface provided m
2
.........................................
4.09.00 Heat transfer data under design
(guaranteed ) condition:
a. Heat (kcal/Hr.) transferred in
NO.
SECTION-VI
PART - G
PAGE
89 OF 149
DA2(II)
STAGE-II (2X660 MW)
iii. Desuperheating zone .........................................
iv. Total heat transferred .........................................
b) L.M.T.D. (deg C)
c) Overall heat transfer co-
efficient (Kcal/hr-m
2
degC)
d) Tube inside fouling factor
(hr-m
2
deg C/Kcal) as
applied to each heat transfer
zone. .........................................
e) Outer tube surface fouling
factor (hr-m
2
-degC/Kcal)
for
f) Velocity through tubes m/sec .........................................
g) Drain level in the Heaters mm
i. Normal mm .........................................
ii. Maximum mm .........................................
iii. Minimum mm .........................................
NO.
SECTION-VI
PART - G
PAGE
90 OF 149
DA2(II)
STAGE-II (2X660 MW)
iv. Clearance between the
maximum operating
level and the bottom
of the tube bundle .........................................
4.10.00 i. Velocity through tubes at maximum m/sec
flow .........................................
ii. Tube side pressure drop at maximum Kgf/cm
2
flow .........................................
4.11.00 Maximum noise level produced during
operating (dBA) .........................................
4.12.00 Tubes
a) Type of tube provided (welded
or seamless)
(Furnish details & experience) .........................................
b) Total no. of U-tubes .........................................
c) No. of extra tubes provided .........................................
d) Effective length of U-tubes mm .........................................
e) Total straight length of one
leg. mm .........................................
f) Outside diameter mm .........................................
g) Wall thickness, before
bending mm(BWG) .........................................
h) Minimum thickness at bend
after bending mm(BWG) .........................................
i) Maximum carbon content in tube .........................................
j) Design pressure Kgf/cm
2
(g) .........................................
k) Design temperature deg. C .........................................
i) Desuperheating zone .........................................
ii) Other zones .........................................
l) Hydrostatic test pressure Kgf/cm
2
(g) ..........................................
NO.
SECTION-VI
PART - G
PAGE
91 OF 149
DA2(II)
STAGE-II (2X660 MW)
m) Type of tube to tube sheet joint .........................................
n) Tube pitch mm .........................................
o) Type of tube pattern .........................................
p) Shell /tube bundle clearance
space mm .........................................
4.13.00 Shell
a. Outside diameter mm .........................................
b. Wall thickness mm .........................................
c. Shell skirt outside diameter mm .........................................
d. Shell skirt thickness mm .........................................
e. Shell skirt length mm .........................................
f. Overall length mm .........................................
g. Withdrawal length mm .........................................
h. Type of dished end for shell
cover (Hemispherical/
Ellipsoidal or any other) .........................................
i. Design pressure Kgf/cm
2
(g) .........................................
j. Length of desuperheating zone mm .........................................
k. Length of drain cooling zone mm .........................................
l. Design temperature deg. C
i Skirt .........................................
. ii Shell .........................................
m. Design vacuum mm/Hg .........................................
n. Hydraulic test pressure Kgf/cm
2
(g) .........................................
o. Corrosion allowance provided mm .........................................
p. Type of shell supports .........................................
NO.
SECTION-VI
PART - G
PAGE
92 OF 149
DA2(II)
STAGE-II (2X660 MW)
q. Whether stainless steel liners
are provided in the flashed
drain inlets or not? .........................................
r. Whether stainless steel band
is provided at the cutting point .........................................
4.14.00 Impingement Plates
a. Number .........................................
b. Thickness mm .........................................
4.15.00 Tube support plate, Tie Rods etc. .........................................
a. No. of tube support plates in .........................................
i. Desuperheating zone .........................................
ii. Drain cooling zone .........................................
iii. Condensing zone .........................................
b. Thickness of tube support plates mm .........................................
c. Spacing of support plates in .........................................
i. Desuperheating zone mm .........................................
ii. Drain cooling zone mm .........................................
iii. Condensing zone mm .........................................
d. Diameter of the tie rods mm .........................................
e. No. of the rods .........................................
f. Number of spacers .........................................
g. Clearance between tube and .........................................
support plate hole in
i. Desuperheating zone mm .........................................
ii. Drain cooling zone mm .........................................
iii. Condensing zone mm .........................................
NO.
SECTION-VI
PART - G
PAGE
93 OF 149
DA2(II)
STAGE-II (2X660 MW)
4.16.00 Shell side Relief Valves
b. Type .........................................
c. Nos. provided .........................................
d. Size .........................................
e. Capacity of each at 10%
accumulation Kg/hr. .........................................
2
(g) .........................................
g. Blow down pressure Kgf/cm
2
(g) .........................................
h. Materials .........................................
ii. Disc. .........................................
iii. Spacing .........................................
iv. Nozzle .........................................
v. Spindle .........................................
guide/ bushing .........................................
vii Bolts .........................................
viii. Nuts .........................................
4.17.00 Tube side Relief Valve
b. Type .........................................
c. Nos. provided .........................................
d. Size and type .........................................
NO.
SECTION-VI
PART - G
PAGE
94 OF 149
DA2(II)
STAGE-II (2X660 MW)
e. Set pressure, Kgf/cm
2
(g) .........................................
f. Blow down pressure Kgf/cm
2
(g) .........................................
g. Materials .........................................
ii. Disc. .........................................
iii. Spacing .........................................
iv. Nozzle .........................................
v. Spindle .........................................
guide/bushing .........................................
vii Bolts .........................................
viii. Nuts .........................................
h. Hand lever provided for testing .........................................
4.18. 00 Materials for Construction (indicate
ASTM Specification
a. Heater Body .........................................
i. Skirt .........................................
ii. Shell .........................................
iii. Head .........................................
b. Water Box and Covers .........................................
i. Water box .........................................
ii. Feed branches .........................................
iii. Water box cover .........................................
c. Tube .........................................
d. Tube sheet (including overlay material) .........................................
NO.
SECTION-VI
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DA2(II)
STAGE-II (2X660 MW)
e. Baffles & support plates .........................................
f. Impingement plates .........................................
g. Antiflash baffles .........................................
h. Nozzles .........................................
i. Flanges .........................................
j. Tie rods and spacers .........................................
k. Bolts .........................................
l. Nuts .........................................
m. Gaskets .........................................
4.19.00 Nozzles connection size (Indicate
No., Size (mm) & type)
a. Feed water /condensate inlet .........................................
b. Feed water /condensate outlet .........................................
c. Steam inlet .........................................
d. Cascading drain inlet .........................................
e. Cascading drain outlet .........................................
f. Drain cooler bypass .........................................
g. Shell drain .........................................
h. Shell vent (Operating) .........................................
i. Start up vent .........................................
j. Water box drain .........................................
k. Water box vent .........................................
l. Water box relief valve .........................................
m. Shell relief valve .........................................
n. Stand pipes .........................................
NO.
SECTION-VI
PART - G
PAGE
96 OF 149
DA2(II)
STAGE-II (2X660 MW)
a. Nos. provided .........................................
condition Kg/hr .........................................
a. Nos. provided .........................................
c. Material of orifice plate
(Indicate ASTM Standard) .........................................
d. Diameter of orifice mm .........................................
e. Diameter of orifice plate mm .........................................
f. Thickness of orifice plate mm .........................................
g. Steam flow through each
orificeKg/hr. .........................................
4.22.00 Stand Pipe
Specification) .........................................
d. Nos. provided .........................................
NO.
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PART - G
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DA2(II)
STAGE-II (2X660 MW)
b. Type .........................................
c. Measurement range mm .........................................
d. Isolation, drain, vent & ball
e. Number provided .........................................
a. Empty .........................................
b. Normal operating .........................................
c. Hydrostatic test weight flooded .........................................
d. Weight of tube bundle .........................................
e. Weight of shell .........................................
f. Weight of water box .........................................
g. Total shipping weight .........................................
NO.
SECTION-VI
PART - G
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DA2(II)
STAGE-II (2X660 MW)
PART - 4
BOILER FEED PUMPS (PER UNIT)
1.01.00 Booster / Main Pump flow (kg/hr) ..........................................
1.02.00 Design inlet condition ..........................................
1.02.01 Suction temp (deg.C) ..........................................
1.02.02 Suction pressure (Booster/
Main pump) ata ..........................................
1.02.03 Specific gravity ..........................................
1.03.00 NPSH required for booster/Main pump ..........................................
1.03.01 3% head breakdown M ..........................................
1.03.02 1% head breakdown M ..........................................
1.03.03 0% head breakdown M ..........................................
1.03.04 40,000 hrs. erosion life of
impeller M ..........................................
1.04.01 Discharge pressure for main pump ata ..........................................
1.04.02 Total dynamic head for pumping unit M ..........................................
1.04.03 Discharge temp for main pump deg. C ..........................................
1.04.04 Discharge pressure for booster ata ..........................................
pump
1.04.05 Shut off head (main +booster
pumps) M ..........................................
1.05.00 Pump speeds .........................................
1.05.01 Main pump rpm ..........................................
1.05.02 Booster pump rpm ..........................................
NO.
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DA2(II)
STAGE-II (2X660 MW)
1.06.00 Power Consumptions of
Motor Driven Pumps:
1.06.01 Main pump input
(50/47.5 Hz) kW ..........................................
1.06.02 Booster pump inlet
(50/47.5 Hz) kW .........................................
1.06.03 Losses in hydraulic coupling
(50/47.5 Hz) kW .........................................
1.06.04 Losses in step up gear box
(50/47.5 Hz) kW .........................................
1.06.05 Total output required at
motor shaft kW .........................................
1.06.06 Efficiency of main pump
(50/47.5 Hz) % .........................................
1.06.07 Efficiency of booster pump
(50/47.5 Hz) % .........................................
1.06.08 Efficiency of drive motor
(50/47.5 Hz) % .........................................
1.06.09 Overall efficiency of pump set
(50.47.5 Hz) % .........................................
1.07.00 Suction specific speeds
1.07.01 Booster pump, indicating flow
at which same is considered US units .........................................
1.07.02 Main pump first stage indicating flow
at which same is considered US units .........................................
1.08.00 Maximum Boiler feed pump speed .........................................
1.08.01 Maximum design pump speed at
50 Hz/47.5 Hz rpm .........................................
1.08.02 NPSH required at the maximum
speed at 3% head break down
at 50 Hz/47.5 Hz, (m) M .........................................
1.08.03 Pump shut off head at maximum
speed (50 Hz/47.5 Hz), metre .........................................
NO.
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DA2(II)
STAGE-II (2X660 MW)
1.08.04 Pump TDH with minimum required M .........................................
recirculation flow and running at
maximum speed
1.09.00 Recirculation data
(i) Normal recirculation flow,
(for extended period) m
3
/hr .........................................
(ii) Onset recirculation flow m
3
/hr .........................................
(iii) Recirculation control valve
design flow m
3
/hr .........................................
(iv) Recirculation control valve
design pressure drop m
3
/hr .........................................
1.10.00 Thermal shock data
1.10.01 Is prewarming necessary in
case of cold start up Yes/No .........................................
1.10.02 Warm up flow, m
3
/hr (if required) .........................................
1.10.03 Maximum allowable step change
of inlet water temp. deg. C .........................................
1.11.00 Maximum axial thrust Kgs .........................................
1.12.00 Hydraulic coupling .........................................
1.12.01 Rated input speed, rpm .........................................
1.12.02 Corresponding output speeds
at the extreme positions of the
control element
a. Maximum rpm .........................................
b) Minimum rpm .........................................
1.12.03 Corresponding useful flow control
range of output speeds
a. Maximum rpm .........................................
b) Minimum rpm .........................................
NO.
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DA2(II)
STAGE-II (2X660 MW)
1.12.04 Maximum continuous output
torque kg-m .........................................
1.12.05 Rated output speed rpm .........................................
1.12.06 Circulation mechanicalc losses at
rated input and output speeds .........................................
1.12.07 Response time .........................................
a) Time taken by the control
element to move from
one extreme position
to other sec .........................................
1.12.08 Make/Model .........................................
1.12.09 Oil tank capacity m
3
.........................................
1.13.00 Boiler Feed Pump
1.13.01 Manufacturer .........................................
1.13.02 Model Number and No. of pumps .........................................
1.13.03 Casing outer type (Barrel, etc.) .........................................
1.13.04 No. of Stages ..........................................
1.13.05 Casing inner type (radially
split etc) .........................................
1.13.06 Casing design pressure, ata
and minimum wall thickness, mm .........................................
1.13.07 Pedestal and sole plates Type .........................................
1.13.08 Direction of rotation from drive end (CW/CCW) ..........................................
1.14.00 Suction connections:
1.14.01 Size/schedule .........................................
1.14.02 Location, top/bottom .........................................
1.15.00 Discharge Connection .........................................
1.15.01 ID/OD, (mm) .........................................
1.15.02 Location top/bottom .........................................
NO.
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DA2(II)
STAGE-II (2X660 MW)
1.16.00 Warm-up connections:
1.16.01 Size .........................................
1.16.02 Quantity and location .........................................
1.16.03 Warm-up flow, m
3
/hr. .........................................
1.17.00 Reheat Attemperator and super
heater attemperator connection
1.17.01 ID (or size/schedule) .........................................
1.17.02 OD (or size/schedule) .........................................
1.17.03 Weld end details .........................................
1.18.00 Balancing Device leak-off
connection .........................................
1.18.01 Type .........................................
1.18.02 Size - schedule .........................................
1.19.00 Developed head per stage at best
efficiency point. .........................................
1.20.00 First stage, meters .........................................
1.20.01 Succeeding stages, meters .........................................
1.21.00 Shaft
1.21.01 Total shaft length, mm .........................................
1.21.02 Shaft dia. at bearings (nom.), mm .........................................
1.21.03 Shaft dia at seals (nom) mm .........................................
1.21.04 Shaft dia. at impeller (nom.), mm .........................................
1.21.05 Shaft dia at balancing drum
(nominal) mm .........................................
1.21.06 Shrink fit at impellers microns .........................................
1.21.07 Shrink fit at balancing drum microns .........................................
1.21.08 Shaft static deflection (at rest) microns .........................................
NO.
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DA2(II)
STAGE-II (2X660 MW)
1.21.09 Shaft span between bearing centre mm .........................................
1.22.00 Bearings
1.22.01 L/D ratio at bearings (L=brg .........................................
length, D-shaft dia).
1.22.02 J ournal bearings - type .........................................
1.22.03 J ournal bearings - size .........................................
1.22.04 J ournal bearings length mm .........................................
1.22.05 J ournal bearings clearance microns .........................................
1.22.06 Thrust bearings - type .........................................
1.22.07 Thrust bearing size .........................................
1.23.00 % of axial thrust carried
by the thrust bearing % .........................................
1.24.00 At what loads is thrust
brg loaded? .........................................
1.25.00 Type of axial balancing device
(drum/opposed impeller) .........................................
1.26.00 Balancing device leak-off
flow m
3
/hr .........................................
1.27.00 Can balancing device handle
axial thrust at all loads and
conditions Yes/No .........................................
1.28.00 Method of indicating shaft axial
position (displacement) .........................................
1.29.00 Balancing device radial clearance, microns .........................................
1.30.00 Balancing designed with diffuser or
volute .........................................
1.31.00 Number of diffuser/volute blades
(tongues), First stage .........................................
1.32.00 Number of blades - Normal stages: .........................................
1.32.01 Diffuser/volute tongue ID First stage mm .........................................
NO.
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DA2(II)
STAGE-II (2X660 MW)
1.32.02 Tongue ID, Normal stages mm .........................................
1.32.03 Impeller OD, First stage mm .........................................
1.32.04 Impeller OD, Normal stages mm .........................................
1.32.05 Clearance between impeller
vane tip; and diff/volute tongue
First stage mm .........................................
1.32.06 Clearance between imp vane tip
and diff/vol tongue, Normal stages mm .........................................
1.32.07 Diam clearances at impeller wear
ring, first stage mm .........................................
1.32.08 Diam clearances at impeller wear
ring, Normal stage mm .........................................
1.33.00 First stage details (Bidder shall
necessarily fill up the following data) :
1.33.01 Type of first stage
1.33.03 Shaft diameter, through eye mm
1.33.05 Inlet angle Degrees
to average meridional velocity mm
1.33.07 Eye peripheral, velocity M/Sec.
1.33.08 Axial fluid velocity in eye M/Sec.
velocity
1.33.11 Width of impeller water way
at discharge mm
NO.
SECTION-VI
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PAGE
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DA2(II)
STAGE-II (2X660 MW)
1.33.13 Impeller eye area, First stage sq.mm .........................................
First stage .........................................
Normal stage .........................................
1.33.16 No. of impeller vanes, First stage .........................................
1.33.17 Number of impeller vanes,
Normal stages .........................................
1.34.00 Impeller vane mounting arrangement
between impeller (in line, staggered) .........................................
1.35.00 Rotor weight, kg .........................................
1.36.00 WR
2
of pump rotor kg-m
2
.........................................
1.37.01 First stage impeller polar moment
of inertia, Kg-m
2
.........................................
1.37.02 First stage impeller transverse
moment of inertia Kg-m
2
.........................................
1.37.03 Normal stage impeller polar
2
.........................................
1.37.04 Normal stage impeller transverse
2
.........................................
1.38.00 Location of centre of gravity of
the Rotor (Datum line at) mm .........................................
1.39.00 Permissible maximum unbalance
in any plane, gm-cm .........................................
1.40.00 Critical speeds: .........................................
1.40.01 First critical speed of rotor in water rpm .........................................
1.40.02 Second critical speed of rotor in
water rpm .........................................
1.40.03 First critical speed of rotor in air rpm .........................................
1.40.04 Second critical speed of rotor in air rpm .........................................
NO.
SECTION-VI
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DA2(II)
STAGE-II (2X660 MW)
1.41.00 Foundation: .........................................
1.41.01 Stiffness vertical Kg/mm .........................................
1.41.02 Stiffness horizontal kg/mm .........................................
1.42.00 Bearing Lubrication: .........................................
1.42.01 Type .........................................
1.42.02 Required flow per journal
bearing m
3
/hr .........................................
1.42.03 Required flow to thrust
bearing m
3
/hr .........................................
1.42.04 Bearing temp (recom/max) Deg. C .........................................
1.42.05 Oil pressure required
(min. /recom/max.) ata .........................................
1.43.00 Pump shaft at coupling: .........................................
1.43.01 Dia meter mm .........................................
1.43.02 Keyway size (if applicable) mm .........................................
1.43.03 Type of fit .........................................
1.43.04 Space between shafts mm .........................................
1.43.05 End float required mm .........................................
1.44.00 Drive shaft at coupling: .........................................
1.44.01 Diameter mm .........................................
1.44.02 Keyway size (if applicable) mm .........................................
1.44.03 Type of fit mm .........................................
1.45.00 Space envelope required to remove
rotating element, including laydown
space for casing or casing parts mm .........................................
1.46.00 Rotor removal cradle
(number required) .........................................
NO.
SECTION-VI
PART - G
PAGE
107 OF 149
DA2(II)
STAGE-II (2X660 MW)
1.47.00 Rotor handling device
(number required) .........................................
1.48.00 End covers for pump flushing, when
internals are removed (each pump) .........................................
1.49.00 Combined first and second critical
speed of the set rpm .........................................
1.50.00 Booster Pumps (Per Unit) .........................................
1.50.01 Manufacturer .........................................
1.50.02 Model number and No. of pumps .........................................
1.50.03 Casing Type .........................................
1.50.04 Casing design pressure ata .........................................
1.50.05 Casing minimum wall thickness mm .........................................
1.50.06 Pedestals and sole plates type .........................................
1.50.07 Suction connections: .........................................
a. Size/schedule .........................................
b. Weld end details .........................................
c. Location top/bottom .........................................
1.50.08 Discharge connections: .........................................
a. Size/schedule .........................................
b. Weld end details .........................................
c. Location top/bottom .........................................
1.50.09 Suction piping design condition ata/
pressure/temp. deg C .........................................
1.50.10 Discharge piping design condition ata/
pressure/temp. degC .........................................
1.50.11 Direction of rotation from driver
end CW or CCW .........................................
1.50.12 Shaft length mm .........................................
NO.
SECTION-VI
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DA2(II)
STAGE-II (2X660 MW)
1.50.13 Shaft diameters, at bearings, at
seals, at impeller mm, mm,mm ...........................................
1.50.14 Shrink fit impeller microns ..........................................
1.50.15 Shaft static deflection microns ..........................................
1.50.16 Shaft span between bearing
centres mm ..........................................
1.50.17 L/D ratio at bearings ..........................................
1.50.18 J ournal bearings (mm,dia) ..........................................
type size length mm
clearance microns
1.50.19 Thrust bearing type ..........................................
Size
Design Load Kg
1.50.20 Pump designed with diffuser or
volute ..........................................
1. Number of diffuser/volute blades ..........................................
2. Diffuser/volute tongue ID mm ..........................................
1.50.21 1. Impeller type ..........................................
2. Impeller OD mm ..........................................
1.50.22 1. Diametrical clearances at impeller
wearing ring mm ..........................................
2. Diametrical clearances at
impeller hub mm ..........................................
3. Impeller eye dia mm ..........................................
4. Impeller eye area mm
2
..........................................
5. Impeller/diffuser width ratio ..........................................
6. Number of impeller vanes ..........................................
1.50.23 Rotor weight, kg ..........................................
1.50.24 GD
-
of pump rotor kg-m
2
..........................................
NO.
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DA2(II)
STAGE-II (2X660 MW)
1.50.25. 1 Impeller polar moment
of inertia, Kg-m
2
..........................................
2 Impeller transverse
2
..........................................
1.50.26 Permissible maximum unbalance
of rotor gm-cm ..........................................
1.50.27 Critical speeds: ..........................................
1. First critical speed in
water rpm ..........................................
2. Second critical speed in
water rpm ..........................................
3. First critical speed in air rpm ..........................................
1.50.28 Foundation: ..........................................
1. Stiffness vertical Kg/mm ..........................................
2. Stiffness horizontal kg/mm ..........................................
1.50.29 Bearing Lubrication: ..........................................
1. Type ..........................................
2. Required flow per journal
bearing m
3
/hr ..........................................
3. Required flow to thrust
bearing m
3
/hr ..........................................
4. Bearing temp (recom/max) Deg. C ..........................................
5. Oil pressure required
(min. /recom/max.) ata ..........................................
1.50.30 Pump shaft at coupling: ..........................................
1. Diameter mm ..........................................
2. Keyway size (if applicable) mm ..........................................
3. Type of fit ..........................................
NO.
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DA2(II)
STAGE-II (2X660 MW)
4. Space between shafts mm ..........................................
5. End float required mm ..........................................
1.50.31 Drive shaft at coupling: ..........................................
1. Diameter mm ..........................................
2. Keyway size (if applicable) mm ..........................................
3. Type of fit ..........................................
1.50.32 Recommended hole size of suction
strainer ..........................................
1. For start-up ..........................................
2. Permanent, if desired by Employer ..........................................
1.51.00 Type of seals (Booster pump/
main pump) ..........................................
1. Model/make ..........................................
2. Material of rotating /stationary faces ..........................................
3. P. V. factor ..........................................
NO.
SECTION-VI
PART - G
PAGE
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DA2(II)
STAGE-II (2X660 MW)
PART-5
AUXILIARY TURBINE DRIVE
1.00.00 Auxiliary Drive Turbine (Per Unit):
A General
1. Manufacturer & Model No. .......................................
2. Numbers offered .........................................
3. Type of Turbine .........................................
4. No. of stages .........................................
5. Casing (split/barrel) .........................................
6. Steam admission (Single/Dual) .........................................
7. Direction of rotation viewed
from steam admission end .........................................
8. Location .........................................
9. Provided with output shafts
at both ends, Yes/No .........................................
10. Rotor (Solid / Built up) .........................................
11. Maximum noise level dBA .........................................
B Conditions: Design b.e.p. Start-
up
1. Steam Source ........... .......... ............
2. Steam conditions at inlet
pressure ata ........... .......... ............
Temperature deg C ........... .......... ............
Enthaply Kcal/Kg ........... .......... ............
3. Turbine operating speed rpm ........... .......... ............
4. Shaft power kw ........... .......... ............
NO.
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DA2(II)
STAGE-II (2X660 MW)
5. Steam consumption kg/hr ........... .......... ............
6. Steam conditions at exhaust:
pressure ata ........... .......... ............
Dryness fraction ........... .......... ............
Enthalpy Kcal/Kg ........... .......... ............
7. Throttle Steam flow for
exhaust pressure of
0.1 ata kg/hr ........... .......... ............
0.13 ata kg/hr ........... .......... ............
0.15 ata kg/hr ........... .......... ............
8. Corresponding enthalpies at
0.1 ata K cal/kg ........... .......... ............
0.13 ata KCal/kg ........... .......... ............
0.15 ata Kcal/kg ........... .......... ............
9. Corresponding dryness
fraction at:
0.1 ata ........... .......... ............
0.13 ata ........... .......... ............
0.15 ata ........... .......... ............
10. Is drive turbine designed
for full arc admission
during start up? ........... .......... ............
11. Is spray water required at low
load operation? ........... .......... ............
12. Critical Speeds rpm ........... .......... ............
First ........... .......... ............
Second ........... .......... ............
NO.
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DA2(II)
STAGE-II (2X660 MW)
13. Turning gear speed rpm ........... .......... ............
C Governing System:
1. Type .........................................
2. Is back-up governor
provided? Yes/No .........................................
3. Mode .........................................
4. Dead band of governor .........................................
5. Percentage regulation and .........................................
range of adjustability
6. Method of Sensing speed .........................................
7. Time delay between speed signal
and governor valve initiation: .........................................
a) For opening through
full travel sec .......................................
b) For closing through
full travel sec .........................................
8. On load Throw off
a) Temporary Speed rise % .........................................
b) Permanent speed rise % .........................................
c) Time taken to reach steady
state sec ..........................................
d) Overall response time of
the governor from moment
of full load throw off to
moment of full closing of
governor valves millisec. ..........................................
9. Local manual speed control
range .........................................
10. Remote speed control range .........................................
NO.
SECTION-VI
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DA2(II)
STAGE-II (2X660 MW)
11. Over speed trip
a) Type ..........................................
b) Number .........................................
c) Method of varying trip speed .........................................
D Bearings:
1. Radial
a) Type .........................................
b) Area mm
2
.........................................
2. Thrust
a) Type .........................................
b) Area mm
2
.........................................
c) Max load kg .........................................
d) Thrust capacity kg .........................................
E. Packing type :
1. Interstage gland seals .........................................
2. End gland seals .........................................
F. Connection:
1. Extraction steam inlet .........................................
2. Alternate steam inlet .........................................
3. Exhaust .........................................
G. Gland Sealing steam:
1. Normal quantity kg/hr .........................................
2. Maximum quantity kg/hr ..........................................
NO.
SECTION-VI
PART - G
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DA2(II)
STAGE-II (2X660 MW)
H. Steam Strainers for gland sealing:
1. Type .........................................
2. Pressure drop ata .........................................
I. Inlet Section :
1. Number of governor controlled
Steam admission valves:
a. For normal supply .........................................
b. For alternate supply .........................................
2. First stage mean diameter mm .........................................
3. First stage blade height mm .........................................
4. First stage nozzle area mm
2
.........................................
a. For normal supply .........................................
b. For alternate supply .........................................
J . Exhaust Section:
1. Flow (Single/Double) .........................................
2. Length of last stage blades mm .........................................
3. Tip diameter of last Stage
wheel mm ..........................................
4. Annulus area of last stage m
2
.........................................
5. No. of openings ..........................................
6. Type of joint ..........................................
K. Valves:
1. Stop valves design pressure ata .........................................
2. Control valves design pressure ata .........................................
3. Stop valves design temperature deg C .........................................
4. Control valves design temperature deg C .........................................
NO.
SECTION-VI
PART - G
PAGE
116 OF 149
DA2(II)
STAGE-II (2X660 MW)
2.00.00 Couplings (Per Unit)
1. Between Turbine and Main Pump:
1.1 Type .........................................
1.2 Make .........................................
1.3 Model No. and number offered .........................................
1.4 Rating and end play limit mm .........................................
2. Between Motor and Gear box /
Hydraulic Coupling:
2.1 Type and size .........................................
2.2 Make .........................................
3. Between Gear box / Hydraulic Coupling
and Boiler Feed Pumps:
3.1 Type and size .........................................
3.2 Make .........................................
4. Between Turbine Driven Booster
Pump and Gear box :
4.1 Type and size .........................................
4.2 Make .........................................
NO.
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5. Between Turbine and Booster
Pump Gear box
5.1 Type and size .........................................
5.2 Make .........................................
6. Between Motor Driven Pump
Shaft and Booster Pump:
6.1 Type and size .........................................
6.2 Make .........................................
7. Between Vertical Motor and Condensate
pump:
7.1 Type and size .........................................
7.2 Make .........................................
3.00.00 Lubrication System for feed Pump Sets
(Per Unit) :
1. Main Oil Pump
1.1 Manufacturer ............... ........................
1.2 Type ............... ........................
1.3 Model number and number offered ............... ........................
1.4 Pump drive ............... ........................
1.5 Rated capacity m
3
/hr ............... ........................
NO.
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1.6 Rated head ata ............... ........................
1.7 NPSH required meters ............... ........................
2. Auxiliary Oil Pump :
2.1 Manufacturer ............... ........................
2.2 Type ............... ........................
2.4 Pump drive ............... ........................
3
/hr ............... ........................
2.6 Rated head ata ............... ........................
3. Emergency Oil Pump :
3.1 Manufacturer ............... ........................
3.2 Type ............... ........................
3.4 Pump drive ............... ........................
3
/hr ............... ........................
3.6 Rated head ata ............... ........................
4. J acking Oil Pump (For turbine driven
units), if required.
4.1 Manufacturer ............... ........................
4.2 Type ............... ........................
4.4 Pump drive ............... ........................
4.5 Rated capacity, m3/hr ............... ........................
NO.
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DA2(II)
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4.6 Rated head, ata ............... ........................
4.7 NPSH required, meters ............... ........................
5. Lube Oil Coolers :
5.1 Manufacturer ............... ........................
5.2 Type ............... ........................
5.3 Model Number ............... ........................
5.4 Number of oil coolers for each unit ............... ........................
5.5 Rating data for each cooler: ............... ........................
- Heat load KCal/hr ............... ........................
- Oil flow rate m
3
/hr ............... ........................
- Water flow rate m
3
/hr ............... ........................
- Oil side pressure drop ata ............... ........................
- Inlet oil temperature
0
C ............... ........................
- Outlet oil temperature
0
C ............... ........................
- Maximum permissible water side
pressure ata ............... ........................
- Surface area m ............... ........................
5.6 Fouling factors used for design
i) Oil side ............... ........................
ii) Water side ............... ........................
5.7 Nozzle sizes, rating and drilling
standards:
- Oil inlet ............... ........................
- Oil outlet ............... ........................
- Water inlet ............... ........................
- Water outlet ............... ........................
NO.
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DA2(II)
STAGE-II (2X660 MW)
5.8 Construction :
- TEMA Class ............... ........................
- Tube OD and wall thickness ............... ........................
5.9 Bidder to indicate data as above for
working oil coolers also ............... ........................
6. Lube oil reservoirs :
6.1 Number per unit ............... ........................
6.2 Type ............... ........................
6.3 Net capacity m ............... ........................
6.4 Overall dimensions ............... ........................
6.5 Method of supporting ............... ........................
7. Lube Oil :
7.1 Type ............... ........................
7.2 Specification ............... ........................
7.3 Quantity required for one
complete filling of one unit m ............... ........................
8. Oil Purification System for
turbine driven Unit :
(A) Centrifuge :
8.1 Type of bowl ............... ........................
8.2 Operating speed rpm ............... ........................
3
/hr ............... ........................
8.4 Make ............... ........................
8.5 Model No. and Number offered ............... ........................
NO.
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DA2(II)
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8.6 Oil heater : ............... ........................
1. Type ............... ........................
2. Rating KW ............... ........................
8.7 Dirty and clean oil pumps :
1. Number per unit ............... ........................
2. Method of drive ............... ........................
3. Type and Make ............... ........................
4. Rated capacity m3/hr ............... ........................
5. Rated head ata ............... ........................
8.8 Oil polishing filter ............... ........................
8.9 Type and Make ............... ........................
8.10 Rated capacity m3/hr ............... ........................
8.11 Differential for normal and alarm
set point ata ............... ........................
8.12 Particulate matter removal
efficiency (centrifuge/filter) ............... ........................
4.00.00 Strainer for boiler feed pumps
(per unit) Temporary Permanent
(if provided)
1. Type ............... ........................
2. Quality ............... ........................
3. Manufacturer ............... ........................
4. Strainer element ............... ........................
a) Nominal size mm ............... ........................
b) Connecting pipe size mm
ODXmm thk ............... ........................
c) Thickness of sheet mm ............... ........................
d) Perforation mm ............... ........................
NO.
SECTION-VI
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DA2(II)
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e) Screen wire size (gauge) ............... ........................
& screen mesh size (gauge)
f) Material of sheet ............... ........................
g) Material of screen wire ............... ........................
h) Total open area of screen
assembly sq.m ............... ........................
i) Ring OD mm ............... ........................
j) Ring thickness mm ............... ........................
k) Total length of strainer assembly, mm ............... ........................
l) Total end connection details ............... ........................
5. Strainer end connection details ............... ........................
6. Hydrostatic pressure and duration of
test for strianers ............... ........................
7. Guaranteed pressure drop at 100%
clean condition & design flow mlc ............... ........................
8. Pressure drop at 50% clogged
condition & design flow mlc ............... ........................
9. Max. differential pressure across
strainer without repture or damage kgf/cm2 ............... ........................
10. Max. particle size possible mm ............... ........................
5.00.00 Strainer for booster pumps (Per Unit)
1. Type ............... ........................
2. Quantity ............... ........................
3. Manufacturer ............... ........................
a) Nominal size mm ............... ........................
ODXmm thk ............... ........................
NO.
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d) Perforation mm ............... ........................
assembly sq.m ............... ........................
i) Ring OD mm ............... ........................
k) Total length of strainer assembly mm ............... ........................
l) Total weight of strainer kg ............... ........................
10. Max. particle size possible mm ................ ........................
6.00.00 Strainer for condensate extraction pumps
1. Type ............... ........................
2. Quantity ............... ........................
3. Manufacturer ............... ........................
a) Nominal size mm ............... ........................
NO.
SECTION-VI
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STAGE-II (2X660 MW)
ODXmm thk ............... ........................
d) Perforation mm ............... ........................
assembly sq.m ............... ........................
i) Ring OD mm ............... ........................
k) Total length of strainer assembly mm ............... ........................
l) Total weight of strainer kg ............... ........................
10. Max. particle size possible mm ............... .....................
7.00.00 Weight kgs
1.0 Turbine driven Boiler Feed Pump ............... ........................
1.1 Per main pump ................. ........................
1. Assembly ................. ........................
NO.
SECTION-VI
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DA2(II)
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2. Casing ................. .......................
3. Rotor (all rotating parts, without
coupling half) ................. ........................
4. Shaft ................. ........................
5. Impeller first stage ................. ........................
6. Impeller normal stage ................. ........................
7. Balancing drum (rotating part only) ................. ........................
8. Inner assembly ................. ........................
1.2 Booster Pump ................. ........................
1. Assembly ................. ........................
2. Casing ................. ........................
a) Removable part ................. ........................
b) Fixed part ................. ........................
3. Rotor (all rotating parts, without
half coupling) ................. ........................
4. Impeller ................. ........................
1.3 Gear Box assembly for Booster pump ................. ........................
1.4 Drive Turbine assembly ................. ........................
1.5 Lube Oil Unit ................. ........................
1.6 Total shipping weight ................. ........................
1.7 Maximum weights ................. ........................
a) Main pump ................. ........................
b) Booster pump ................. ........................
c) Gear Box ................. ........................
d) Drive turbine ................. ........................
e) Others ................. ........................
NO.
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DA2(II)
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2. Motor-driven Boiler Feed Pump ................. ........................
1.1 Per Main-pump ................. ........................
1. Assembly ................. ........................
2. Casing ................. .......................
3. Rotor (all rotating parts,
without coupling half) ................. .......................
. 4. Shaft ................. ........................
5. Impeller first stage ................. ........................
6. Impeller normal stage ................. ........................
7. Balancing drum
(rotating part only) ................. ........................
8. Hydraulic coupling assembly ................. ........................
including accessories
1.2 Hydraulic coupling assembly
including accessories ................. ........................
1.3 Drive Motor ................. ........................
a) Assembly ................. ........................
b) Rotor ................. ........................
1.5 Maximum weights ................. ........................
a) Feed Pump ................. ........................
b) Drive motor ................. ........................
c) Gearbox/Hydraulic coupling ................. ........................
d) Others ................. ........................
3. Condensate Pump ................. .......................
3.1 Per pump assembly ................. ........................
3.2 Rotating elements of pump ................. ........................
NO.
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3.3 Suction barrel or can ................. ........................
3.4 Impellers ................. ........................
a) First stage ................. ........................
b) Normal stage ................. .....................
3.5 Bowl assembly ................. ........................
3.6 Discharge head ................. ........................
3.7 Drive motor ................. ........................
a) Assembly ................. ........................
b) Rotor only ................. ........................
3.8 Maximum weights to be handled ................. ........................
a) During erection ................. ........................
b) During maintenance ................. ........................
8.00.00 Materials of construction
Indicate ASTM designations whenever
possible Otherwise furnish details like
applicable standards, casting/forging,
chemical composition, etc. ................. ........................
8.01.00 Boiler Feed Pumps :
1. Outer casing ................. ........................
2. Discharge head (barrel and head) ................. ........................
3. Inner casing ................. ........................
4. Diffusers or volutes ................. ........................
5. Casing wear rings ................. ........................
6. Impellers (First Stage/other stages) ................. ........................
7. Impellers wear rings ................. ........................
8. Pump shaft ................. ........................
NO.
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DA2(II)
STAGE-II (2X660 MW)
9. Shaft sleeves ................. ........................
10. Balancing drum ................. ........................
- Rotating part ............... ........................
- Stationary part ............... ........................
11. Internal gaskets ................. ........................
12. Interstage packing, if applicable ................. ........................
13. Casing bolts, studs, nuts
(for outer casing) ................. ........................
14. Pump suction nozzle ................. ........................
15. Pump discharge nozzle ................. ........................
16. Overlay on casing at high velocity zones ................. ........................
8.02.00 Booster Pumps :
1. Casing ................. ........................
2. Impeller ................. ........................
3. Casing wear rings ................. ........................
4 . Impeller wear rings ................. ........................
5. Shaft ................. ........................
6. Shaft sleeves ................. ........................
Note: Indicated materials used for various
components covered under clause no.
8.01.00 and 8.02.00 above for two
separate stations for rate parameters
8.03.00 Condensate Pumps :
1. Top Case ................. .....................
2. Discharge head ................. ........................
3. Suction barrel/can ................. ........................
4. First stage impeller ................. ........................
NO.
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DA2(II)
STAGE-II (2X660 MW)
5. Other Impellers ................. ........................
6. Impeller wear rings ................. ........................
7. Suction bell and bowls ................. ........................
8. Sleeves bearings ................. ........................
9. Shaft ................. ........................
10. Packing ................. ........................
11. Glands ................. ........................
12. Gaskets ................. ........................
13. Shaft sleeve ................. ........................
14. Bowl bolts and other internal fasteners ................. ........................
8.04.00 Auxiliary Drive Turbine
1. High pressure casing ................. ........................
2. Exhaust casing ............... ........................
3. Low pressure steam chest ............... ........................
4. Low pressure nozzles ............... ........................
5. High pressure steam chest ............... ........................
6. High pressure nozzles ............... ........................
7. Blades ............... ........................
8. Shrouds ............... ........................
9. Wheel ............... ........................
10. Shaft ............... ........................
11. Shaft material under seals ............... ........................
12. Low pressure governor valve ............... ........................
13. High pressure governor valve ............... ........................
NO.
SECTION-VI
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STAGE-II (2X660 MW)
8.05.00 Gear Box (for turbine driven Booster)
1. Gear Box ............... ........................
2. Oil seals ................. ........................
3. High speed shaft ................. ........................
4. Low speed shaft ................. ........................
5. Pinion, material and hardness ................. ........................
6. Gear, material and hardness ................. ........................
7. Tooth plating, if any ................. ........................
8.06.00 Hydraulic coupling
1. Housing ................. ........................
2. Inner casing ................. ........................
3. Outer casing ................. ........................
4. Rotor (impeller and runner) ................. ........................
5. Shaft ................. ........................
6. Gears ................. ........................
8.07.00 Lube Oil System Components
1. Main Oil Pump ................. ........................
1.1 Casting ................. ........................
1.2 Impeller/rotor ................. ........................
1.3 Trim ................. ........................
2. Auxiliary Oil Pump ................. ........................
2.1 Casting ................. ........................
2.2 Impeller/rotor ................. ........................
2.3 Trim ................. ........................
NO.
SECTION-VI
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DA2(II)
STAGE-II (2X660 MW)
3. Emergency Oil Pump ................. ........................
3.1 Casting ................. ........................
3.2 Impeller/rotor ................. ........................
3.3 Trim ................. ........................
4. J acking Oil Pump (if required) ................. ........................
4.1 Casting ................. ........................
4.2 Impeller/rotor ................. ........................
4.3 Trim ................. ........................
5. Lube Oil Coolers ................. ........................
5.1 Shell ................. ........................
5.2 Tube ................. ........................
5.3 Tube sheet ................. ........................
5.4 Water Box ................. ........................
5.5 Support plates ................. ........................
6. Centrifugal bowl ................. ........................
7. Oil reservoir ................. ........................
8. Working Oil Coolers(for Hydraulic
Coupling)
8.1 Shell ................. ........................
8.2 Tube ................. ........................
8.3 Tube sheet ................. ........................
8.4 Water Box ................. ........................
8.5 Support plates ................. ....................
NO.
SECTION-VI
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DA2(II)
STAGE-II (2X660 MW)
8.08.00 Mechanical seals
1. Seal faces, stationary/rotating ................. ..................
2. Mechanical seal cooler shell ................. ..................
3. Mechanical seal cooler shell ................. ..................
NO.
SECTION-VI
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DA2(II)
STAGE-II (2X660 MW)
PART - 6
TURBINE HALL E.O.T. CRANES
1.00.00 Technical Particulars
i) Name of the manufacturer .........................................
ii) Type and class of crane .........................................
iii) Guaranteed lifting capacity of
the main hook tonnes .........................................
iv) Guaranteed maximum lifting
capacity of the auxiliary hook
tonnes .........................................
v) Guaranteed maximum lift of
the main hook metres .........................................
vi) Guaranteed maximum lift of
auxiliary hook metres .........................................
vii) Maximum speed at full load: .........................................
a) Main hoist metres/min .........................................
b) Auxiliary hoist meters/min .........................................
c) Trolley cross travel metres/min .........................................
d) Bridge travel metres/min .........................................
e) Creep speed of main hoist metres/min .........................................
f) Creep speed of auxiliary metres/min .........................................
hoist
viii) Crane bridge .........................................
a) Type .........................................
b) Method of fabrication .........................................
ix) Trucks .........................................
1. Number of trucks .........................................
2. Number of wheels per truck .........................................
NO.
SECTION-VI
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DA2(II)
STAGE-II (2X660 MW)
3. Centre to centre distance of
wheels of end carriage mm .........................................
a) Inner wheels .........................................
x) Trolley : .........................................
a) Method of fabrication .........................................
b) Centre to centre distance of
transverse wheels mm .........................................
xi) Wheels Truck Trolley
a) Type ............... ......................
b) Diameter mm ............... ......................
c) Material ............... ......................
d) Type of bearings ............... ......................
xii) Motor particulars for Size (KW) Speed
(rpm)
a) Main hoist ............... ......................
b) Auxiliary hoist ............... ......................
c) Trucks ............... ......................
d) Trolley ............... ......................
xiii) Type of brakes for
Hoists ............... ......................
Trucks ............... ......................
Trolley ............... ......................
xiv) Hoisting rope Main Auxiliary
Construction ............... ......................
Steel quality ............... ......................
Diameter mm ............... ......................
NO.
SECTION-VI
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DA2(II)
STAGE-II (2X660 MW)
Number of falls ............... ......................
Minimum breaking load (kg/cm
2
) ............... ......................
Factory of safety ............... ......................
xv) Crane hooks ............... ......................
a) Type ............... ......................
b) Size ............... ......................
c) Material ............... ......................
xvi) Controllers for motors
a) Type ............... ......................
b) Manufacturer ............... ......................
xvii) Limit Switches Hoist Bridges &
Trolley
a) Manufacturer ............... ......................
b) Type ............... ......................
c) Current Carrying capacity amps ............... ......................
xviii) Conductors: Cross Main
runway
a) Type ............... ......................
b) Size ............... ......................
c) Current rating amps ............... ......................
d) Voltage ............... ......................
xix) Type of collectors: ........................................
a) Main collectors ..........................................
b) Trolley collectors ..........................................
xx) Cables / wires .......................................
a) Rated voltage V .......................................
NO.
SECTION-VI
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DA2(II)
STAGE-II (2X660 MW)
b) Rated current amps .......................................
c) Type of insulation .......................................
d) Short-time current rating (amps) .......................................
e) Resistance per 1000 metres
(ohms) .......................................
f) Applicable standard .......................................
xxi) Dynamic wheel loading: .......................................
a) Impact vertical tonnes .......................................
b) Acceleration metres/sec
2
.......................................
c) Deceleration metres/sec
2
.......................................
d) Impact Horizontal Tonnes .......................................
xxii) Static wheel loadings: .......................................
a) Minimum tonnes/axle .......................................
b) maximum tonnes/axle .......................................
xxiii) Rope drums Main Auxiliary
Hoist Hoist
a) Diameter mm .............. ....................
b) Thickness of the drum at the
bottom of the grooves mm ............... ....................
c) Depth of grooves mm ............... ....................
d) Pitch of rope grooves mm ............... ....................
xxiv) Diameter of sheaves .......................................
a) Main hoist mm .......................................
b) Auxiliary hoist mm .......................................
xxvi) Runway rail .......................................
a) Weight per metre kg .......................................
b) Section .......................................
NO.
SECTION-VI
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STAGE-II (2X660 MW)
xxvii) Type and rating of VVVF drive
a) MH .......................................
b) AH .......................................
c) CT .......................................
d) LT .......................................
xxviii) Voltage control range of drive for
a) MH .......................................
b) AH .......................................
c) CT .......................................
d) LT .......................................
xxix) Accuracy of drive output for
a) MH .......................................
b) AH .......................................
c) CT .......................................
d) LT .......................................
xxx) Drive voltage (V) & current (A)
rating for
a) MH .......................................
b) AH .......................................
c) CT .......................................
d) LT .......................................
(xxxi) Type & model of Radio Remote control .......................................
(xxxii) Frequency of Radio Remote control .......................................
NO.
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DA2(II)
STAGE-II (2X660 MW)
xxxiii) Minimum working clearance .......................................
required as per clearance
diagram No. for dimensions.
a) L mm .......................................
b) M mm .......................................
c) V mm .......................................
d) W mm .......................................
xxxiv) Nett weight of crane bridge tonnes .......................................
xxxv) Nett weight of trolley Tonnes .......................................
xxxvi) Nett weight of complete crane Tonnes .......................................
NO.
SECTION-VI
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DA2(II)
STAGE-II (2X660 MW)
PART- 7
OTHER EQUIPMENT/DEVICES
State if the following are included
in the scope and furnish details for
each
1.00.00 Piping with valves, hangers, insul-
ation, fittings, specialities etc. &
instrumentation for the following
systems.
1.01.00 Lube oil system for turbine generator
unit and its accessories including
emergency oil supply system to air
side of generator seal oil system
and control lube oil system Yes/No. .......................................
1.02.00 Turbine gland steam sealing system Yes/No. .......................................
1.03.00 Turbine control fluid system Yes/No. .......................................
1.04.00 Main steam and hot reheat lines
portion between strainers and turbine Yes/No. .......................................
1.05.00 Extraction lines in condenser neck Yes/No. .......................................
1.06.00 Exhaust hood spray & flash tanks
desuperheating Yes/No. .......................................
1.07.00 Turbine and integral system drains Yes/No. .......................................
1.08.00 CW system between butterfly
valves and condenser water-box Yes/No. .......................................
1.09.00 Air extraction lines for condenser
air evacuation and water box priming Yes/No. .......................................
1.10.00 Generator seal oil system, hydrogen
& CO
2
systems and stator water
system Yes/No. .......................................
1.11.00 Auxiliary cooling water system for
TG coolers Yes/No .......................................
1.12.00 Instrument and service air system Yes/No. .......................................
1.13.00 Wet steam washing system Yes/No. .......................................
NO.
SECTION-VI
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DA2(II)
STAGE-II (2X660 MW)
1.14.00 Reheater entrapped steam
releasing system Yes/No. .......................................
1.15.00 Corrosion protection system
for TG under long shut down Yes/No. .......................................
2.00.00 Pressure relief diaphragms as
required in LP exhaust hood Yes/No. .......................................
3.00.00 Bolt heating equipment with
control Yes/No. .......................................
4.00.00 Turbine flange heating system
if required Yes/No. .......................................
5.00.00 Hand barring device Yes/No. .......................................
6.00.00 Base plates/sole plates fixtures,
embedments, inserts etc. as
required Yes/No. .......................................
7.00.00 Foundation bolts as required Yes/No. .......................................
8.00.00 Blanking arrangement for steam
blowing Yes/No. .......................................
9.00.00 Condenser waterbox handling
arrangement Yes/No. .......................................
10.00.00 First fill and one year topping
requirements of lubricants,
and other consumable Yes/No. .......................................
11.00.00 Temperature detectors for
heat exchangers, stator
winding, stator core, bearings etc. Yes/No. .......................................
NO.
SECTION-VI
PART - G
PAGE
141 OF 149
DA2(II)
STAGE-II (2X660 MW)
PART - 8
CODES AND STANDARDS
1.01.00 Material specification for major
components of turbine, gener-
ator and condenser (Furnish a
list .......................................
1.02.00 Design and construction code
for turbine, generator and con-
denser .......................................
1.03.00 Governor performance charac-
teristics .......................................
1.04.00 Fluctuations / limitations of
variations of pressure / tempe-
rature at turbine throttle and
reheat inlet steam temperature .......................................
1.05.00 Specification for turbine lubric-
ating oil .......................................
1.06.00 Specification for turbine
control fluid .......................................
1.07.00 Design, manufacturing & testing
code for condenser .......................................
code for vacuum pumps .......................................
code for non-return valves on
extraction & CRH lines .......................................
code for heat exchangers (other
than condenser) .......................................
code for CW butterfly valves .......................................
code for CW expansion joints .......................................
code for HP-LP bypass valves .......................................
NO.
SECTION-VI
PART - G
PAGE
142 OF 149
DA2(II)
STAGE-II (2X660 MW)
1.14.00 English translation of all codes &
standards followed by Bidder. .......................................
1.15.00 Information to justify the superiority
of stds followed by Bidder in case
of those varying from specified
standards .......................................
1.16.00 Specific variations and deviations
from specified standards (if
applicable) .......................................
NO.
SECTION-VI
PART - G
PAGE
143 OF 149
DA2(II)
STAGE-II (2X660 MW)
PART - 9
START- UP & LOADING DATA
1.00.00 LOADING RATES
1.01.00 Load pick-up rates from 30%
MCR to 50% MCR after Constant Variable
Pressure Pressure
1.01.01 4 hours of shutdown MW/min ................ ....................
1.01.06 Absolute cold condition MW/min ................ ....................
MCR to 80% MCR after Constant Variable
pressure Pressure
MCR to full rated load after Constant Variable
Pressure Pressure
NO.
SECTION-VI
PART - G
PAGE
144 OF 149
DA2(II)
STAGE-II (2X660 MW)
1.04.00 Time required to bring the
unit on the line after Constant Variable
Pressure Pressure
1.04.01 4 hours of shutdown min ................ ....................
1.04.06 Absolute cold condition min ................ ....................
1.05.00 Time required to bring the
unit upto 30% load form Constant Variable
synchronisation after Pressure Pressure
1.05.06 Absolute cold condition min ................ ....................
1.06.00 Conditions, if any, limiting
the time intervals in items
1.04.00 & 1.05.00 above ................ ....................
2.00.00 Total number of starts for
which the TG set is Constant Variable
designed over 30 years Pressure Pressure
2.01.01 Start after 4 hours of shutdown ................ ....................
NO.
SECTION-VI
PART - G
PAGE
145 OF 149
DA2(II)
STAGE-II (2X660 MW)
2.01.06 Absolute cold start ups ................ ....................
3.00.00 Furnish Life Expenditure Curves for
the various conditions of start-up
indication cl. 2.00.00 above and
cyclic load variations under both
constant pressure and variable
pressure mode of operation ................ ....................
4.00.00 Furnish start-up curves for various
conditions under both constant
pressure and variable pressure mode
of operation. For variable pressure
operation, the throttling reserve shall
be adjustable in steps & upto a
maximum of 20% ................ ....................
NO.
SECTION-VI
PART - G
PAGE
146 OF 149
DA2(II)
STAGE-II (2X660 MW)
PART 10
AVAILABILITY DATA
1.00.00 Availability data shall be furnished
by the Bidder for the TG set offered
to justify provenness of the set. This
data or any additional data which the
Bidder desires to submit shall atleast
be for two different stations belonging
to different customers. The Bidder
shall furnish adequate supporting
documents in proof of the source of
data as originating from the reference
customers.
1.01.00 Availability Hrs/year ..........................................
1.02.00 Maintenance outage rate Hrs/year ..........................................
1.03.00 Forced outage rate Hrs/year ..........................................
1.04.00 Causes of outage Hrs/year
..........................................
..........................................
..........................................
1.05.00 Remedial measures adopted
..........................................
..........................................
..........................................
NO.
SECTION-VI
PART - G
PAGE
147 OF 149
DA2(II)
STAGE-II (2X660 MW)
PART - 11
WEIGHTS AND DIMENSIONS
1.00.00 WEIGHTS
1.02.00 Weight and name of the heaviest piece
to be handled during erection Tonnes ..........................................
1.02.01 Weight and name of the heaviest piece Tonnes ..........................................
to be handled during erection by turbine
hall EOT crane
1.02.02 Weight and name of the heaviest
piece to be handled by the station
EOT crane after erection Tonnes ..........................................
2.00.00 DIMENSIONS
2.01.00 Over all length of turbine from the
front standard to the turbine coupling m ..........................................
2.02.00 width at widest point m ..........................................
2.03.00 Width at operating floor line m ..........................................
2.04.00 Height of turbine shaft centre lint
above the operating floor m ..........................................
2.05.00 Minimum height required for removal
of the turbine shaft, with slings provided
for this purpose, measured from the
pedestal floor to the throat of the lifting
hook m .........................................
2.06.00 Minimum height required for removal
of the turbine casing, with slings
provided for this purpose, measured
from the pedestal floor to the throat of
the lifting hook. m ..........................................
2.07.00 Minimum height requirement, greater
than that for items 2.05.00 & 2.06.00
above, for lifting any other part of the
turbine and name of the part (Identify) m ..........................................
2.08.00 Maximum distance, that the top of the
than that oil tank may be placed, below
the top of the pedestal m ..........................................
NO.
SECTION-VI
PART - G
PAGE
148 OF 149
DA2(II)
STAGE-II (2X660 MW)
2.09.00 Floor dimensions required for setting
down the largest part of the turbine
during overhaul m x m ..........................................
2.10.00 Suggest dimensions of a rectangle
inside which all parts of the turbine
may be placed during a complete
overhaul m x m ..........................................
2.11.00 Shipping dimensions
2.11.01 Turbine (Component wise attach a
separate sheet) m x m x m ..........................................
2.11.02 Lube oil coolers m x m x m ..........................................
2.11.03 Gland steam coolers m x m x m ..........................................
3.00.00 HANDLING ARRANGEMENT
Proposed arrangement for handling
of the following major items during
erection and during maintenance and
their weights:
(Furnish detailed write-up, drawings
and other technical data)
Sl. No. Components Weight Handling arrangement
During During maintenance erection
1.0 HP cylinder assembled
2.0 IP cylinder assembled
3.0 LP bladed rotor
4.0 HP bladed rotor
5.0 IP bladed rotor
6.0 LP casing
7.0 Generator stator
assembly
8.0 Generator rotor
assembly
9.0 Condenser
NO.
SECTION-VI
PART - G
PAGE
149 OF 149
DA2(II)
STAGE-II (2X660 MW)
10. Condensate extraction
pumps
11. LP heater no.1
12. LP heater no.2
13. LP heater no.3
14. Gland steam condenser
15. Deaerator
16. Boiler feed pumps
17. BFP Booster pumps
18. HP heater no.5A & B
19. HP heater no. 6A & B
20 HP heater no. 7A & B
21. Any others
4.00.00 ANY OTHER DATA
SECTION-VI
PART - G
STAGE-II (2X660 MW)
CHAPTER-III
INSTRUCTIONS
NO.
SECTION-VI
PART - G
PAGE
1 OF 4
DA2(III)
STAGE-II (2X660 MW)
SUB-SECTION - DA2 (III)
INSTRUCTIONS
The Employer's requirements of data and drawings from the successful Bidder in respect
of the equipment covered under this portion of the Package are broadly indicated in this
part of the specification. These data/drawings shall be submitted by the successful Bidder
in 12 (twelve) copies to the Employer during the period commencing from the fourth week
and ending at the twelfth week from the date of Notice of Award of Contract. In the case
of drawings, a polyester reproducible and one (1) micro film of each drawing shall also
be submitted by the successful Bidder to the Employer. Schedule of submission of these
and any other data/drawings not specifically included herein but required for project
engineering shall be furnished alongwith the bid proposal. The actual schedule of these
data/drawing requirements shall be mutually discussed and agreed to between the
Employer and the successful Bidder before the issue of notice of Award of Contract. The
successful Bidder shall also furnish to the Employer any addition data/drawing identified by
the Employer during post award engineering. Such requirements shall be met by the
successful Bidder within the time identified by the Employer so as to meet the overall
project schedule.
NO.
SECTION-VI
PART - G
PAGE
2 OF 4
DA2(III)
STAGE-II (2X660 MW)
GENERAL
1.00.00 CONTRACT DRAWINGS
1.01.00 Steam Turbine and Auxiliaries
1.01.01 Final TG Foundation drg. indicating the total embedment requirements.
1.01.02 Drawing indicating the final loading data and fixing details of the equipment.
1.01.03 Cross sectional arrangement/drawings.
1.01.04 Campbell diagrams showing the points of resonance for various stages.
1.01.05 Piping diagrams including complete piping schemes layouts, location and loading drawings
etc. for all piping.
1.01.06 Drawing showing clearly the terminal details.
1.01.07 Drawings showing the edge preparation details of terminals for welding to EMPLOYER'S
piping & equipment.
1.01.08 P & I diagrams for TG Integral system for steam, condensate, drains, DM cooling water,
compressed air, lube and control fluid, circulating water, gland sealing steam, stator cooling
water, seal oil, H
2
and CO
2
Systems, wet steam washing, exhaust hood spray, HP-LP
bypass, condenser air evacuation, condenser tube cleaning etc.
1.01.09 Allowable forces & moments on nozzles of turbine main-steam stop & control valves, reheat
stop & control valves, HP-LP bypass valves, condenser, heaters, CEP, Deareator, BFP,
MDBFP, BFPDT etc.
1.01.10 Drawing showing the bolt (casing) loading and strains and indicating the estimated period in
which retightening or replacement of bolts are required alongwith the instructions.
1.01.11 Erection assembly drawing as detailed below:
a) Turbine including casings, rotors, nozzles, exhaust connections, emergency stop
valves, Interceptor valves, non-return valves, nozzle valves, turning gear arrangement
etc.
b) Wet steam washing system
c) Forced cooling system
d) Exhaust hood spray system
e) Seal steam system
f) Governing system & Control fluid system.
NO.
SECTION-VI
PART - G
PAGE
3 OF 4
DA2(III)
STAGE-II (2X660 MW)
g) HP-LP bypass system.
h) Pumps including, emergency oil pump, stand by oil pump, starting oil pump.
i) Central lube oil storage & purification system.
j) Condenser air evacuation system.
k) Condenser on load tube cleaning system.
1.01.12 Condenser tube layout including withdrawal space of the condenser necessary for tube
banks, steam laying arrangement inside the condenser, Condenser hotwell and deaerating
section layout.
1.01.13 Condenser waterbox handling arrangement.
2.00.00 OTHER DOCUMENTS
2.01.00 General
2.01.01 Complete technical literature including characteristic curves, data sheets, sizing calculations
etc. for all control valves, process valves and flow measuring devices including that for PG
test.
2.01.02 Characteristic curves of all the actuators in respect of valves.
2.01.03 Description of the method to be adopted for protection of the equipment during manufacture,
shipment and storage at site.
2.01.04 Shipping breakdown of all equipment
2.01.05 Complete list of all the maintenance tools included in the proposal.
2.01.06 Necessary pamphlets to illustrate the features of design and construction of the component
parts of all equipment and systems furnished.
2.01.07 Detailed descriptions of all equipment and systems furnished under the scope of this
specification.
2.01.08 Instructions for erection, testing commissioning, operation and maintenance of the various
equipment and their systems.
2.01.09 Performance & guarantee test procedure, test scheme & Instrument list etc.
2.01.10 Final list of equipment, instruments and device included in scope of supply alongwith their
specification, location, electrical supply details, actuation setting, name of supplier etc.
2.01.11 Data sheets of flow nozzles and other instruments for PG test.
NO.
SECTION-VI
PART - G
PAGE
4 OF 4
DA2(III)
STAGE-II (2X660 MW)
2.01.12 Drawings of flow nozzles and other instrument for PG test.
2.01.13 Cooling water requirements equipment-wise, stating the quantity, quality pressure etc.
2.01.14 Heat load of the equipment located in the TG hall covered under this package.
2.01.15 Details of the following:
a) Atmospheric relief diaphragm - type, rupture, pressure etc.
b) Insulation-type of insulation (matters or loose form), fibre diameter and length,
shot contents, max. size of shot, loss of weight during incombustibility test, max.
sulphur and carbon content etc.
2.02.00 Turbine and Auxiliaries
2.02.01 Results of vibration analysis on condenser tubes.
2.02.02 Transient speed rise analysis of turbine
2.02.03 Auxiliary Steam requirement for steam turbine (quantity, pressure and temperature)
2.02.04 Details of dynamic balancing of TG rotor and blade vibration tests.
2.02.05 Governing system stability Analysis results.
SECTION-VI
PART - G
STAGE-II (2X660 MW)
SUB-SECTION DA3
(NOT USED)
SECTION-VI
PART - G
STAGE-II (2X660 MW)
SUB-SECTION DA4
Clause
No.
BIDDER'S NAME...........
SECTION-VI
PART - G
PAGE
1 OF 4
DA4
STAGE-II (2X660 MW)
1.00.00 TYPE OF PLANT Unit Polor / Biplor Type
1.01.00 GENERAL
1.02.00 Manufacturer
1.03.00 Guaranteed performance data
1.03.01 Hydrogen generation
Plant Capacity (NM
3
/hr) .......................................................................
1.03.02 No. of Streams ......................................................................
1.03.03 Capacity of each Stream ......................................................................
1.03.04 Hydrogen Purity (%) ......................................................................
1.03.05 Moisture content ......................................................................
1.03.06 Whether the Plant System Yes/No
& equipments are designed
as per the rules of Explo-
sives Authority of India?
1.04.00 Whether the plant is designed
for :
i) Continuous duty ? Yes/No
ii) Parallel operation of Yes/No
streams ?
iii) Operation of electrolyser Yes/No
in part Load ?
iv) Operation from the Yes/No
control panel ?
v) Flexibility of isolating of Yes/No
any cell of electrolyser
and operation for rest
of the streams ?
vi) Automatic operation of Yes/No
standby compressors?
vii) Automatic change over Yes/No
of gas holders ?
Clause
No.
SECTION-VI
PART - G
PAGE
2 OF 4
DA4
STAGE-II (2X660 MW)
1.05.00 Whether complete instrumen- Yes/No
tation and control system
provided as specified
1.06.00 Whether complete ventilation Yes/No
system as provided for no.
of plants as specified
2.00.00 EQUIPMENTS
A) Rectifiers
i) Make & Model No. .....................................................................
of rectifier
ii) Type of rectifier .....................................................................
iii) Rating in (KW) .....................................................................
B) Electrolysers
i) Manufacturer .....................................................................
ii) Capacity of the elec- .....................................................................
trolyser in (Nm
3
/hr)
(Rated)
iii) Pressure of hydrogen .....................................................................
gas generated
(Kg/cm
2
(g))
iv) Temperature of hy- .....................................................................
drogen gas generated
v) Consumption of electri- .....................................................................
city in KW/NM
3
of H
2
C) Gas holders of Hydrogen Hydrogen Oxygen
and Oxygen
i) No. of gas holders ............................... ..............................
offered
ii) Capacity and size of ............................... ..............................
each gas holder (m
3
)
Clause
No.
SECTION-VI
PART - G
PAGE
3 OF 4
DA4
STAGE-II (2X660 MW)
D) De-oxy-unit and
gas cooler
i) Manufacturer .....................................................................
ii) Type .....................................................................
iii) Capacity .....................................................................
E) Hydrogen Gas drier
i) Type .....................................................................
ii) Make .....................................................................
F) Compressors for Hydrogen
i) Manufacturer .....................................................................
ii) No. of compressor .....................................................................
offered
iii) Type of compressor .....................................................................
iv) Delivery Pressure .....................................................................
(Kg/cm
2
(g))
v) Capacity (Nm
3
/hr) .....................................................................
vi) Speed (rpm) .....................................................................
vii) Type of drive .....................................................................
viii) No. of stages of .....................................................................
compressor
G) Gas Filling Manifold
i) No. of Manifolds .....................................................................
ii) No. of filling points .....................................................................
H) High pressure cylinder
testing apparatus
i) Manufacturer & .....................................................................
Model No.
ii) Rating of electric .....................................................................
motor (KW)
Clause
No.
SECTION-VI
PART - G
PAGE
4 OF 4
DA4
STAGE-II (2X660 MW)
3.00.00 A) Cooling Water Required .....................................................................
for Hydrogen Generation
Plant per stream (M/hr.)
B) Temperature rise (deg.C) .....................................................................
4.00.00 DM water required for Hydrogen .....................................................................
Generation Plant per stream
(M/hr.) at its rated capacity
SECTION-VI
PART - G
STAGE-II (2X660 MW)
SUB-SECTION DA5
EQUIPMENT COOLING
WATER SYSTEM
CLAUSE
NO.
SECTION-VI
PART - G
PAGE
1 OF 3
DA5
STAGE-II (2X660 MW)
EQUIPMENT COOLING WATER
SYSTEM
I. GENERAL
1.01.00 Primary Circuit (DM Water)
1.01.01 Flow of DM water in primary
circuit for TG & Aux. (M
3
/HR.) .......................................................
1.01.02 Design DM Water flow (M
3
/HR.) .......................................................
1.02.00 Seconary Circuit (Circulating water)
1.02.01 Flow for TG circuit (M
3
/HR) .......................................................
1.02.02 Flow for SG circuit (M
3
/HR) .......................................................
1.02.03 Total secondary water flow .......................................................
required (M
3
/HR.)
1.03.00 PUMPS DM Cooling Aux Cooling.
Water Pumps Water Pumps
(DMCW) (ACW)
1.03.01 Type of Pump ........................... . ......................
1.03.02 Number offered per unit ........................... . ......................
2.00.00 Technical particulars :
2.01.00 Guranteed Capacity ........................... . ......................
2.02.00 TDH at rated ........................... . ......................
capacity in MWC
2.03.00 Efficiency ........................... . ......................
2.04.00 Rated Output of Motor (KW) ........................... . ......................
2.05.00 Pump speed (RPM) ........................... . ......................
3.00.00 Whether material of construction is YES/NO YES / NO
as per specification?
4.00.00 Whether Mechanical seal provided
for DM CW pumps? Yes/No
CLAUSE
NO.
SECTION-VI
PART - G
PAGE
2 OF 3
DA5
STAGE-II (2X660 MW)
I I HEAT EXCHANGERS
1.00.00 General
1.01.00 Numbers offered per unit ................................. ......................................
1.02.00 Manufacturer ................................. ......................................
1.03.00 Guaranteed Performance
Data for Individual heat
Exchanger:
DM Water Si de Secondary Cooling
Water Si de
1.03.01 Flow in heat Exchanger (M
3
/hr) ................................. ......................................
1.03.02 Inlet Temp.
o
C ................................. ......................................
1.03.03 Outlet Temp.
o
C ................................. ......................................
1.03.04 Total heat transfer area in M
2
................................. ......................................
heat exchanger
1.03.05 Pressure drop across heat ................................. ......................................
exchanger
1.04.00 Whether Material of construction YES / NO
of PHE is as per specification?
1.05.00 Whether frames suitable for YES / NO
addition of 25% plates
I I I . ECW Overhead Surge Tank
1.01.00 Capacity of tank .......................................................................
1.02.00 Number of tanks per unit .......................................................................
IV. Self Cleaning Strainer (ACW side)
1.01.00 Number offered per unit .......................................................................
1.02.00 Material of filter element .......................................................................
1.03.00 Pressure drop in strainer in
a. Clean condition .......................................................................
CLAUSE
NO.
SECTION-VI
PART - G
PAGE
3 OF 3
DA5
STAGE-II (2X660 MW)
b. 50 % choked condition .......................................................................
c. 100 % choked condition .......................................................................
1.04.00 Manufacturer ........................................................................
V. Chemical Dosing System:
1.01.00 No. of Chemical dosing Tank .......................................................................
(per unit)
1.02.00 Tank Capacity (M
3
) .......................................................................
1.03.00 Material of Construction of tank as
per specification YES / NO
VI) Whether required Valves,
Instruments are provided or not ? YES / NO
SECTION-VI
PART - G
STAGE-II (2X660 MW)
SUB-SECTION DA6
POWER CYCLE PIPING
CLAUSE
NO.
SECTION-VI
PART - G
PAGE
1 OF 12
DA6
STAGE-II (2X660 MW)
1.00.00 DATA SHEET FOR PIPES AND FITTINGS
1.01.00 Pipe sizes for various piping systems under the bidders scope:
Note: This Schedule shall be filled for each piping system covered under the Specification.
However, the pipe sizes shall be finalized during detailed stage.
Sl Nominal Out side Inside Wall Tolerance (mm) Name of

pipe size DIA Dia Thickness Piping
(mm) (mm) (mm) (mm) OD I D THK System
CLAUSE
NO.
SECTION-VI
PART - G
PAGE
2 OF 12
DA6
STAGE-II (2X660 MW)
1.02.00 Line J oint type for
a) Piping 65 mm NPS and over ..........................................................
b) Piping 50 mm NPS and less ..........................................................
1.03.00 Material Specifications
1.03.01 Pipes as per specification YES/NO
(If not, please specify the offered
material & system) ..........................................................
1.03.02 Fittings as per specification
material & system)
a) 65 mm NPS and over YES/NO
..........................................................
b) 50 mm NPS and less YES/NO
..........................................................
1.03.03 Bends as per specification
material & system)
a) 65 mm NPS and over YES/NO
..........................................................
b) 50 mm NPS & less YES/NO
..........................................................
1.04.00 Dimensional Standard
1.04.01 Pipes ..........................................................
1.04.02 Fittings
a) 65 mm NPS and over ..........................................................
b) 50 mm NPS and less ..........................................................
CLAUSE
NO.
SECTION-VI
PART - G
PAGE
3 OF 12
DA6
STAGE-II (2X660 MW)
1.04.03 Bends
a) 65 mm NPS and over ..........................................................
b) 50 mm NPS & less ..........................................................
1.05.00 General
1.05.01 Basic codes and standards for YES/NO
Design, fabrication and erection
as per specification ..........................................................
(If not, please specify)
1.05.02 Basic codes and standards for YES/NO.
testing including hydro test, inspection
as per specification (If not, please specify) ..........................................................
2.00.00 DATA SHEET FOR CAST CS & AS
GATE, GLOBE & CHECK VALVES
2.01.00 Type of valves- as per specification YES/NO
(If not, please specify) ..........................................................
2.01.01 Design code ..........................................................
2.01.02 Rating as per design Code YES/NO
2.01.03 Make ..........................................................
2.01.04 Type of operator provided as per spec YES/NO
2.02.00 Materials, as per specification
(if not, please specify the offered material
for CS/AS Gate/ globe/ check valves separately)
2.02.01 Body YES/NO
2.02.02 Bonnet/Cap YES/NO
2.02.03 Disc YES/NO
2.02.04 Spindle YES/NO
2.02.05 Body seat YES/NO
2.02.06 Disc seat YES/NO
CLAUSE
NO.
SECTION-VI
PART - G
PAGE
4 OF 12
DA6
STAGE-II (2X660 MW)
2.02.07 Back seat (for gate &
globe valve) YES/NO
2.02.08 Bonnet / cap gasket YES/NO
2.02.09 Gland packing YES/NO
2.03.00 Testing pressure w.r.t design YES/NO
pressure
2.03.01 Test code ..........................................................
2.04.00 General
2.04 .01 Name plates and tags provided Yes/No
as specified in specifications
2.05.00 Leakage Rate as per spec. Yes/No
2.06.00 a) Hardness of seat ..........................................................
b) Any differential hardness
provided ..........................................................
3.00.00 DATA SHEET FOR FORGED
CS & AS GATE, GLOBE,ANGLE &
CHECK VALVES
3.01.00 Type of valves as per specification YES/NO
3.01.01 Design code ..........................................................
3.01.02 Rating as per design Code YES/NO
3.01.03 Make ..........................................................
(if not, please specify the offered material
for CS/AS Gate/ globe/ check valves separately)
3.02.01 Body YES/NO
3.02.02 Bonnet/Cap YES/NO
3.02.03 Disc YES/NO
CLAUSE
NO.
SECTION-VI
PART - G
PAGE
5 OF 12
DA6
STAGE-II (2X660 MW)
3.02.07 Back seat (for gate &
globe valve) YES/NO
3.02.08 Bonnet/cap gasket YES/NO
3.03.00 Testing pressure w.r.t design YES/NO
pressure
3.03.01 Test code ..........................................................
3.04.00 General
3.04 .01 Name plates and tags provided Yes/No
as specified in specifications
3.05.00 Leakage Rate as per spec. Yes/No
provided ..........................................................
4.00.00 DATA SHEET FOR SAFETY &
RELIEF VALVE
4.01.00 Service ..........................................................
4.03.00 Make/Manufacturer ..........................................................
4.04.00 Design Data
4.04.01 Design code ...........................................................
4.04.02 Relieving capacity as per code Yes/No
4.04.03 Allowable over-pressure as per spec. YES/NO
4.04.04 IBR certificate provided as YES/NO
called for in Spec.
CLAUSE
NO.
SECTION-VI
PART - G
PAGE
6 OF 12
DA6
STAGE-II (2X660 MW)
4.05.00 Construction Features
4.05.01 Type ..........................................................
4.05.02 Body pattern ..........................................................
a) Type ..........................................................
b) Size ..........................................................
4.05.03 End connections
a) Inlet
i) Type ..........................................................
ii) Size ..........................................................
b) Outlet
i) Type ..........................................................
ii) Size ..........................................................
4.06.0 Materials , as per specifications
(if not, please specify the offered material)
4.06.01 Body YES/NO
4.06.02 Trim YES/NO
4.06.03 Spring YES/NO
4.06.04 Lever YES/NO
4.06.05 Bellows YES/NO
4.06.06 Gasket YES/NO
4.07.00 General
4.07.01 Hydrostatic test pressure w.r.t YES/NO
design pressure
4.07.02 Name plates and tags provided
as specified in specifications YES/NO
4.07.03 Technical literature/
catalogues furnished YES/NO
CLAUSE
NO.
SECTION-VI
PART - G
PAGE
7 OF 12
DA6
STAGE-II (2X660 MW)
4.08.00 Maximum accumulation %........................................................
4.09.00 Maximum blow down % .........................................................
4.10.00 Hardness of seats ..........................................................
4.12.00 Leakage Rate ..........................................................
5.00.00 DATA SHEET FOR THERMAL
INSULATION FOR HOT
SURFACES
ITEM
5.01.00 Type of Insulating material ..........................................................
5.02.00 Name of the manufacturer ..........................................................
5.03.00 DESIGN DATA
5.03.01 Density of insulating material ..........................................................
5.03.02 Whether the insulating Yes/No
material is corrosive to
carbon steel or alloy steel
surfaces in contact
5.03.03 Sheating material ..........................................................
5.04.04 Material standard of Insulation ..........................................................
5.05.05 Emissivity of sheathing materials ..........................................................
5.05.06 Standard for testing insulating
material samples ..........................................................
5.05.07 Any other data specified ..........................................................
6.00.00 DATA SHEET FOR SS
PIPES & FITTINGS
6.01.00 Line joint type for:
a) Piping 50mm and less .........................................................
6.02.00 Material Specification
a) Pipes 50 mm and less .........................................................
b) Fittings 50 mm and less .........................................................
CLAUSE
NO.
SECTION-VI
PART - G
PAGE
8 OF 12
DA6
STAGE-II (2X660 MW)
6.03.00 Dimensional standard
a) Pipes .........................................................
b) Fittings .........................................................
c) Bends .........................................................
6.04.00 Basic codes and standard for
design ,fabrication and erection as per spec. YES/NO
....
6.05.00 Basic codes and standards for
testing including hydrotest YES/NO
and inspection as per spec.
(If not, please specify) ............
7.00.00 DATA SHEET FOR HANGER/
SUPPORTS
7.01.00 Manufacturer ..........................................................
7.02.00 Basic codes and standards for
i) Design ..........................................................
ii) Fabrication ..........................................................
iii) Erection ..........................................................
7.03.00 Minimum load adjustment
capacity of support for CLH ..........................................................
7.04.00 Over travel allowed as % YES/NO
of design travel as per spec.
7.05.00 Supporting effort variation for CLH/VSH FOR CLH ..%
FOR VSH .............%.
7.06.00 Each rod of double tie rod
hanger designed for full Yes/No
hydro test load
7.07.00 Minimum Rod Diameter
(a) Pipe 50 mm Nb and smaller .....................................................mm
(b) Pipe 65 mm Nb & above ..mm
CLAUSE
NO.
SECTION-VI
PART - G
PAGE
9 OF 12
DA6
STAGE-II (2X660 MW)
8.00.00 DATA SHEET FOR STAINLESS
STEEL GATE GLOBE AND
CHECK VALVES
8.01.00 Type of valves as per specification YES/NO
8.02.00 Design code ..........................................................
8.02.01 Rating as per specification YES/NO
8.02.02 Type of end connection ..........................................................
8.03.00 Make/Manufacturer ..........................................................
(if not, please specify the offered material)
8.04.01 Body YES/NO
8.04.02 Bonnet, Cap YES/NO
8.04.03 Disc YES/NO
8.04.07 Back seat (for globe valve) YES/NO
8.04.08 Bonnet/cap gasket YES/NO
8.05.00 Testing pressure w.r.t. design pressure YES/NO
8.06.00 General
8.06.01 Name plates and tags provided
as specified in specifications YES/NO
8.06.02 Technical literature/catalogues YES/NO
8.07.00 Leakage Rate as per spec. YES/NO
CLAUSE
NO.
SECTION-VI
PART - G
PAGE
10 OF 12
DA6
STAGE-II (2X660 MW)
b) Any differential hardness provided ..........................................................
9.00.00 DATA SHEET FOR
BUTTERFLY VALVE
9.01.00 Valve size .........................................................
9.02.00 Valve Design Code/Rating .........................................................
9.03.00 Type of end connection .........................................................
9.04.00 Make/Manufacturer .........................................................
9.06.00 MATERIALS OF CONSTRUCTION AS
PER SPECIFICATION
( if not, please specify material.)
9.06.01 Body YES/NO
9.06.02 Disc YES/NO
9.06.03 Seat YES/NO
9.06.04 Shaft YES/NO
9.06.05 Bearings YES/NO
9.06.06 Gear casing YES/NO
9.06.07 Retaining segments YES/NO
9.06.08 Pins, plugs and internal hardware YES/NO
9.06.09 Lining of body or disc YES/NO
9.06.10 Companion flanges, if applicable YES/NO
9.06.11 Gears YES/NO
9.07.00 TESTS AND INSPECTION
9.07.01 Whether all the tests and
inspection as detailed in the
specification are included Yes/No..............................................
CLAUSE
NO.
SECTION-VI
PART - G
PAGE
11 OF 12
DA6
STAGE-II (2X660 MW)
10.00.00 DATA SHEET FOR CORRUGATED
METALLIC EXPANSION J OINTS
10.01.00 Size & Type .........................................................
10.02.00 Design Code .........................................................
10.03.00 Make/Manufacturer .........................................................
10.04.00 CONSTRUCTION FEATURES
10.04.09 Permissible cyclic-life ..Cycles
10.05.00 MATERIALS AS PER SPECIFICATION
(if not, please specify material)
10.05.01 Bellows YES/NO
10.05.02 Sleeve YES/NO
10.05.03 Flange YES/NO
10.05.05 Bolts, studs, tie rods and
limit rods YES/NO
10.05.06 Gaskets YES/NO
10.05.07 External cover YES/NO
10.06.00 TESTING
10.06.01 Hydrostatic test pressure bar (g) ............................................
10.06.02 Vacuum test mm of HG ......................................
11.00.00 DATA SHEET FOR FLASH
TANKS
(Please Furnish for each flash tank)
11.01.00 Manufacturer .........................................................
11.02.00 Type .........................................................
11.03.00 Design and Fabrication Code .........................................................
11.04.00 DESIGN PARAMETERS
a) Design pressure .........................................................
b) Design temperature .........................................................
CLAUSE
NO.
SECTION-VI
PART - G
PAGE
12 OF 12
DA6
STAGE-II (2X660 MW)
11.05.00 Size (dia x height) in mm .........................................................
11.06.00 Material (indicate standard and .........................................................
grade)
1200.00 DATA SHEET FOR SPRING LOADED HP
FEED WATER HEATER BYPASS VALVES.
12.01.00 Size of Valve .........................................................
12.02.00 Design code ..........................................................
12.03.00 Rating & design Code .........................................................
12.04.00 Make ..........................................................
12.05.00 End Connection .........................................................
12.06.00 Relieving capacity .........................................................
12.07.00 IBR Certificate .....
12.08.00 Materials:
12.08.01 Body .
12.08.02 Bonnet/Cap .
12.08.03 Disc/valve head .
12.08.04 Spindle/stem .
12.08.05 Body seat .
12.08.06 Disc seat .
12.08.07 Bonnet - cap gasket .
12.08.08 valve Guide .
12.08.09 Spring .
12.09.00 Testing pressure w.r.t design .
pressure
12.10.00 Test code ..........................................................
provided ..........................................................
SECTION-VI
PART - G
STAGE-II (2X660 MW)
SUB-SECTION DA7
LOW PRESSURE PIPING
CLAUSE NO.
BIDDERS NAME

STAGE-II (2X660 MW)
SECTION - VI
PART-G

DA 7

PAGE
1 OF 11

GENERAL

1.00.00 This proforma is to be completely filled in for all the main equipment/components offered.

Bidder has to state whether the following equipment/services as specified in the Technical
Specification have been offered.

1.01.00 Complete LP piping with valves, fittings & specialities Yes/No
as per specification / scope

1.02.00 Unused special tools and tackles Yes/No

1.03.00 Mandatory spare parts as per Specification Yes/No

1.04.00 Recommended spare parts for three year's operation Yes/No

1.05.00 Special cables (if any) Yes/No

1.06.00 Tanks as per specification Yes/No

1.07.00 Painting and anti-corrosive protection of all above Yes/No
ground/trench piping included.

1.08.00 Water proofing and anti-corrosive protection of all buried piping Yes/No
included.

1.09.00 Excavation and backfilling for buried piping included Yes/No

1.10.00 All supports, hangers, trestles, racks, anchor bolts, Yes/No
foundation bolts, insert plates & supporting structures
etc. included

1.11.00 Teflon sealant tapes for all screwed joints included Yes/No

1.12.00 Civil and concrete work for Anchor blocks & thrust Yes/No
blocks for buried piping included

2.00.00 TECHNICAL INFORMATION AND DRAWINGS TO BE SUBMITTED WITH THE
PROPOSAL

2.01.00 Manufacturer's descriptive and illustrative literature on each category of tanks, valves,
specialities, instruments, valve actuators, strainers, expansion joints etc.

2.02.00 A write-up on the manufacturing and testing facilities in the shop of the manufacturer.

2.03.00 Any other relevant literature, drawings, certificates that the bidders may desire to submit, to
complete the bid.

2.04.00 Type test certificate for all pipes, valves, fittings, instruments, strainers, expansion joints etc.

2.05.00 Detailed experience list about the design, manufacturer, supply and erection of the
completely low pressure piping system.

2.06.00 The Bidder shall enclose with his proposal a list of items of non Indian origin, if any together
with the name and country of origin of the manufacturer.
CLAUSE NO.
BIDDERS NAME

STAGE-II (2X660 MW)
SECTION - VI
PART-G

DA 7

PAGE
2 OF 11

2.07.00 The information sought out in data sheets (Technical Particulars) enclosed herewith in this
Sub-section, shall be furnished by the Bidder in the format specified. The Bidder shall
enclose these data sheets completely filled up with his proposal.

2.08.00 Bidder shall submit the single line flow diagram or P&ID or piping engineering diagram
indicating the schemetic arrangement for each system indicating the pipe size, instruments,
drains, vents, system parameters like pressure / temperature / flow etc.

2.09.00 Tank

2.09.01 Outline & sectional drawing of each category of tanks indicating overall dimensions, plate
thickness and connections provided.

2.09.02 Bill of material for tank

2.10.00 Piping, Valve & Fittings

2.10.01 Bill of material for piping, valves, fittings etc. indicating the system name, length, size,
thickness, material specification, pressure & temperature/rating and valve standards.

2.10.02 Outline and sectional drawing of each size/rating/type of valve and speciality offered.

2.10.03 A detailed write-up on protection and anticorrosive painting / coating (with reference to
relevant standards) to be provided on overground and burried pipes as well as other
equipments/components.

2.10.04 Calculation sheets for stiffening of large diameter burried pipes against ovality formation in
use, if necessary.

2.11.00 Instruments

2.11.01 A list of instruments

2.11.02 List of annunciations.

CLAUSE NO.
BIDDERS NAME

STAGE-II (2X660 MW)
SECTION - VI
PART-G

DA 7

PAGE
3 OF 11

3.00.00 TECHNNICAL PARTICULARS

The following formats are
to be filled for each type
of equipment/components

3.01.00 PIPING AND FITTINGS

Following details shall be
furnished for each and every
system of piping separately

3.01.01 System ............................... (to be filled by Bidder).................

Above 50 mm size 50 mm size & below
3.01.02 Material of construction
& standard

a) Pipes : .................................... ....................................

b) Fittings : .................................... ....................................

3.01.03 Design Pressure &

Temperature

a) Pipes : .................................... .....................................

b) Fittings : .................................... .........................................

3.01.04 Hydraulic Test Pressure

a) Shop test : .................................... .........................................

i) Pipes : .................................... .........................................

ii) Fittings : .................................... .........................................

b) Site test : .................................... .........................................

3.01.05 Manufacturer

a) Pipes : .................................... .........................................

b) Fittings : .................................... .........................................

3.02.00 Flanges

a) Manufacturer : .................................... .........................................

b) Material standard/ : .................................... .........................................
specification

c) Type : .................................... .........................................

CLAUSE NO.
BIDDERS NAME

STAGE-II (2X660 MW)
SECTION - VI
PART-G

DA 7

PAGE
4 OF 11

d) Standard : .................................... .........................................

e) Gasket Material &
standard : .................................... .........................................

3.03.00 Nuts, Bolts and Gaskets Nuts Bolts Gaskets

a) Manufacturer : .......................... ..................... ......................

b) Grade : ......................... ..................... ......................

c) Standard & codes : .......................... .................. ...................

3.04.00 Galvanising

a) Galvanising standard : .......................... .................. ...................

3.05.00 VALVES & SPECIALITIES

3.05.01 Cast Iron Body Val ves Gate Globe Check

i) Manufacturer : .......................... .................. ...................

ii) Material of construction : .......................... .................. ...................
(indicate standard)

a) Body : .......................... .................. ...................

b) Bonnet : .......................... .................. ...................

c) Wedge/Disc : .......................... .................. ...................

d) Seating Surfaces : .......................... .................. ...................

e) Hinge pin for non- : .......................... .................. ...................
return (check) valves

f) Stem : .......................... .................. ...................

g) Back seat : .......................... .................. ...................

h) Handwheel : .......................... .................. ...................

i) Bolts : .......................... .................. ...................

j) Nuts : .......................... .................. ...................

k) Gaskets : .......................... .................. ...................

l) Gland packing : .......................... .................. ...................

m) Counter flanges : .......................... .................. ...................

CLAUSE NO.
BIDDERS NAME

STAGE-II (2X660 MW)
SECTION - VI
PART-G

DA 7

PAGE
5 OF 11

iii) Flange standard : .......................... .................. ...................

iv) Valve standard : .......................... .................. ...................

v) Manufacturer's catalogues Yes/No Yes/No Yes/No
furnished

3.05.02 Steel Body Val ves Gate Ball Globe Plug Check

i) Manufacturer : .......................... .................. ...................

ii) Material of construction : .......................... .................. ...................
(indicate standard)

a) Body : .......................... .................. ...................

b) Bonnet : .......................... .................. ...................

c) Wedge/Disc : .......................... .................. ...................



f) Stem : .......................... .................. ...................

g) Back seat : .......................... .................. ...................

h) Handwheel : .......................... .................. ...................

i) Bolts : .......................... .................. ...................

j) Nuts : .......................... .................. ...................

k) Gaskets : .......................... .................. ...................

l) Gland packing : .......................... .................. ...................


iii) End connection standard

a) Flange : .......................... .................. ...................

b) Butt welded : .......................... .................. ...................

c) Socket welded : .......................... .................. ...................


furnished

CLAUSE NO.
BIDDERS NAME

STAGE-II (2X660 MW)
SECTION - VI
PART-G

DA 7

PAGE
6 OF 11

3.05.03 Stainless steel Body Val ves Gate Ball Globe Plug Check

i) Manufacturer : .......................... .................. ...................

ii) Material of construction
(indicate standard)

a) Body : .......................... .................. ...................

b) Bonnet : .......................... .................. ...................

c) Wedge/Disc : .......................... .................. ...................



f) Stem : .......................... .................. ...................

g) Back seat : .......................... .................. ...................

h) Handwheel : .......................... .................. ...................

i) Bolts : .......................... .................. ...................

j) Nuts : .......................... .................. ...................

k) Gaskets : .......................... .................. ...................

l) Gland packing : .......................... .................. ...................


iii) End connection standard

a) Flange : .......................... .................. ...................

b) Butt welded : .......................... .................. ...................

c) Socket welded : .......................... .................. ...................

iv) Valve standard

v) Manufacturer's
catalogues Yes/No Yes/No Yes/No
furnished

3.05.04 Gun Metals Body Valves Gate Globe Check

i) Manufacturer : .......................... .................. ...................

CLAUSE NO.
BIDDERS NAME

STAGE-II (2X660 MW)
SECTION - VI
PART-G

DA 7

PAGE
7 OF 11

ii) Material of construction
(indicate standard)

a) Body : .......................... .................. ...................

b) Bonnet : .......................... .................. ...................

c) Wedge/Disc : .......................... .................. ...................



f) Stem : .......................... .................. ...................

g) Handwheel : .......................... .................. ...................

h) Gland packing : .......................... .................. ...................

iii) Type of Body / Bonnet : .......................... .................. ...................
Connection


furnished

3.05.05 Butterfly Valves C.I.* Fabricated* Cast car- S.S.+ Austenitic
Body steel body bon steel body Ductile
body Iron
(Cast)
Valves for
Sea Water
Appliction

Note: Bidder to choose only one option (either C.I. body or Fabricated steel body BF
val ves as per Tech. Spec., Part-B) and indicate the data in the relevant accordingly for
sizes 300 NB and above for Non-DM-water application

i) Manufacturer : .......... ................. ............... ......... ............

ii) Manufacturing Standards/ : .......... ................. ............... ......... ............
Pressure class

iii) Material of construction
(indicate standard)

a) Body : .......... ................. ............... ......... ............

b) Disc : .......... ................. ............... ......... ............

c) Shaft : .......... ................. ............... ......... ............

d) Seating/clamping : .......... ................. ............... ......... ............
CLAUSE NO.
BIDDERS NAME

STAGE-II (2X660 MW)
SECTION - VI
PART-G

DA 7

PAGE
8 OF 11

e) Seal : .......... ................. ............... ......... ............

f) Shaft bearing : .......... ................. ............... ......... ............

g) Bolts : .......... ................. ............... ......... ............

h) Nuts : .......... ................. ............... ......... ............

i) Counter Flanges : .......... ................. ............... ......... ............

iv) Maximum Torque
required for opening : .......... ................. ............... ......... ............

iv) Flange standard : .......... ................. ............... ......... ............

v) Manufacturer's catalogues Yes/No Yes/No Yes/No Yes/No Yes/No
furnished

3.05.06 Float Valve

i) Manufacturer : .......................... .................. ...................

ii) Material of Construction : .......................... .................. ...................
(Indicate standard)

iii) Dimension Standard/ : .......................... .................. ...................
Deisgn Code

CLAUSE NO.
BIDDERS NAME

STAGE-II (2X660 MW)
SECTION - VI
PART-G

DA 7

PAGE
9 OF 11

1.00.00 TECHNICAL INFORMATION AND DATA TO BE SUBMITTED AFTER AWARD OF
CONTRACT

All document/data sheets/calculations / BOMS/GA drgs/erection drgs/fabrication drgs/layout
drgs/schedules/information write ups/instruction manuals etc. submitted under this Sub-
section shall be for Employer's review/approval.

1.01.00 After finalisation of the Contract, the Contractor shall submit various drawings and data
sheets to Employer for review and approval. The actual submission schedule of these
drawings/data sheets shall be discussed and mutually agreed to, between the Employer and
the bidder before the issue of notice of award of contract. The various drawings and data
sheets to be furnished shall include the following.

1.02.00 Final version of all drawings and data sheets enclosed with the proposal. Revision of any
data furnished earlier must meet the approval of Employer.

1.03.00 Single line flow diagram, P&ID/Piping engineering diagrams of all low pressure piping system
including valves, instrumentation, terminal points, etc. suitably tagged and showing clearly
the scope of work, pipe size, design parameters, temp/pressure /Flow etc,.

1.04.00 Layout Drawings

1.04.01 Detailed dimensional piping layout drawings of all piping systems included along with cross
sectional drawings and showing all supports and equipment.

1.04.02 Equipment GA drawing, GA/fabrication drawings for various fittings/specialities / accessories.

1.04.03 Isometric drawings wherever required.

1.04.04 Arrangement of pipe supports, trenches, racks, trestles, pedestals, hangers etc.

1.05.00 Foundation design and load data, for equipments and supports/hangers supporting structure
etc. Loading data and insert locations wherever required for hangers shall also be indicated.

1.06.00 Design and layout data/drg for trenches (if any), embedment plates/ anchorblocks/thrust
blocks etc.

1.07.00 Calculation & Data Sheets

1.07.01 a) Calculation and data Sheets for large dia pipes and stiffening of large dia buried
pipes against ovality in use, if necessary.

b) Calculations for Body thickness for Fabricated steel body valves it applicable.

c) Calculations for Anchor Block/ Thrust Blocks, if any.

d) Pipe support trestle/ foundation design calculations.

e) Strainer sizing calculation & thickness calculations.

1.07.02 Data sheets for selection of all pipes/valves/tanks/fittings etc.

1.07.03 Particulars of proposed tests at shop and site for pipes, valves, tank and other equipment.

CLAUSE NO.
BIDDERS NAME

STAGE-II (2X660 MW)
SECTION - VI
PART-G

DA 7

PAGE
10 OF 11

1.07.04 Reports on shop tests and also test certificates for pipes, valves, tank and other equipment.

1.07.05 Material test certificate.

1.07.06 Hydraulic and air leakage test results for tank, pipes and valves as applicable.

1.07.07 Non-destructive test results as applicable.

1.07.08 If stage inspection is called for, the various stages of inspection, together with a programme
shall be submitted to the Employer. The inspection and test procedures shall also be
submitted for Employer's approval.

1.07.09 Test reports, certified performance curves and other particulars as required by applicable
clause of this specification.

1.07.10 Details of cleaning procedure and paint application procedure.

1.07.11 Details of Hydraulic test procedure. Details of Exacavation / bed preparation/laying of buried
piping/anticorrosive protection application, backfilling, compaction etc.

1.07.12 Test results of anticorrosive coating.

1.08.00 Bill of material

1.08.01 Bill of material for Pipe

1.08.02 Bill of material for Pipe Fittings

1.08.03 Bill of material of Tanks.

1.08.04 Bill of material for Valves

1.08.05 Bill of material for Strainers

1.08.06 Bill of material for Expansion J oints

1.08.07 Bill of material for Instruments.

1.09.00 Instruction Manual

1.09.01 The instruction Manuals shall present the following basic categories of information in a
comprehensive manner prepared for use by operation and/or maintenance personnel:

i) Instruction for Erection

ii) Instruction for pre-commissioning check-up, operation, abnormal conditions,
maintenance and repair.

iii) Recommended inspection points and periods of inspection.

iv) Schedule of preventive maintenance.
v) Ordering information for all replaceable parts.

vi) Recommendation for type of lubricants, lubricating points, frequency of lubrication
and lubricant changing schedule.
CLAUSE NO.
BIDDERS NAME

STAGE-II (2X660 MW)
SECTION - VI
PART-G

DA 7

PAGE
11 OF 11

1.09.02 The information shall be organised in a logical and orderly sequence. A general description
of the equipment including significant technical characteristics shall be included to familiarise
operation and maintenance personnel with the equipment.

1.09.03 Necessary drawings and/or other illustration shall be included or copies of appropriate final
drawings shall be bound in the manual. Test, adjustment and calibration information, as
appropriate, shall be included and shall be identified to the specific equipment. Safety and
other warning notices and installation, maintenance and operating cautions shall be
emphasized.

1.09.04 A parts list shall be included showing part nomenclature, manufacturer's part number and/or
other information necessary for accurate identification for ordering of replacement parts.

1.09.05 The instruction Manual shall include the list of spare parts that have been procured along
with the equipment. It shall also include list of all unused special tools and tackles furnished
with complete drawings and instructions for use of such tools and tackles.

1.09.06 The Instruction Manual will need approval of Employer in the same fashion as that for
drawing.

SECTION-VI
PART - G
STAGE-II (2X660 MW)
SUB-SECTION DA8
LAYOUT REQUIREMENT
Clause
No.
SECTION-VI
PART - G
PAGE
1 OF 1
DA8
STAGE-II (2X660 MW)
LAYOUT REQUIREMENTS
Bidder to furnish the following
the layout drgs :
1) Main Plant Layout
plan at 0.0M (Transformer
Yard to Chimney)
2) Main Plant Cross Sections ........................................................................
3) Main Plant Longitudinal ........................................................................
Sections
4) Equipment layout plan ........................................................................
at 0.0m
at mezzanine floors
at operating
7) Layout of BC bay at ........................................................................
various elevations
8) GA of turbine hall ........................................................................
EOT crane
9) Compressor House Layout ........................................................................
10) CW Piping around the
condenser ........................................................................
11) CEP Pit General
arrangement drgs. ........................................................................
SECTION-VI
PART - G
STAGE-II (2X660 MW)
SUB-SECTION DA9
ELEVATOR
BIDDER'S NAME CLAUSE
NO.
SECTION-VI
PART - G
PAGE
1 OF 1
DA9
STAGE-II (2X660 MW)
1.00.00 SCHEDULE OF GUARANTEED AND
OTHER TECHNICAL PARTICULARS
1.01.00 Lift Particulars
(i) Load carrying capacity of
the lift in Kgs.
(ii) Type of loading for which
the lift is designed
(iii) Type of lift.
(iv) Speed (Meter/sec.)
(v) Travel (metres)
(vi) Floors served by the lift
(vii) Landing Entrances:
(a) No. size and type
of doors
(b) Method of operation
of doors
(viii) Size of lift well
(ix) Car dimensions
(a) Internal size of the
lift car
(b) External size of the
car platform
(x) Weight of car
2.00.00 SAFETY GEAR
(i) Type
(ii) Operation
(iii) Distance travelled
from start to stop
SECTION-VI
PART - G
STAGE-II (2X660 MW)
SUB-SECTION DA10
OTHER CRANES & HOISTS
BIDDER'S NAME CLAUSE
NO.
SECTION-VI
PART - G
PAGE
1 OF 1
DA10
STAGE-II (2X660 MW)
1.00.00 EOT TYPE CRANES : (IS:3177 - Latest Edition & IS:807 - Latest Edition)
(a) Manufacturer
(b) Type
(c) Number offered
(d) Crane capacity (Tonne)
(e) SPAN
(f) Height of Lift
(g) Safe Working Load
(h) MOTORS :
(i) Hoist (Main)
(ii) Micro Hoist (Main)
(iii) Long Travel/Cross Travel
(i) Speeds
(i) Main Hoist Mtrs/Min.
(ii) Cross Travel "
(iii) Long Travel "
(j) Brakes (Type/Details)
1.01.00 HOT/Monorail Cranes : (IS : 3832 Latest)
(a) Manufacturer
(b) Type and Number offered
(c) Crane capacity
(d) Height of Lift
(e) Hoisting Motor Details
(f) Brakes
(g) Hook Details
(h) Other Details, if any
SECTION-VI
PART - G
STAGE-II (2X660 MW)
SUB-SECTION DA11
CLAUSE
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SECTION-VI
PART - G
PAGE
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DA11 TANDA THERMAL POWER PROJECT
STAGE-II (2X660 MW)
NAME OF SUPPLIER ..........................................................................
1.00.00 Chemical consumption ..........................................................................
1.01.01 Hydrochloric Acid (30% conc.)
required for regeneration of
one vessel charge, Kgs ..........................................................................
1.01.02 Sodium Hydroxide (48% purity)
required for regeneration of
one vessel charge, Kgs. ..........................................................................
2.00.00 CONDENSATE POLISHING SERVICE
VESSELS
(a) Design Service flow rate (m/hr) ..........................................................................
per vessel
(b) Resin sluice Rate (m/hr)
and simultaneous Air (NM/hr) ..........................................................................
(c) Vessel Details
(i) Design Pressure Kg/m
(gauge) ..........................................................................
(ii) Type CYLIDRICAL / SPHERICAL
(iii) Vessel material ..........................................................................
(vi) Lining Material & thickness ..........................................................................
(vii) Freeboard (%) ..........................................................................
(e) Resin Details
(i) Resin-Manufacturer Cation: ................................................
Anion: ................................................
Inert : ................................................
(ii) Volume (litres) per vessel Cation: ................................................
Anion: ................................................
Inert : ................................................
(iii) Type of resin Cation: ................................................
Anion: ................................................
Inert : ................................................
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SECTION-VI
PART - G
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DA11 TANDA THERMAL POWER PROJECT
STAGE-II (2X660 MW)
(f) By-pass control valve ..........................................................................
(i) Type & No. ..........................................................................
(ii) Actuator type ..........................................................................
(h) Whether design calculation
justifying resin volume selection
to achieve the guaranteed
chemical consumption furnished Yes/No
(i) Whether system description &
Control philosophy furnished Yes/No
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SECTION-VI
PART - G
PAGE
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DA11
STAGE-II (2X660 MW)
3.00 CONDENSATE POLISHING RESIN CATION ANION RESIN MIXED RESIN
EXTERNAL REGENERATION SEPARATION REGENERATION REGENERATION STORAGE
3.1. Air Mix (Nm/hr) and pressure kg/cm ...................... ............................. .......................... ........................
3.2 Resin sluicing Rate (M/hr) ...................... ............................. .......................... ........................
and simultaneous Air (Nm/hr)
3.3 Resin Separation Flow Rate (m/hr) ...................... ............................. .......................... ........................
3.4 Vessel Details
3.5 Design Pressure kg/cm (g) ...................... ............................. .......................... ........................
3.6 Tank Size (dia x shell ht) mm ...................... ............................. .......................... ........................
3.7 Vessel Material ...................... ............................. .......................... ........................
3.8 Lining (Material/thickness) ...................... ............................. .......................... ........................
3.9 Collectors & Distributors
i) Rinse Inlet
(a) Type ...................... ............................. .......................... ........................
(b) Material ...................... ............................. .......................... ........................
ii) Regenerant Inlet
(a) Type ...................... ............................. .......................... ........................
(b) Material ...................... ............................. .......................... ........................
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SECTION-VI
PART - G
PAGE
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DA11
STAGE-II (2X660 MW)
RESIN CATION ANION RESIN MIXED RESIN
SEPARATION REGENERATION REGENERATION STORAGE
iii) Outlet
(a) Type ...................... ............................. .......................... ........................
(b) Material ...................... ............................. .......................... ........................
3.10 Regeneration
a) Dilute Regeneration Concentration (%) ...................... ............................. .......................... ........................
b) Total volume of waste effluent
per regeneration / vessel (m) ...................... ............................. .......................... ........................
3.11 Whether system description
& Control philosophy furnished Yes/No Yes/No Yes/No Yes/No
4.00 ATMOSPHERIC VESSELS RESIN MAKE- ALKALI ALKALIDAY ACID MEASU-
UP HOPPER PREP TANK TANK RING TANK
4.1 Number Provided
4.2 Vessel Details
4.2.1 Vessel Material ...................... ............................. .......................... ........................
4.2.2 Lining (Material / Thickness) ...................... ............................. .......................... ........................
4.3 Whether breather /seal etc
provided for the acid tank and alkali tanks ----- YES /NO YES /NO YES /NO
CLAUSE
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SECTION-VI
PART - G
PAGE
5 OF 8
DA11
STAGE-II (2X660 MW)
5.00 CENTRIFUGAL PUMPS ALKALI TRANSFER CUM- D.M. WATER REGENERATION
RECIRCULATION PUMPS PUMPS
5.1 Pump Manufacturer ............................................... ......................................................
5.2 Number ............................................... ......................................................
5.3 Capacity M/hr ............................................... ......................................................
5.4 T.D.H. MWC ............................................... ......................................................
5.5 Materi al
5.5.1 Pump Casing ............................................... ......................................................
5.5.2 Impeller ............................................... ......................................................
5.5.3 Shaft ............................................... ......................................................
5.5.4 Shaft Sleeves ............................................... ......................................................
5.6 Motor rating (KW) ............................................... ......................................................
CLAUSE
NO.
SECTION-VI
PART - G
PAGE
6 OF 8
DA11
STAGE-II (2X660 MW)
6. METERING PUMPS
ACID ALKALI
6.1 Pump Manufacturer ........................... .....................................
6.2 Liquid Handled ........................... .....................................
6.3 Sp. Gravity ........................... .....................................
6.4 Type ........................... .....................................
6.5 Motor Rating (KW) at 50
o
C ........................... .....................................
6.6 Operating Conditions
6.6.1 Capacity (m/hr) ........................... .....................................
6.6.2 Discharge Pressure [kg/cm(g)] ........................... .....................................
6.6.3 Capacity adjustable range ........................... .....................................
6.6.4 Type of protection against ........................... .....................................
shut off head operation
6.7 Materi al
6.7.1 Diaphragm ........................... .....................................
6.7.2 Liquid end ........................... .....................................
6.7.3 Casing ........................... .....................................
7.0 ACTIVATED CARBON FILTER
7.1 Service Rate (m/hr) ..........................................................................
7.2 Backwash rate (m/hr) ..........................................................................
7.3 Vessel Details
7.3.1 Design Pressure (Kg/mg) ..........................................................................
7.3.2 Vessel material ..........................................................................
7.3.3 Lining Material & Thickness ..........................................................................
7.4 Activated Carbon Material
7.4.1 Supplier ..........................................................................
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SECTION-VI
PART - G
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DA11
STAGE-II (2X660 MW)
7.4.2 Grade / Type ..........................................................................
7.4.3 Surface area (m/gram) ..........................................................................
7.4.4 Iodine number ..........................................................................
9.0 AIR BLOWERS For Service Vessels For Regeneration
in each unit
9.1 Manufacturer ................................ ......................................
9.2 Type ................................ ......................................
9.3 Discharge Capacity NM/hr ................................ ......................................
Discharge pressure ................................ ......................................
9.4 Efficiency at rated duty point ................................ ......................................
9.5 Motor rating ................................ ......................................
9.6 Inlet Filter-cum-silencer provided Yes/No Yes/No
10. HOT WATER TANK
10.1 Capacity & performance
10.1.1 Capacity (litres) ........................................................................
10.1.2 Outlet Temp. (
o
C) ........................................................................
10.1.3 Recovery Time (Hr.) ........................................................................
10.1.4 Heat Input (kcal/hr) ........................................................................
10.2 Vessel Details
10.2.1 Design pressure ........................................................................
10.2.2 Vessel Material ........................................................................
10.2.3 Lining Material & thickness ........................................................................
11 RESIN TRANSFER PIPELINE & VALVES
11.1 Size of Pipe ........................................................................
11.2 Valves
11.2.1 Type ........................................................................
CLAUSE
NO.
SECTION-VI
PART - G
PAGE
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DA11
STAGE-II (2X660 MW)
11.2.2 Manufacturer ........................................................................
11.2.3 Size ........................................................................
11.2.4 Material of body ........................................................................
11.2.5 Material of trim ........................................................................
11.3 Over Pressure Protection Device
11.3.1 Type ........................................................................
11.3.2 Material of construction
(a) Body ........................................................................
(b) Internals ........................................................................
12.0 RESIN TRAPS SERVICE ACTIVATED WASTE
VESSEL CARBON EFFLUENT OF
OUTLET FILTER REGENERATION
OUTLET VESSELS
12.1 Make ................... .................... ........................
12.2 Type of Internal ................... .................... ........................
12.3 Nos. Provided ................... .................... ........................
12.4 Screen Opening ................... .................... ........................
12.5 Material of Construction
12.5.1 Body ................... .................... ........................
12.5.2 Screen ................... .................... ........................
12.5.3 Lining ................... .................... ........................
12.6 In place Manual Backwashing
Provided? Yes/No Yes/No Yes/No
SECTION-VI
PART - G
STAGE-II (2X660 MW)
SECTION - VI
PART - G
MODULE - II
ELECTRICAL
SECTION-VI
PART - G
STAGE-II (2X660 MW)
ELECTRICAL SECTION
MODULE - II
DB0 : GENERAL
DB1 : GENERATOR AND GENERATOR
AUXILIARIES SYSTEM
DB2 : MOTORS
DB3 : POWER AND CONTROL CABLES
DB4 : CABLING EARTHING AND LIGHTNING
PROTECTION
DB5 : ELECTRICAL ACTUATOR
DB6 : LIGHTING (H
2
GENERATION PLANT)
DB7 : LT SWTICHGEAR & LT BUSDUCTS
SECTION-VI
PART - G
STAGE-II (2X660 MW)
DB0
GENERAL
Clause No.
.........................................................
(Bidder's Name)
GENERAL
SECTION-VI
PART - G
PAGE
1 OF 1
DB0 :
GENERAL
STAGE-II (2X660 MW)
1.00.00 Information and drawings to be submitted alongwith the proposal
The following information and drawings of the proposed equipment shall be submitted
in required number of copies by the Bidder alongwith his proposal :
1.01.00 Complete technical literature supported by catalogues for all the equipments and accessories
covered in his scope of supply.
1.02.00 Drawings showing adequate details of equipment/panels and accessories offered and typical
drawings of major schemes offered.
1.03.00 Type test and routine test reports for all the equipments and accessories covered under
Bidder's scope of supply.
1.04.00 Technical data sheets (guaranteed technical particulars) of the equipments offered.
2.00.00 Information and drawings to be submitted after the award of the contract.
2.01.00 Contractor shall submit all the drawings, data documents, manuals, catalogues etc. as
per the requirements given under applicable Sub-sections of the specification.
2.02.00 Contractor shall also submit the technical data sheets (Guaranteed Technical Particulars)
of all the equipments being supplied in the format to be handed over to the successful
bidder.
2.03.00 Instruction manuals for all the equipments and accessories covered in Bidder's scope
of supply.
3.00.00 Check list for information and drawings to be submitted with the bid (This checklist
must be attached to the data sheet).
Document Enclosed
3.01.00 Type test and routine test reports Yes/No
for all the equipments and accessories
3.02.00 Drawings showing adequate details Yes/No
of equipment/panels and accessories
offered
3.03.00 Complete technical literature supported Yes/No
by catalogue for all the equipments and
accessories
SECTION-VI
PART - G
STAGE-II (2X660 MW)
DB1
GENERATOR AND GENERATOR
AUXILIARIES SYSTEMS
Clause No.
......................................................
(Bidder's Name)
GENERATOR AND GENERATOR AUXILIARY SYSTEMS
SECTION-VI
PART - G
PAGE
1 OF 24
DB1 : GEN. &
GEN. AUX.
SYSTEMS
STAGE-II (2X660 MW)
GENERATOR AND GENERATOR
AUXILIARY SYSTEMS
1.00.00 GENERATOR PARAMETERS
1.01.00 Manufacturers Name ...........................
(Shall be as per approved QA make)
1.01.01 Type Designation ...........................
1.01.02 Model No. ............................
1.02.00 Rated/economic maximum MVA ............................
continuous output at rated
Hydrogen Pr. and secondary
cooling water temp. mentioned MW ............................
in specification (Part-B)
1.02.01 Maximum continuous output MVA ............................
(with VWO, HP heaters out
conditions etc.) at rated hydro- MW ............................
gen pressure and secondary
cooling water temperature
mentioned in specification (Part-B) ............................
1.03.00 Rated terminal voltage KV ............................
1.04.00 Rated stator current Amps ............................
1.05.00 Rated frequency Hertz ............................
1.06.00 Rated power factor ............................
1.07.00 Field current at economic Amps ............................
maximum continous rating
1.08.00 Field voltage at economic Volts ............................
maximum continuous rating
1.09.00 Maximum continuous permissible
variation range in ............................
a) Rated terminal voltage % ............................
b) Rated frequency % ............................
c) Combined permissible
variation of frequency
and voltage % ............................
Clause No.
......................................................
(Bidder's Name)
SECTION-VI
PART - G
PAGE
2 OF 24
DB1 : GEN. &
GEN. AUX.
SYSTEMS
STAGE-II (2X660 MW)
1.10.00 a) Number of Phases ............................
b) Number of parallel paths/phase ...........................
c) Line terminals brought out ............................
d) Neutral terminals brought out ............................
1.11.00 Whether space provided in generator
leads to mount bushing current
transformers? Yes/No ............................
1.12.00 Compliance with IEC standard No. ............................
1.13.00 Type & class of insulation system
a) Stator ............................
b) Rotor ............................
1.14.00 Details of winding support ............................
system
1.15.00 Details of core and core ............................
support system
1.16.00 Type of Excitation system ............................
1.17.00 Generator efficiency at : ............................
a) 100% load % ............................
b) 80% load % ............................
c) 60% load % ............................
d) 40% load % ............................
e) 25% load % ............................
f) MCR condition % ............................
Clause No.
......................................................
(Bidder's Name)
SECTION-VI
PART - G
PAGE
3 OF 24
DB1 : GEN. &
GEN. AUX.
SYSTEMS
STAGE-II (2X660 MW)
1.18.00 Minimum guaranteed short
circuit ratio corresponding
to economic maximum
continuous capability ............................
1.19.00 Permissible tolerance in SCR +/- ............................
1.20.00 Enclosure class of protection ............................
for the generator
1.21.00 Rated Hydrogen pressure Kg/cm
2
............................
(gauge)
1.22.00 Rated hydrogen cooling Kg/cm
2
............................
water pressure at (gauge)
i) Cooler inlet ............................
ii) Cooler outlet ............................
1.23.00 Hydrogen cooling water flow
at normal load m
3
/hr ............................
1.24.00 Basic impulse insulation withstand
voltage of stator winding with res-
pect to earth (For standard wave
kVshape of 1.2/50 micro sec) (peak) ............................
1.25.00 Symmetrical run short circuit
current with generator isolated-initial
saturated value and sustained value
Ini t i al Sustained
Val ue Val ue
a) 3 phase KA ...... .......
b) Single phase to neutral KA ...... .......
1.26.00 Short circuit current P.U
1.26.01 Subtransient current
a) on 3 phase short circuit ...........................
b) on 2 phase short circuit ...........................
c) on 1 phase short circuit ...........................
Clause No.
......................................................
(Bidder's Name)
SECTION-VI
PART - G
PAGE
4 OF 24
DB1 : GEN. &
GEN. AUX.
SYSTEMS
STAGE-II (2X660 MW)
1.26.02 Transient Current
a) On 3 phase short circuit ............................
b) On 2 phase short circuit ............................
c) On 1 phase short circuit ............................
1.26.03 Steadystate current on 2 phase short circuit ............................
1.27.00 Whether suitable for specified
earth fault current and duration Yes/No ............................
1.28.00 Indicate values of earth current and duration ............................
1.29.00 3 phase short circuit withstand time Secs ............................
1.30.00 Saturation factor ............................
1.31.00 Waveform factor ............................
1.32.00 Permissible unbalanced loading
subject to rated current not being
exceeded in any phase ............................
a) Maximum continuous negative
phase sequence current (I
2
)
amps ............................
b) Maximum value of I
2
2
t for
transient operation under
system conditions (where t
is in seconds) ............................
1.33.00 Maximum permissible capacitive
loading at full load MVAR ............................
1.34.00 Maximum capacitive loading for
stability at rated voltage and zero
power factor MVAR ............................
1.35.00 Generator reactances in percent at
rated KV and MVA
1.35.01 Direct axis synchronous reactance
(unsaturated) X
d
% ............................
Clause No.
......................................................
(Bidder's Name)
SECTION-VI
PART - G
PAGE
5 OF 24
DB1 : GEN. &
GEN. AUX.
SYSTEMS
STAGE-II (2X660 MW)
1.35.02 Direct axis synchronous reactance
(saturated) X
d
% ............................
1.35.03 Quadrature axis synchronous reactance
(unsaturated) X
q
% ............................
1.35.04 Direct axis transient reactance (unsaturated)X
d
% ............................
1.35.05 Direct axis transient reactance (saturated)X
d
% ............................
1.35.06 Quadrature axis transient reactance (unsaturated)X
q
% ............................
1.35.07 Direct axis sub-transient reactance (saturated)X
d
% ............................
1.35.08 Direct axis sub-transient reactance (unsaturated)X
d
% ............................
1.35.09 Quadrature axis sub-transient reactance
(unsaturated)X
q
% ............................
1.35.10 Quadrature axis sub-transient reactance
(saturated)X
q
% ............................
1.35.11 Negative phase sequence reactance (unsaturated) X
2
% ............................
1.35.12 Negative phase sequence reactance (saturated)X
2
% ............................
1.35.13 Zero phase sequence reactance (unsaturated)X
0
% ............................
1.35.14 Zero phase sequence reactance (saturated) X
0
% ............................
1.35.15 Potier reactance X
p
% ............................
1.35.16 Leakage reactance X
t
a) Combined % ............................
b) Stator % .............................
c) Rotor % ............................
d) Damper winding % ............................
1.35.17 Permissible tolerance in all
guaranteed reactance values % +/- ............................
Clause No.
......................................................
(Bidder's Name)
SECTION-VI
PART - G
PAGE
6 OF 24
DB1 : GEN. &
GEN. AUX.
SYSTEMS
STAGE-II (2X660 MW)
1.35.18 Effective winding capacitance to earth .......................................
a) Per phase Micro ......................
farad
b) All phases connected Micro ............................
together farad
1.35.19 Effective surge impedance
to neutral per phase Ohms ............................
1.35.20 Synchronous impedance Ohms ............................
1.35.21 The Harmonic voltage generated by
the generator at 100%, 75%, 50%,
25% and no load ............................
1.36.00 Armature resistance per phase at:
a) 25 deg. C Ohms ............................
b) 75 deg. C ohms ............................
1.37.00 Field resistance at :
a) 25 deg. C Ohms ............................
b) 75 deg. C Ohms ............................
1.38.00 Effective negative sequence resistance ............................
1.39.00 Zero sequence resistance ............................
1.40.00 Guaranteed maximum temperatures with
the secondary cooling water inlet tempe-
rature as per specification (Part-B) while
output considered after excluding
excitation power for static excitation
system.
1.40.01 Guaranteed maximum absolute temperatures
when generator delivers at its terminals
500MW at 0.85 p.f ............................
a) Stator windings deg.C ............................
Clause No.
......................................................
(Bidder's Name)
SECTION-VI
PART - G
PAGE
7 OF 24
DB1 : GEN. &
GEN. AUX.
SYSTEMS
STAGE-II (2X660 MW)
b) Stator core ............................
c) Primary water at
inlet of stator winding deg.C ............................
d) Primary water at outlet
of stator winding deg.C ............................
e) Rotor windings deg.C ............................
f) Cold gas deg. ............................
g) Hot gas in the stator
and rotor deg.C ............................
h) Water at inlet of gas
cooler deg.C ............................
i) Water at outlet of gas cooler deg.C ............................
1.40.02 Guaranteed maximum absolute
temperatures when generator delivers
maximum capacity of its turbine (with
VWO, HP heaters out etc.)
at 0.85 p.f. at its terminals
a) Stator Windings deg.C ............................
b) Stator core ............................
c) Primary water at inlet of stator winding deg.C ............................
d) Primary water at outlet of stator winding deg.C ............................
e) Rotor windings deg.C ............................
f) Cold gas deg.C ............................
g) Hot gas in the stator and rotor deg.C ............................
h) Water at inlet of gas cooler deg.C ............................
i) Water at outlet of gas cooler deg.C ............................
Clause No.
......................................................
(Bidder's Name)
SECTION-VI
PART - G
PAGE
8 OF 24
DB1 : GEN. &
GEN. AUX.
SYSTEMS
STAGE-II (2X660 MW)
1.40.03 Actual/Estimated absolute temperature when
the generator delivers different output in
steps of 50 MW upto rated output sensed
by each temperature detector provided in
stator core and winding for the following cases
a. At max. leading MVAR generation ............................
b. At max. lagging MVAR generation ............................
(please provide separate tables)
1.41.00 Distilled water/Deminera-lised water (Primary water)
a) Pressure at inlet of stator winding Kg/cm
2
(g) ........................
b) Pressure at outlet of stator winding Kg/cm
2
(g) ........................
c) Flow of primary water at normal load m
3
/hr ............................
1.42.00 Generator losses (Indicate where one loss
component is included in another one)
a) No load loss KW ............................
i) Iron loss KW ............................
ii) Rotor copper loss KW ............................
b) Full load loss KW ............................
i) Iron loss KW ............................
ii) Stator copper loss KW ............................
iii) Stray load loss KW ............................
iv) Rotor copper loss KW ............................
v) Friction and windage loss KW ............................
vi) Mechanical losses including
bearing losses KW ............................
vii) Exciter and exciter rheostat losses KW ............................
viii) Collector brush contact losses KW ............................
Clause No.
......................................................
(Bidder's Name)
SECTION-VI
PART - G
PAGE
9 OF 24
DB1 : GEN. &
GEN. AUX.
SYSTEMS
STAGE-II (2X660 MW)
ix) Rotary rectifier losses KW ............................
x) Fan loss KW ............................
xi) Shaft seal loss KW ............................
xii) Eddy current loss KW ............................
xiii) Any other loss (to be defined) KW ............................
xiv) Total loss at full load KW ............................
1.43.00 Type of Cooling & cooling medium
a) Stator Winding ............................
b) Stator Core ............................
c) Rotor ............................
d) Bushing ............................
1.44.00 Time required for the TG set
to deAccelerate from synchronous
speed to barring gear speed
i) Under normal unit tripping sec. ............................
ii) Under condenser vaccum
broken condition sec. ............................
1.45.00 Dissipation of losses in
a) Hydrogen cooler KW ............................
b) Stator water cooler KW ............................
c) Seal oil cooler KW ............................
d) Exciter air cooler KW ............................
e) Excitation system panels KW ............................
1.46.00 Inertia constant (H)
a) Generator & Exciter KW-Sec/KVA ............................
Clause No.
......................................................
(Bidder's Name)
SECTION-VI
PART - G
PAGE
10 OF 24
DB1 : GEN. &
GEN. AUX.
SYSTEMS
STAGE-II (2X660 MW)
b) Complete turbine KW-Sec/KVA ........................
1.47.00 i) Maximum continuous MVA
capacity of generator ............................
a) on loss of flow of stator
winding cooling water MVA ............................
b) with one hydrogen cooler out
of operation MVA ............................
ii) MVA rating at 110%V operation MVA ............................
1.48.00 Maximum inductive capacity MVAR ............................
1.49.00 Guaranteed maximum noise level
at 1 meter from the generator dBA ............................
1.50.00 Guaranteed maximum 100 Hz ............................
vibration velocity of
i) Stator end winding mm/sec pk ......................
ii) Stator core mm/sec pk ......................
iii) Core bore ring mm/sec pk ......................
iv) Stator casing/wrapper mm/sec pk ......................
v) Stator phase lead/ mm/sec pk ......................
flexible connector
1.51.00 Main Weights
a) Heaviest lift of generator
stator with trunnions etc. ............................
b) Weight of complete
Generator Stator Tonnes ............................
c) Weight of complete rotor Tonnes ............................
d) Weight of complete
generator Tonnes ............................
e) Weight of lifting beam
assembly Tonnes ............................
Clause No.
......................................................
(Bidder's Name)
SECTION-VI
PART - G
PAGE
11 OF 24
DB1 : GEN. &
GEN. AUX.
SYSTEMS
STAGE-II (2X660 MW)
1.52.00 Critical speeds of Gen. + Exciter (if any)
a) First RPM ............................
b) Second RPM ............................
c) Third RPM ............................
1.53.00 Paint Shade ............................
1.54.00 Value of generator shaft torsion oscillation (in rad)
(a) Maximum value ............................
(b) Minimum value ............................
1.55.00 Intertia (Kg/m2) of each TG shaft section
including the rotor and exciter
(a) ............................
(b) ............................
(c) ............................
(d) ............................
(e) ............................
(f) ............................
1.56.00 Spring constant/stiffness (Nm/rad) for each coupling
between TG shaft section
(a) ............................
(b) ............................
(c) ............................
(d) ............................
(e) ............................
(f) ............................
Clause No.
......................................................
(Bidder's Name)
SECTION-VI
PART - G
PAGE
12 OF 24
DB1 : GEN. &
GEN. AUX.
SYSTEMS
STAGE-II (2X660 MW)
1.57.00 Time constants:
i) T'do ............................
ii) T"do ............................
iii) T'qo ............................
iv) T''qo ............................
2.00.00 EXCITATION SYSTEM
2.01.00 Voltage regulation under conditions of rated
speed, voltage & output
a) at 0.85 power factor lag
i) with AVR % ......................
ii) without AVR % ......................
b) at unity power factor
i) with AVR % ......................
ii) without AVR % ......................
c) at 0.90 power factor lead
i) with AVR % ......................
ii) without AVR % ......................
2.02.00 Excitation requirement at Volts & Amps
a) Rated load ............................
b) No load ............................
c) At maximum capacitive load
(at Zero Active power) ............................
d) Under field forcing condition ............................
2.03.00 Short circuit torque as a ratio of full
load torque ............................
Clause No.
......................................................
(Bidder's Name)
SECTION-VI
PART - G
PAGE
13 OF 24
DB1 : GEN. &
GEN. AUX.
SYSTEMS
STAGE-II (2X660 MW)
2.04.00 Number, type and rating of CTs
and PTs used exclusively
for EHG and generator excitation
system
2.05.00 Automatic Voltage Regulators
a) Manufacturer ............................
b) Type ............................
c) Power supply to the regulator Volts ............................
d) Range of generator voltage adjustment % ............................
i) in auto position ............................
ii) in manual position ............................
e) Frequency range of operation Hz ............................
f) Temperature range of operation deg.C ............................
g) Accuracy % ............................
h) Dead band ............................
i) Excitation system response
time with AVR (The
time for the generator field
voltage to attain 95% of the
difference between field forcing
voltage & rated excitation
voltage with 5% drop in
generator terminal voltage
and generator rated MVA) ............................
j) Time required for the generator
terminal voltage to get restored
to within 2% of the nominal
preset value when subjected to
sudden loss of rated output ............................
k) Excitation system response ratio,
as defined in clause 3.2.6 of
IEEE-421 A standard ............................
Clause No.
......................................................
(Bidder's Name)
SECTION-VI
PART - G
PAGE
14 OF 24
DB1 : GEN. &
GEN. AUX.
SYSTEMS
STAGE-II (2X660 MW)
l) Excitation control
system band width as
defined in IEEE 421 A ............................
m) Overall dimension of the
AVR panel (mmxmmxmm) ............................
n) Total heat lost in
AVR panel (KW) ............................
2.06.00 Static Excitation System (if applicable)
2.06.01 Rectifier Transformer
a) Type ............................
b) Frequency Hz ............................
c) Phase ............................
d) Capacity kVA ............................
e) Voltage ............................
i) High Voltage Volts ............................
ii) Low Voltage Volts ............................
f) Percentage impedance ............................
g) Vector Group ............................
h) Mode of connection between
low Voltage terminals and
thyristor converter ............................
i) Class of insulation ............................
j) Conductor cross-section area of ............................
i) HV Winding mm
2
............................
ii) LV Winding mm
2
............................
k) Type of cooling ............................
Clause No.
......................................................
(Bidder's Name)
SECTION-VI
PART - G
PAGE
15 OF 24
DB1 : GEN. &
GEN. AUX.
SYSTEMS
STAGE-II (2X660 MW)
l) Weight of the transformer (Kg) .............................
m) Overall dimension LxBxH (mm X mm X mm) ............................
n) Recommended location ............................
2.06.02 Rectifier Assembly
a) Type Designation ............................
b) Rated rectifier current
output amp ............................
c) Rated rectifier voltage
output Volts ............................
d) Ceiling current rating output amps ............................
e) Ceiling voltage rating output Volts ............................
f) Ceiling duty duration sec ............................
g) Rectifier sink/base temp.
for field forcing duty at MCR deg.C ............................
h) Rated peak inverse voltage of
rectifier used Volts ............................
i) Frequency of input supply
voltage Hz ............................
j) Voltage drop across rectifier cell Volts ............................
k) Type of bridge 3phase/
2phase/
any other ............................
l) Over voltage with-standing capacity
m) Overall dimension of each
panel/assembly for
rectifier/convertor (mmxmmxmm) ............................
n) Resistance of the discharge
resistor in generator field
circuit at 20 deg. C ohm ............................
Clause No.
......................................................
(Bidder's Name)
SECTION-VI
PART - G
PAGE
16 OF 24
DB1 : GEN. &
GEN. AUX.
SYSTEMS
STAGE-II (2X660 MW)
o) Total heat loss in rectifier/converter
panel at rated output KW ...........................
p) Type of converter cooling
arrangement KW ............................
q) Maximum temp. of rectifier
cell for ceiling duty ............................
i) J unction temp. ............................
ii) Sink temp. ............................
r) Total no. of rectifier cells ............................
per parallel path of a bridge arm
s) No. of parallel paths per bridge arm ............................
t) Total no. of 3 phase bridges ............................
u) Maximum no. of rectifier cells/
bridge without which the rectifier
can give output corresponding to
generator MCR including field forcing
requirement ............................
v) Total no. of panels for the
complete rectifier/converter
power circuits ............................
2.06.03 Generator field breaker
a) Manufacturer ............................
b) Type designation ............................
c) Rated Voltage Volts ............................
d) Rated Current Amps. ............................
e) Catalogues attached
as annexure no. ............................
f) Overall dimension of
panel (mmxmmxmm) ............................
Clause No.
......................................................
(Bidder's Name)
SECTION-VI
PART - G
PAGE
17 OF 24
DB1 : GEN. &
GEN. AUX.
SYSTEMS
STAGE-II (2X660 MW)
3.00.00 AUXILIARY SYSTEMS
3.01.00 Stator Water Cooling System(As Applicable)
3.01.01 Pump motor sets
a) Number of pump motor sets
i) Working ............................
ii) Standby ............................
b) KW & Voltage rating of driving
motors for pump
i) Regular ............................
ii) Standby ............................
c) Power consumption of pump
motor at design duty point
i) Regular ............................
ii) Standby ............................
d) Shut off head mwc ............................
e) Pressure at the outlet of Kg/
the pump cm
2
(g) ............................
3.01.02 Primary water heat exchanger
a) Total no. of coolers ............................
b) Capacity rating of each 100%/50% ............................
cooler
c) Material of :
i) Cooler tubes
ii) Cooler sheet
iii) Water box
Clause No.
......................................................
(Bidder's Name)
SECTION-VI
PART - G
PAGE
18 OF 24
DB1 : GEN. &
GEN. AUX.
SYSTEMS
STAGE-II (2X660 MW)
d) Total heat load on coolers KW............................
e) Heat transfer coefficient Kcal/hr/deg. ............................
f) Log mean temperature deg.C ............................
g) Heat transfer area required
for rated load M
2
............................
h) Heat transfer area provided
in the coolers M
2
............................
i) Shell design pressure Kg/Cm ............................
j) Quantity of primary water per
cooler M
3
............................
k) Quantity of secondary
water per cooler M
3
............................
l) Pressure drop of primary
water through cooler kg/cm
2
............................
m) Pressure drop of secondary
water through cooler kg/cm
2
............................
3.01.03 Primary water strainer
a) No. of strainers
i) Permanent ............................
ii) Temporary ............................
b) Mesh size ............................
c) Strainer material ............................
d) Strainer body material ............................
3.01.04 General
a) Whether material other than
stainless steel is used
anywhere, which can come in
Clause No.
......................................................
(Bidder's Name)
SECTION-VI
PART - G
PAGE
19 OF 24
DB1 : GEN. &
GEN. AUX.
SYSTEMS
STAGE-II (2X660 MW)
contact with primary water
in the stator water circuit,
except the winding. Yes/No ............................
b) Duration of refilling the
mixed bed demineraliser months ............................
c) Dissolved oxygen content
in primary water for
normal operating regime ppb ............................
3.02.00 Gas System Data
a) Volume of Hydrogen space
in generator m
3
............................
b) Cooling gas flow m
3
/min ............................
c) Volume of CO
2
at NTP required
for displacing air m
3
............................
d) Volume of CO
2
at NTP required
for displacing hydrogen m
3
............................
e) Volume of H
2
at NTP required
for displacing carbon di-oxide
and to bring the casing to the
rated pressure m
3
............................
f) Purity of H
2
required
i) Normal % ............................
ii) Minimum allowable % ............................
g) Leakage of H
2
by volume at
NTP per day at rated H
2
pressure
in the generator m
3
............................
h) Volume of Nitrogen at NTP required
to displace CO
2
in the generator m
3
............................
i) Volume of air at NTP required to
displace CO
2
in the generator
and pressurise it for gas
tightness test. m
3
............................
Clause No.
......................................................
(Bidder's Name)
SECTION-VI
PART - G
PAGE
20 OF 24
DB1 : GEN. &
GEN. AUX.
SYSTEMS
STAGE-II (2X660 MW)
j) No. of cylinders proposed to be furnished for
each generator.
i) Hydrogen ............................
ii) Carbon dioxide ............................
iii) Nitrogen ............................
k) Standards to which the cylinders conform
i) Hydrogen ............................
iii) Nitrogen ............................
l) Internal Volume of the Cylinders at NTP
i) Hydrogen ............................
iii) Nitrogen ............................
j) Volume of H
2
required
for one start-up at NTP ...........................................m
k) No of cylinders normally connected
at the manifold for
i) Hydrogen ............................
iii) Nitrogen ............................
3.03.00 Seal Oil System
3.03.01 Seal Oil Pump Motor Set on
the air side stream
Standard Emergency
a) Type .................. ..................
Clause No.
......................................................
(Bidder's Name)
SECTION-VI
PART - G
PAGE
21 OF 24
DB1 : GEN. &
GEN. AUX.
SYSTEMS
STAGE-II (2X660 MW)
b) Numbers .................. ..................
c) Capacity m
3
/hr .................. ..................
d) Discharge pressure kg/cm
2
.................. ..................
e) Shut-off Head mwc .................. ..................
f) Size of motor KW .................. ..................
g) Power consumption of motor
at design duty point KW .................. ..................
3.03.02 Seal Oil Pump Motor Set on the
hydrogen side stream
Standard Emergency
a) Type .................. ..................
b) Numbers .................. ..................
c) Capacity m
3
/hr .................. ..................
d) Discharge pressure kg/cm
2
.................. ..................
e) Shut-off Head mwc .................. ..................
f) Size of motor KW .................. ..................
g) Power consumption of motor KW .................. ..................
3.03.03 Seal Oil cooler ............................
a) Total no. of coolers ............................
b) Capacity rating at each ............................
cooler 100%/50%
c) Material of ............................
i) Cooler tubes ............................
ii) Cooler sheet ............................
iii) Water box ............................
Clause No.
......................................................
(Bidder's Name)
SECTION-VI
PART - G
PAGE
22 OF 24
DB1 : GEN. &
GEN. AUX.
SYSTEMS
STAGE-II (2X660 MW)
d) Total heat load on KW ............................
coolers
e) Heat tranfer coefficient Kcal/hr/m
2
deg.C ............................
f) Log mean temperature ............................
difference
g) Heat transfer area required M
2
............................
for rated load
h) Heat transfer area provided ............................
in the cooler M
2
i) Shell design pressure Kg/cm
2
............................
j) Rated cooling water Kg/cm
2
............................
pressure at the inlet
k) Pressure drop across MWC ............................
the cooler
3.03.04 Seal Oil Strainer
a) No. of strainers
i) Permanente ............................
ii) Temporary ............................
b) Mesh size ............................
c) Strainer material ............................
d) Strainer body material ............................
3.03.05 Vapour extraction unit (in seal oil drain)
a) Type ............................
b) Capacity m
3
/hr ............................
c) Size of motor KW ............................
Clause No.
......................................................
(Bidder's Name)
SECTION-VI
PART - G
PAGE
23 OF 24
DB1 : GEN. &
GEN. AUX.
SYSTEMS
STAGE-II (2X660 MW)
4.00.00 ADDITIONAL INFORMATION TO BE FURNISHED
4.01.00 Permissible overload versus time
duration curve beyond MCR rating
matching with turbine capability (with
temperature limits for class F insulation) ............................
4.01.01 Number of starts/stops for which
generator is rated ............................
4.02.00 Details of de-excitation techniques &
de-excitation time (i.e. time for the
generator field current to fall from rated
load value to 10% of the same for a
sustained internal fault) ............................
4.03.00 Surge capacitor requirement for the
generator must be stated with reasons ............................
4.04.00 Experience in respect of providing the
supervisory instrumentation system for
the generator ............................
4.05.00 What provisions are made for automatic
generator runback (Turbine control point
set back) on loss of cooling ? ............................
4.06.00 Furnish permissible volts/Hz vs time
characteristics of the generator ............................
4.07.00 Details of recommended generator ............................
neutral grounding system
4.08.00 Details of generator rotor winding
temperature monitoring system and
rotor winding earth fault detection system ............................
4.09.00 Basis of selecting the proven generator
and excitation system, cooling arrange-
ment including gas circulating fan,
insulation, core and winding support
system backed up with following : ............................
i) No. of units of identical size
and design in operation with
their years of commercial ope-
ration along with utitlity names ............................
Clause No.
......................................................
(Bidder's Name)
SECTION-VI
PART - G
PAGE
24 OF 24
DB1 : GEN. &
GEN. AUX.
SYSTEMS
STAGE-II (2X660 MW)
ii) Operational availability records from
the utitlities including type of failure/
breakdown and corrective actions
taken etc. ............................
4.10.00 Detailed literature for the excitation
system proposed for the generator
enclosed Yes/No
4.11.00 Detailed writeup on various limiters
enclosed Yes/No
4.12.00 Complete scheme and write-up
of hot air blowing system or
better arrangement to prevent
condensation of moisture during
long shut down of generators
(as applicable) ............................
4.13.00 Complete scheme and detailed writeup
on power system stabilizer enclosed Yes/No
4.14.00 Laplace domain transfer function block Yes/No
diagram that represents the generator
excitation system in accordance
with the IEEE standard excitation
model is enclosed. The values of all
time constants and gains are also to be
furnished by manufacturer
SECTION-VI
PART - G
STAGE-II (2X660 MW)
DB2
MOTORS
Clause No.
...........................................................
(Bidder's Name)
MOTORS
PAGE
1 OF 12
DB2 :
MOTORS
SECTION-VI
PART - G
STAGE-II (2X660 MW)
Applicable Data to be filled for each rating of HT, LT and DC motors
MOTORS
1.00.00 GENERAL
1.01.00 Manufacturer & Country of origin .......................................................
1.02.00 Equipment driven by motor .......................................................
1.03.00 Motor type .......................................................
1.04.00 Quantity .......................................................
2.00.00 DESIGN AND PERFORMANCE DATA
2.01.00 Frame size .......................................................
2.02.00 Type of duty .......................................................
2.03.00 Type of enclosure and method .......................................................
of cooling, Degree of protection
2.04.00 Applicable standard to which .......................................................
motor generally conforms
2.05.00 Type of mounting .......................................................
2.06.00 Direction of rotation as viewed .......................................................
from DE END
2.07.00 Standard continuous rating at .......................................................
40 deg.C. ambient temp. (KW)
2.08.00 De rated rating for specified .......................................................
normal condition i.e. 50 deg.C
ambient temperature (KW)
2.09.00 Rated Voltage (volts) .......................................................
2.10.00 Permissible % variation of
a) Voltage (Volts) .......................................................
b) Frequency (Hz) .......................................................
c) Combined voltage and frequency .......................................................
Clause No.
...........................................................
(Bidder's Name)
MOTORS
PAGE
2 OF 12
DB2 :
MOTORS
SECTION-VI
PART - G
STAGE-II (2X660 MW)
2.11.00 Minimum permissible starting .......................................................
Voltage (Volts)
2.12.00 Rated speed (RPM) at rated .......................................................
voltage and frequency
2.13.00 At rated Voltage and frequency
a) Full load current (Amps) .......................................................
b) No load current (Amps) .......................................................
2.14.00 Power Factor at
a) 100% load .......................................................
b) NO load .......................................................
c) Starting .......................................................
2.15.00 Efficiency at rated voltage
and frequency,
a) 100% load .......................................................
b) 75% load .......................................................
c) 50% load .......................................................
2.16.00 Starting current (amps) at
a. 100 % voltage .......................................................
b. 85% voltage .......................................................
c. 80% voltage .......................................................
d. Min permissible voltage .......................................................
2.17.00 Starting time (secs) with
minimum permissible voltage
a. Without driven equipment .......................................................
coupled
b. With driven equipment coupled .......................................................
Clause No.
...........................................................
(Bidder's Name)
MOTORS
PAGE
3 OF 12
DB2 :
MOTORS
SECTION-VI
PART - G
STAGE-II (2X660 MW)
2.18.00 Safe stall time (secs) with
100% and 110% of rated voltage
a. From hot condition .......................................................
b. From cold condition .......................................................
2.19.00 Torques in Kg-m and in %
of FLT
a. Starting torque at min. .......................................................
permissible voltage
b. Pull up torque at rated .......................................................
voltage
c. Pull out torque .......................................................
d. Min accelerating torque .......................................................
(kg.m) available
e. Rated torque (kg.m) .......................................................
2.20.00 Stator winding DC resistance .......................................................
per phase (ohms at 20 Deg.C.)
2.21.00 GD2 value of motors .......................................................
2.22.00 No of permissible successive .......................................................
starts when motor is in
hot condition
2.23.00 a. locked rotor KVA input .......................................................
b. Locked rotor KVA/KW .......................................................
2.24.00 Bearings
a. Type .......................................................
b. Manufacturer .......................................................
c. Self Lubricated or forced .......................................................
Lubricated
Clause No.
...........................................................
(Bidder's Name)
MOTORS
PAGE
4 OF 12
DB2 :
MOTORS
SECTION-VI
PART - G
STAGE-II (2X660 MW)
d. Recommended Lubricants .......................................................
e. Guaranteed Life in Hours .......................................................
f. Whether Dial Type thermometer .......................................................
provided
g. Oil pressure Gauge/switch .......................................................
i. Range .......................................................
ii. Contact Nos. & ratings .......................................................
iii. Accuracy .......................................................
2.25.00 Vibration
a) Velocity (mm/s) .......................................................
b) Displacement (microns) .......................................................
2.26.00 Noise level (DB) or Noise pressure .......................................................
or Noise power
3.01.00 Stator winding insulation / Armature
winding insulation in case of
a. Class & Type .......................................................
b. Tropicalised (Yes/No) .......................................................
c. Temperature rise over
specified max.
i. Cold water temperature .......................................................
of 39 DEG. C.
ii. Ambient Air 50 DEG. C. .......................................................
(for air cooled motor)
d. Method of temperature .......................................................
measurement
Clause No.
...........................................................
(Bidder's Name)
MOTORS
PAGE
5 OF 12
DB2 :
MOTORS
SECTION-VI
PART - G
STAGE-II (2X660 MW)
e. Stator winding connection .......................................................
f. Number of terminals .......................................................
brought out
3.02.00 Type of terminal box for
a. stator leads .......................................................
b. space heater .......................................................
c. Temperature detectors .......................................................
d. Instrument switch etc. .......................................................
3.03.00 For main terminal box
a. Location
b. Entry of cables .......................................................
c. Suitable for cable size ------------Cores X --------------SQMM
(To be matched with cable
size envisaged by owner)
d. Fault level (MVA) .......................................................
3.04.00 For bearing
a. Type .......................................................
b. Manufacturer .......................................................
c. Recommended lubricant .......................................................
d. Oil quantity .......................................................
e. Max cold oil temp. to .......................................................
bearing (deg . C)
f. Guaranteed life in Hrs .......................................................
g. Lubrication type .......................................................
Clause No.
...........................................................
(Bidder's Name)
MOTORS
PAGE
6 OF 12
DB2 :
MOTORS
SECTION-VI
PART - G
STAGE-II (2X660 MW)
h. Whether dial type thermometer .......................................................
provided
i. Oil pressure gauge/ switch .......................................................
3.05.00 Type of cooler
a. CACA / CACW / Number .......................................................
for HT motors
3.06.00 Cooling water requirements
(if applicable)
a. Quantity required (M3/hr) .......................................................
b. Maximum permissible inlet .......................................................
water temp. in deg.C
c. Pressure of water (KSC) .......................................................
at inlet to coolers
d. Outlet temperature (deg.C) .......................................................
of water at full load
e. Cold air temp. (deg.C) .......................................................
at outlet
3.07.00 Paint shade .......................................................
3.08.00 Max. permissible temperature .......................................................
of rotor (deg.C)
3.09.00 Temp. Rise of rotor during .......................................................
1st start (deg.C)
3.10.00 Temp. rise of rotor during .......................................................
2nd start (deg.C)
3.11.00 Surge withstand voltage (stator winding) .......................................................
only for HT Motors
a) 0.3/3 micro sec surge (KVp) .......................................................
b) 1.2/50 micro sec surge (KVp) .......................................................
Clause No.
...........................................................
(Bidder's Name)
MOTORS
PAGE
7 OF 12
DB2 :
MOTORS
SECTION-VI
PART - G
STAGE-II (2X660 MW)
3.12.00 Weight of
a. Motor stator (KG) .......................................................
b. Motor Rotor (KG) .......................................................
c. Total weight (KG) .......................................................
4.00.00 LIST OF ACCESSORIES.
a) RTDs for winding for HT .......................................................
motors (Type/Nos/Leads/
Location/make/Res.at 0 Deg.C)
b) RTDs for bearing for HT .......................................................
motors (Type/Nos/Leads
location/make/Res.at 0 Deg.C)
c) RTDs for Hot Air for HT .......................................................
motors (Type/No/Leads)
d) RTDs for Cold Air for HT .......................................................
motors (Type/No./Leads)
e) Space Heaters for motors
beyond 30KW rating
i) Nos. .......................................................
ii) Power (Watts) .......................................................
iii) Supply Voltage .......................................................
f) Stator Terminal Box
(For HT motor)
i) Type .......................................................
ii) Fault Level (MVA) .......................................................
iii) Fault Level duration .......................................................
(secs)
Clause No.
...........................................................
(Bidder's Name)
MOTORS
PAGE
8 OF 12
DB2 :
MOTORS
SECTION-VI
PART - G
STAGE-II (2X660 MW)
g) Neutral TB for HT motors
i) Type .......................................................
h) Current Transformer for
HT motors
i) Nos. .......................................................
ii) Ratio .......................................................
iii) Accuracy Class .......................................................
iv) Knee Point Voltage-Vk .......................................................
(Volts)
v) Exciting Current .......................................................
vi) Max Secondary .......................................................
Resistance
i) Dial Type Thermometer
for HT motors (Type/make/
Accuracy/Connection type
& size
i) For Bearings (Nos.) .......................................................
ii) For Air Temp (Nos.)
a. Hot Air .......................................................
b. Cold Air .......................................................
iii) Contact Rating .......................................................
iv) Range .......................................................
v) Supply Votlage .......................................................
j) Rotor Terminal Box .......................................................
k) TBs for RTDs. BTDs & .......................................................
Space Heater (Yes/No)
Clause No.
...........................................................
(Bidder's Name)
MOTORS
PAGE
9 OF 12
DB2 :
MOTORS
SECTION-VI
PART - G
STAGE-II (2X660 MW)
l) Sole Plate (Yes/No) .......................................................
m) Foundation & Anchoring .......................................................
bolts (Yes/No)
n) Base Frame (Yes/No) .......................................................
o) speed switch (Yes/No)
i) No of contacts and .......................................................
contact ratings of
speed switch
p) Insulation of bearing (Yes/No) .......................................................
q) Forced oil lubrication (Yes/No) .......................................................
r) Oil level indicator (Yes/No) .......................................................
s) Noise reducer (Yes/No) .......................................................
t) Flow switch for CACW
motor (Quantity)
contact ratings
u) Water leakage detector
for HT motors
contact ratings
v) Grounding pads
i) No and size on .......................................................
motor body
ii) Nos on terminal Box .......................................................
w) Vibration pads
i) No and size .......................................................
ii) Location .......................................................
x) Any other fitments .......................................................
Clause No.
...........................................................
(Bidder's Name)
MOTORS
PAGE
10 OF 12
DB2 :
MOTORS
SECTION-VI
PART - G
STAGE-II (2X660 MW)
5.00.00 LIST OF CURVES
i. Torque speed characteristic .......................................................
of the motor
ii. Calibration characteristic of .......................................................
platinum type resistance
temperature detector
iii. Calibration characteristic .......................................................
of platinum BTD
iv. Thermal withstand characteristic .......................................................
v. starting current Vs. Time .......................................................
vi. starting. current Vs speed .......................................................
vii. Neg. sequence current vs Time .......................................................
viii. P.F. and Effi. Vs Load .......................................................
6.00.00 Additional Data to be filled
for each rating of DC Motor
6.01.00 Rated armature voltage (Volt) .......................................................
6.02.00 Rated field excitation (Amp) .......................................................
6.03.00 Permissible % variation in voltage .......................................................
6.04.00 Minimum Permissible Starting .......................................................
voltage (volt)
6.05.00 At rated voltage
i) Full load Armature current. .......................................................
(Amp)
ii) Full load Field current (Amp) .......................................................
iii) No load Armature current (Amp) .......................................................
6.06.00 Full load Field current (Amp) .......................................................
Clause No.
...........................................................
(Bidder's Name)
MOTORS
PAGE
11 OF 12
DB2 :
MOTORS
SECTION-VI
PART - G
STAGE-II (2X660 MW)
6.07.00 No load Aramature current (Amp) .......................................................
6.08.00 Minimum permissible field current
(Amp) to avoid overspeeding at
i) Maximum permissible voltage .......................................................
ii) Rated voltage .......................................................
iii) Minimum Permissible Voltage .......................................................
6.09.00 Resistance (indicative Values) in ohm
i) Armature winding .......................................................
(Arm + IP + Series)
at 25 deg.C
ii) Field Winding at 25 deg. C .......................................................
6.10.00 Inductance (indicative values)
i) Armature winding .......................................................
ii) Field winding .......................................................
6.11.00 Value of trimmer resistance (ohm)
to be connected in series with
the shunt field to obtain rated
speed at
i) 220 V DC .......................................................
ii) 250 V DC .......................................................
iii) 187 V DC .......................................................
6.12.00 Value of the external resistance (ohm) .......................................................
required to be connected in series
with armature during starting only
6.13.00 Technical data sheet for external .......................................................
resistance box
6.14.00 Terminal box arrangement .......................................................
Clause No.
...........................................................
(Bidder's Name)
MOTORS
PAGE
12 OF 12
DB2 :
MOTORS
SECTION-VI
PART - G
STAGE-II (2X660 MW)
6.15.00 GA drawing of motor .......................................................
6.16.00 Starting time calculation .......................................................
6.17.00 Starter resistance design calculation .......................................................
6.18.00 Electrical connection diagram of motor .......................................................
SECTION-VI
PART - G
STAGE-II (2X660 MW)
DB3
POWER AND CONTROL CABLES
Clause No.
...........................................................
(Bidder's Name)
PAGE
1 OF 2
DB3 : POWER
AND CONROL
CABLES
SECTION-VI
PART - G
STAGE-II (2X660 MW)
(Use separate sheet for each type and size of cables)
1.00.00 Make ............................ .....................
1.02.00 Country of Manufacturer ............................ .....................
1.03.00 Type & designation ............................ .....................
1.04.00 Applicable standard ............................ .....................
1.05.00 Cable size & no. of cores ............................ .....................
1.06.00 Rated voltage ............................ .....................
1.07.00 Catalogue attached as Annexure No. ............................ .....................
1.08.00 Continuous current rating ............................ .....................
for max. conductor temperature
a) When laid in air at an ambient ............................ .....................
temperature of 50 deg. C
b) When buried in soil having ............................ .....................
thermal resistivity of 150 deg.C
cm/n at a depth of 1000 mm
at ground ambient temperature
of 40 deg. C
1.09.00 Short circuit withstand capacity and ............................ .....................
duration for
a) Conductor ............................ .....................
b) Screen ............................ .....................
c) Armour ............................ .....................
1.10.00 Conductor ............................ .....................
a) Material ............................ .....................
b) Nominal cross section ............................ .....................
area in sq. mm
Clause No.
...........................................................
(Bidder's Name)
PAGE
2 OF 2
DB3 : POWER
AND CONROL
CABLES
SECTION-VI
PART - G
STAGE-II (2X660 MW)
c) Shape of conductor ............................ .....................
d) DC resistance at 20
o
C (Maxm.) ............................ .....................
1.11.00 Insulation
a) Material ............................ .....................
b) Nominal thickness (in mm) ............................ .....................
c) Type of curing (for XLPE) ............................ .....................
1.12.00 Metallic screen (wherever applicable)
a) Material ............................ .....................
b) Type ........................... ....................
c) Short Ckt. (KA) & Period (Sec.)
1.13.00 Material & Type of Inner sheath ............................ .....................
1.14.00 Armour material & shape ............................ .....................
1.15.00 Outer sheath material & type ............................ .....................
1.16.00 Over all dia of cable (in mm) ............................ .....................
1.17.00 Guaranteed value of minimum ............................ .....................
oxygen index of outer sheath
1.18.00 Maximum acid-gas generation ............................ .....................
by weight (%) of outer sheath
1.19.00 Smoke Density rating of outer sheath ............................ .....................
SECTION-VI
PART - G
STAGE-II (2X660 MW)
DB4
CABLING EARTHING AND
LIGHTNING PROECTION
Clause No.
...........................................................
(Bidder's Name)
CABLING EARTHING AND LIGHTNING PROTECTION
PAGE
1 OF 3
DB4 : CAB.
EARTH. & LIGHT.
PROTEC.
SECTION-VI
PART - G
STAGE-II (2X660 MW)
CABLE SUPPORT SYSTEM
1.00.00 Cable Trays, Fittings & Accessories
1.01.00 Makers, Name, Country of ............................ .....................
manufacturer
1.02.00 Type & Material of cable tray ............................ .....................
2.00.00 Conduit Pipes & Accessories
2.01.00 Maker's Name and Country of ............................ .....................
manufacture
2.02.00 Material ............................ .....................
2.03.00 Class of duty ............................ .....................
2.04.00 Type of Coating ............................ .....................
2.05.00 Applicable Standard ............................ .....................
3.00.00 Junction Boxes
manufacture
3.02.00 Material ............................ .....................
3.04.00 Degree of Protection ............................ .....................
4.00.00 Cable Glands
manufacture
4.02.00 Type of cable gland ............................ .....................
4.04.00 Material ............................ .....................
Clause No.
...........................................................
(Bidder's Name)
PAGE
2 OF 3
DB4 : CAB.
EARTH. & LIGHT.
PROTEC.
SECTION-VI
PART - G
STAGE-II (2X660 MW)
5.00.00 Cable lugs & Terminals
5.01.00 Maker's Name & Country of ............................ .....................
Manufacturer
5.02.00 Material ............................ .....................
5.03.00 Applicable Standard
(i) HT ............................ .....................
(ii) LT ............................ .....................
6.00.00 Earthing System
Equipment earthing
i) Material .............................. .....................
ii) Size ............................ .....................
iii) Applicable Standard ............................ .....................
7.00.00 Lightning Protection System
i) Applicable Standard ............................ .....................
ii) Size & material for Air termi- ............................ .....................
nation and down conductor
8.00.00 Cable Jointing/Termination Kits
(a) Maker's Name & Country
of Manufacturer ............................ .....................
(b) Type of System
(i) Termination H.T./L.T. ............................ .....................
(ii) J oints H.T./L.T. ............................ .....................
(c) Outdoor/Indoor ............................ .....................
Clause No.
...........................................................
(Bidder's Name)
PAGE
3 OF 3
DB4 : CAB.
EARTH. & LIGHT.
PROTEC.
SECTION-VI
PART - G
STAGE-II (2X660 MW)
9.00.00 Cable Tray Support System
(a) Maker's Name, Country
of Manufacturer
(b) Type & Material of cable
tray support system
(c) Catalogue and indicative
sketch attach as annexure No.
SECTION-VI
PART - G
STAGE-II (2X660 MW)
DB5
ELECTRICAL ACTUATOR
Clause No.
...........................................................
(Bidder's Name)
ELECTRICAL ACTUATOR
PAGE
1 OF 3
DB5 :
ELECTRICAL
ACTUATOR
SECTION-VI
PART - G
STAGE-II (2X660 MW)
ACTUATOR DATA SHEET:
Sl.No. Description Unit Data
1. Actuator Manufacturer
2. Model
3. Torque Range & RPM Kg-M
4. Duty Cycle (ON-OFF/Regulating)
5. Local/Remote Selector Switch (Lockable)
6. Enclosure/Degree of Protection
7. Admissible Ambient Temperature
O
C
8. Average/Nominal Output KW
9. Rated Voltage V
10. Rated Frequency Hz
11. No. of Phases/No of Wires (3ph/3wires) Ph/Wires
12. Frame Size
13. Admissible Voltage Variation %
14. Admissible Frequency Variation %
15. Admissible Combined Volt. & Freq. Variation %
16. Nominal Current (Average) A
17. Starting Current A
18. Full Load Speed RPM
19. Insulation Class
20. Power Factor (Average Load)
21. Average Load fficiency %
22. Temp. Rise Over Ambient Temp. of 50
O O
C
Clause No.
...........................................................
(Bidder's Name)
ELECTRICAL ACTUATOR
PAGE
2 OF 3
DB5 :
ELECTRICAL
ACTUATOR
SECTION-VI
PART - G
STAGE-II (2X660 MW)
23. Cable Gland Size/No: Power
(Double Compression Cable Gland)
24. Cable Gland Size/No: Control
(Double Compression Cable Gland)
25. Gear Box Lubrication
26. Position Limit Switches
(a) Quantity Nos.
(b) No. of Contacts Nos.
27. Torque Switches
(a) Quantity Nos.
(b) No. of Contacts Nos.
28. Voltage/Current Rating of Switches V/A
29. Position Transmitter-ON/OFF Duty Yes/No
30. Position Transmitter-Inching Yes/No
Duty (If provided)
31. Space Heater Power Supply Details
32. Cable size for Space Heater Terminal
33. Thermostat (One no. per phase) 3 Nos.
34. Internal Wiring Cable Size
35. Control Circuit Diagram (Enclosed) Yes/No
36. Integral Starter Provided Yes/No
37. Weight-Actuator Kg
38. Motor Suitable for ON-OFF/Inching
Clause No.
...........................................................
(Bidder's Name)
ELECTRICAL ACTUATOR
PAGE
3 OF 3
DB5 :
ELECTRICAL
ACTUATOR
SECTION-VI
PART - G
STAGE-II (2X660 MW)
39. Motor Type & Ref. Stanard
40. OLR Set Value (Recommended) A
41 Plug & Socket
(Integral mounted on the Actuator)
42. The Colour Coding of Cables
For 9 Pin Plug & Socket Suitable
For 4 Pair, 0.5 SQMM Copper Cables
43. Single Phase Yes/No
Sequence Protection Provided
44. Wrong Phase Yes/No
Sequence Protection Provided
45. Paint Shade
46. Secondary Gear Box
Gear Box Model & Ratio
Gear Box Make
Travel Time Secs
Secondary Gear Box Maximum Output Torque Kgm
Type of Enclosure
SECTION-VI
PART - G
STAGE-II (2X660 MW)
DB6
LIGHTING (H
2
GENERATION PLANT)
Clause No.
.........................................................
(Bidder's Name)
LIGHTING (H
2
GENERATION PLANT)
PAGE
1 OF 3
DB6 : LIGHTING
(H
2
GENERATION
PLANT)
SECTION-VI
PART - G
STAGE-II (2X660 MW)
LIGHTING
1.00.00 Lighting Panel
(a) Make .............................. ..........................
(b) Applicable standard .............................. ..........................
(c) Enclosure .............................. ..........................
(d) Catalogue attached as annexure no. .............................. ..........................
2.00.00 Miniature Circuit Breaker
(a) Make .............................. ..........................
(b) Type designation .............................. ..........................
(c) Applicable standard .............................. ..........................
(d) Rated current & voltage .............................. ..........................
(e) Breaking capacity at 0.6 p.f. .............................. ..........................
(f) Catalogue attached as annexure no. .............................. ..........................
3.00.00 Isolator
(a) Make .............................. ..........................
(b) Type designation .............................. ..........................
4.00.00 Fuses
(a) Make .............................. ..........................
(b) Type .............................. ..........................
(c) Applicable Standard .............................. ..........................
5.00.00 Contactor
(a) Make .............................. ..........................
(b) Type & duty .............................. ..........................
Clause No.
.........................................................
(Bidder's Name)
LIGHTING (H
2
GENERATION PLANT)
PAGE
2 OF 3
DB6 : LIGHTING
(H
2
GENERATION
PLANT)
SECTION-VI
PART - G
STAGE-II (2X660 MW)
6.00.00 Synchronous timer (if applicable)
(a) Make .............................. ..........................
(b) Type .............................. ..........................
7.00.00 Lighting fixtures & Accessories
(a) Make of lighting fixtures & .............................. ..........................
accessories
(b) Catalogue for each type of .............................. ..........................
fixture attached as annexure no.
8.00.00 Switches
(a) Make .............................. ..........................
(b) Type .............................. ..........................
(c) Catalogue attached as annexure no. .............................. ..........................
(e) Applicable standard .............................. ..........................
9.00.00 Receptacle/Sockets
(a) Make .............................. ..........................
(b) Type .............................. ..........................
10.00.00 J unction Boxes
(a) Make .............................. ..........................
(b) Type .............................. ..........................
(c) Material .............................. ..........................
(d) Applicable standard .............................. ..........................
Clause No.
.........................................................
(Bidder's Name)
LIGHTING (H
2
GENERATION PLANT)
PAGE
3 OF 3
DB6 : LIGHTING
(H
2
GENERATION
PLANT)
SECTION-VI
PART - G
STAGE-II (2X660 MW)
11.00.00 Terminal Blocks
(a) Make .............................. ..........................
(b) Type .............................. ..........................
(c) Rating .............................. ..........................
12.00.00 Rigid steel Conduits/Fittings
& accessories
(a) Make .............................. ..........................
(b) Material .............................. ..........................
13.00.00 Flexible steel conduit
(a) Make .............................. ..........................
14.00.00 Lighting Wires
(a) Make .............................. ..........................
(c) Voltage grade .............................. ..........................
(d) Size .............................. ..........................
(e) Conductor material .............................. ..........................
(f) Insulation .............................. ..........................
15.00.00 Type test reports of all items for
Lighting enclosed at annexure no. .............................. ..........................
SECTION-VI
PART - G
STAGE-II (2X660 MW)
DB7
LT SWITCHGEAR & LT BUSDUCTS
CLAUSE NO.
BIDDERS NAME

STAGE-II (2X660 MW)

SECTION - VI
PART-G

DB:7 LT SWITCHGEARS
& LT BUSDUCTS

PAGE
1 OF 11

LT SWITCHGEARS & LT BUSDUCTS
1.00.00 SWITCHGEAR & MCC
a) General
i) Manufacturer's Name
..........................

ii) Type designation ..........................
iii) Country of origin ..........................
b) Rated voltage ..........................
c) Symmetrical short circuit withstand current at rated
voltage of switchgear /MCC cubicle.
..........................
d) Peak short circuit withstand current ..........................
e) Rated current at ambient ..........................
f) Degree of protection as per IS:13947
i) Breaker / MCC cubicles ..........................
ii) Busbar chamber ..........................
g) Cubicle sheet metal details
i) Cold rolled / hot rolled ..........................
ii) Thickness, structural & load bearing members ..........................
iii) Thickness, front & rear ..........................
iv) Thickness, Sides & top ..........................
v) Thickness of gland plates ..........................
h) Painting shade & Thickness as per IS :5
i) External surfaces(front & rear) ..........................
ii) Extreme end covers ..........................
CLAUSE NO.
BIDDERS NAME

STAGE-II (2X660 MW)

SECTION - VI
PART-G

DB:7 LT SWITCHGEARS
& LT BUSDUCTS

PAGE
2 OF 11

i) Minimum Clearance in air for Busbars
i) Between phases ..........................
ii) Between phase & earth ..........................
j) Standard height, width & depth of typical panel
i) Circuit breaker panel ..........................
ii) MCC panels (S.F./D.F.) ..........................
iii) Circuit breaker panel with Bus trunking /Bus Duct
Termination
..........................
iv) ACDB/DCDB ..........................
v) AC/DC Fuse boards ..........................
k) Width of cable alley ..........................
l) Shrouding arrangement in cable alley provided or not YES/NO
m) Earth busbar size & material ..........................
n) Approx. Weight of one panel With circuit breaker ..........................
o) Recommended dynamic loading for foundation design ..........................
p) Approx. weight of one MCC panel ..........................
2.00.00 POWER BUSBARS & INSULATORS
a) Material & applicable standards ..........................
b) Bare/painted / epoxy insulated/sleeved ..........................
c) Continuous current rating at an ambient temp. of 50
0
C ..........................
d) Temperature rise over design ambient temperature for
continuous current rating deg. C
..........................
e) Material of the support insulators ..........................
f) One second current rating (kA) ..........................
CLAUSE NO.
BIDDERS NAME

STAGE-II (2X660 MW)

SECTION - VI
PART-G

DB:7 LT SWITCHGEARS
& LT BUSDUCTS

PAGE
3 OF 11

3.00.00 CONTROL SUPPLY TRANSFORMER
a) Make ..........................
b) Type ..........................
c) Material & class of insulation ..........................
d) Voltage rating & taps ..........................
e) Continuous rating (VA) ..........................
4.00.00 CIRCUIT BREAKER
a) Manufacturer's name and country of manufacturer ..........................
b) Manufacture's type and designation ..........................
c) Rated Voltage ..........................
d) Rated operating duty ..........................
e) Design ambient temperature ..........................
f) Rated current at design ambient temperature ..........................
g) Derating factor for site operating conditions inside
panel
..........................
h) Continuous current at ambient temp. ..........................
i) Rated symmetrical breaking current ..........................
j) Rated peak making current ..........................
k) Rated short time rating (for 1 sec.) ..........................
l) Rated peak momentary rating ..........................
m) Number of openings, the circuit breaker is capable of
performing without inspection, replacement of contacts
or other parts at 100% rated breaking current
..........................
n) No. of breaker auxiliary contacts provided on fixed
portion of breaker & their rating
..........................
CLAUSE NO.
BIDDERS NAME

STAGE-II (2X660 MW)

SECTION - VI
PART-G

DB:7 LT SWITCHGEARS
& LT BUSDUCTS

PAGE
4 OF 11

o) Trip free and anti pumping features have been
provided (Furnish description)
YES/NO
p) Power operating mechanism ..........................
q) Spring charging motor details
i) Type ..........................
ii) Rating Watts ..........................
iii) Rated voltage ..........................
iv) Class of insulation ..........................
v) Time for fully charging the closing spring ..........................
r) Emergency Manual charging facility provided YES/NO
s) Limits of voltage for satisfactory operation of the
following devices as percentage of normal voltage

i) Motor ..........................
ii) Closing coil ..........................
iii) Tripping coil ..........................
t) Manual operating mechanism ..........................
u) i) Type of Releases provided ..........................
ii) Available range of following parameters for each
type of release offered
..........................
v) i) Maximum Tripping Time ..........................
ii) Maximum Closing time ..........................
w) i) Closing coil VA ..........................
ii) Tripping coil VA ..........................
x) Telescopic trolley
i) Make ..........................
CLAUSE NO.
BIDDERS NAME

STAGE-II (2X660 MW)

SECTION - VI
PART-G

DB:7 LT SWITCHGEARS
& LT BUSDUCTS

PAGE
5 OF 11

ii) Type designation ..........................
iii) Dimensions ..........................
5.00.00 AIR BREAK SWITCHES
(The following details shall be furnished for each type & rating)
a) Make ..........................
b) Type ..........................
c) Applicable standards ..........................
d) Rated current at design ambient temperature (Amps) ..........................
e) Design ambient temperature Deg C ..........................
f) Rated breaking current (kA) ..........................
g) Maximum through fault current withstand kA ..........................
h) Door interlock as specified has been provided ? YES/NO
i) No. of auxiliary contacts and its rating ..........................
6.00.00 CONTROL/SELECTOR SWITCH
a) Make ..........................
b) Type Designation ..........................
c) Voltage grade ..........................
7.00.00 CONTACTOR
(The following details shall be furnished for each type and rating)
a) Make ..........................
b) Type & applicable standards ..........................
c) Rated voltage of main and auxiliary contacts ..........................
d) Rated voltage of coils ..........................

CLAUSE NO.
BIDDERS NAME

STAGE-II (2X660 MW)

SECTION - VI
PART-G

DB:7 LT SWITCHGEARS
& LT BUSDUCTS

PAGE
6 OF 11

e) Limits of operation
i) Supply voltage variation +/-% ..........................
ii) Supply frequency variation for closing (+/-)% ..........................
iii) Drop out voltage % ..........................
f) Rated (thermal) current A ..........................
g) Rated duty ..........................
h) Rated utilisation category as per IS:13947 ..........................
i) Rated breaking capacity kA ..........................
j) Rated making capacity - kA ..........................
k) Coil VA burden ..........................
8.00.00 AUXILIARY CONTACTOR
a) Make ..........................
b) Type ..........................
c) Catalogue attached as Annexure No. ..........................
9.00.00 FUSES
a) Make ..........................
b) Type ..........................
c) Category ..........................
10.00.00 CURRENT TRANSFORMERS
(The following details shall be provided for each type & rating)
a) Make ..........................
b) Applicable standards ..........................
c) Ratio ..........................
d) VA Rating ..........................
CLAUSE NO.
BIDDERS NAME

STAGE-II (2X660 MW)

SECTION - VI
PART-G

DB:7 LT SWITCHGEARS
& LT BUSDUCTS

PAGE
7 OF 11

e) Accuracy class ..........................
f) Class & type of insulation ..........................
11.00.00 VOLTAGE TRANSFORMERS
a) Make ..........................
b) Ratio ..........................
c) VA Rating ..........................
d) Accuracy class ..........................
e) Over voltage factor ..........................
f) Class & type of insulation ..........................
12.00.00 Numerical relays( If applicable)
a) General Technical Details and Drawings Enclosed ..........................
b) Make/Model No ..........................
c) Place of Manufacture ..........................
d) Hardware version number ..........................
e) Firmware version number ..........................
f) Rated Voltage Vn (phase-to-neutral) ..........................
g) Rated Current In ..........................
h) Rated Frequency ..........................
i) Over voltage capability - continuous ..........................
j) Over voltage capability 3s ..........................
k) Burden on voltage transformers (VA per phase) ..........................
l) Over current capability - continuous ..........................
m) Over current capability 1s ..........................
n) Burden on current transformers (VA per phase) ..........................
CLAUSE NO.
BIDDERS NAME

STAGE-II (2X660 MW)

SECTION - VI
PART-G

DB:7 LT SWITCHGEARS
& LT BUSDUCTS

PAGE
8 OF 11

o) Reference standards ..........................
p) Operating principle ..........................
q) No Of communication Ports ..........................
r) Compliance to IEC-61850 ..........................
s) Built-in functions provided in the relay (list out) ..........................
t) Protection Functions ..........................
u) Measurements ..........................
v) Monitoring Functions ..........................
w) Control functions ..........................
x) Detailed Technical Catalogue for offered Relays
enclosed
..........................
y) Spares and Repairs
a) State availability of spares in country and spares
holding in country of origin
..........................
b) Maximum repair turnaround time ..........................
c) Define the proposed repair strategy ..........................
d) Recommended spares list ..........................
z) List of reference sites in operation for more than 1 year ..........................
13.00.00 THERMAL OVERLOAD RELAY & SINGLE PHASING PREVENTER
(The following details shall be furnished for each type & rating)
a) Make & type designation ..........................
b) Catalogue ..........................
14.00.00 VOLTMETER
a) Make ..........................
b) Type ..........................
CLAUSE NO.
BIDDERS NAME

STAGE-II (2X660 MW)

SECTION - VI
PART-G

DB:7 LT SWITCHGEARS
& LT BUSDUCTS

PAGE
9 OF 11

c) Catalogue ..........................
15.00.00 AMMETER
a) Make ..........................
b) Type ..........................
c) Catalogue ..........................
16.00.00 PUSH BUTTONS
a) Make ..........................
b) Type designation ..........................
c) Catalogue ..........................
17.00.00 INDICATING LAMPS
a) Make ..........................
b) Type ..........................
c) Catalogue ..........................
18.00.00 LOCAL STARTERS
a) Make & Type ..........................
b) Catalogue ..........................
19.00.00 415 V NON SEGREGATED BUSDUCTS(If applicable)
a) Manufacturer's name & address ..........................
b) Type of busduct ..........................
c) Material and cross section of busbars ..........................
d) Rated voltage (volts) ..........................
e) Maximum voltage at which busduct can operate
continuously (volts)
..........................
f) Continuous current rating of busbars (Amps) ..........................
CLAUSE NO.
BIDDERS NAME

STAGE-II (2X660 MW)

SECTION - VI
PART-G

DB:7 LT SWITCHGEARS
& LT BUSDUCTS

PAGE
10 OF 11

g) Short circuit current ratings & duration (kA /Sec) ..........................
h) Momentary current rating kA peak ..........................
i) Temperature rise over the ambient temperature
i) Busbars ..........................
ii) Enclosures ..........................
j) Material of support insulator ..........................
k) No. and arrangement of support insulators ..........................
l) Material of Gaskets ..........................
m) One minute power frequency withstand voltage (kV) ..........................
n) Minimum creepage distance over insulator (mm) ..........................
o) Conductor treatment ..........................
p) Clearance (mm) ..........................
i) Phase to Phase ..........................
ii) Phase to earth ..........................
q) Average weight per meter of busduct (kg) ..........................
r) Material and thickness of Busduct ..........................
s) Shape & size of enclosure ..........................
20.00.00 LIGHTING / WELDING TRANSFORMERS
a) Make ..........................
b) Voltage Ratio ..........................
c) kVA Rating ..........................
d) Vector Group ..........................
e) Type of Cooling ..........................
f) Percentage impedance ..........................
CLAUSE NO.
BIDDERS NAME

STAGE-II (2X660 MW)

SECTION - VI
PART-G

DB:7 LT SWITCHGEARS
& LT BUSDUCTS

PAGE
11 OF 11

g) Details of taps provided ..........................
h) Class of insulation ..........................
i) Degree of protection for enclosure ..........................
j) Whether mounted inside MLDB or outside ..........................
k) If it is mounted outside dimension of the enclosure ..........................
21.00.00 Metering Network and Energy Meters (For Motor>& = 100 KW)(If applicable)
a) Energy Meters
i. Manufacturer's type designation ..........................
ii. Accuracy (Power and Energy) ..........................
iii. Input Voltage ..........................
iv. Input current ..........................
v. Mounting ..........................
vi. Communication (in Built 485 Port) ..........................
vii. Data recorded in Non-volatile memory ..........................
viii. Burden ..........................
b) Type designation of RS 485 Converter ..........................
c) Type designation of LAN cable ..........................
d) Type Designation of Data Cable ..........................
22.00.00 Ethernet switches (For Networking of Numerical Relays)(If applicable)
a) Compliance to IEC 61850 ..........................
b) No of Ports ..........................
c) Power supply to Ethernet Switches ..........................

SECTION-VI
PART - G
STAGE-II (2X660 MW)
SECTION - VI
PART - G
MODULE - III
SECTION-VI
PART - G
STAGE-II (2X660 MW)
CONTROL & INSTRUMENTATION
MODULE - III CHAPTER - I : Technical Data to be Submitted
alongwith the Bid.
DC 01 : C&I Data Requirements
CHAPTER - II : Technical information and Data
to be submitted after Award of Contract
DC 02 : Post Award Technical Data
Requirements
SECTION-VI
PART - G
STAGE-II (2X660 MW)
CHAPTER-I
CLAUSE NO.
Bidders Name ..

STAGE-II (2X660 MW)
SECTION - VI
PART-G

DC-01
C&I DATA
REQUIRMENTS

PAGE
1 OF 13

DC 01

C&I DATA
REQUIREMENTS
CLAUSE NO.
Bidders Name ..

STAGE-II (2X660 MW)
SECTION - VI
PART-G

DC-01
C&I DATA
REQUIRMENTS

PAGE
2 OF 13

1.01.00 INSTRUCTIONS TO BIDDERS
1.01.01 The following table describes the non applicabilty of the subsequent clauses for
the current scope of the work identified under this package.

1.01.02 The Bidder shall ensure that all information, data, performance curves, technical
literature (catalogues/instruction manuals) and drawings furnished with the
proposal fully describe all equipment/systems covered under this proposal and fully
meet the requirements of this and related Sub-sections and other applicable
specification documents.

1.01.03 The Bidder shall use one of the following responses while filling the questionnaire
and proposal data sheets included in this part.

a) The Section No. and Page No. of the proposal where the required
information/data has been furnished by the Bidder.

b) An answer (data or narrative description).

c) A Not-Applicable statement (N.A.)

1.01.04 Bids not meeting the above requirement or not containing full description/data/
technical literature/details regarding past experience for similar application for the
proposed equipment may be treated as non responsive and this will be considered
as an adequate reason for rejection of the concerned Bid.

1.01.05 The Employer reserves the right to ask for further details regarding technical
features, application particulars, performance, past experience for similar
applications or any other information as may be required to fully satisfy himself
regarding suitability, quality, reliability and full compliance with this specification for
all equipment and systems offered by the Bidder.

1.01.06 Bidder shall furnish with his proposal the original Technical Data Sheets completely
filled in and five Photostat Copies of the data sheets (photocopies of the original).
In no case, the Bidder shall retype/redraft these data sheets.

Sl
No
Clause No Key words of the
clause
Applicability Remarks
1 Not applicable Not applicable Not applicable
CLAUSE NO.
Bidders Name ..

STAGE-II (2X660 MW)
SECTION - VI
PART-G

DC-01
C&I DATA
REQUIRMENTS

PAGE
3 OF 13

1.01.07 It may be noted that this technical data sheet is for Bidding purpose only. During
detailed engineering, the Bidder shall be required to furnish all additional data
about the equipment/System being supplied, even if such details are not asked for
in this part.

1.01.08 Bidder should legibly fill in all the data asked for in these sheets either by hand in
black ink or preferably by typing the matter. All the filled in data sheets should be
duly returned with the bid.

1.01.09 Continuation sheets may be suitably attached whenever the need arises. These
pages may be suitably numbered accordingly.

1.01.10 Corrections should be avoided. However, whenever it is imperative to carry out
correction, this should be done neatly and should be initialled by the authorised
signatory.

1.01.11 Each page of the technical data sheet should be initialled by the authorised
signatory & should bear the legal stamp of the company.

1.01.12 Bidder should indicate his name on each sheet.

1.02.00 BIDDER'S / C&I SYSTEM SUB-SUPPLIER
ORGANISATION STRUCTURE

1.02.01 Details regarding quality assurance Procedures
and test facilities available in the Works of Bidder
/ C&I System/ Sub-Supplier Page No .......... Sec. No.........
1.02.02 Reference list of comparable control and
instrumentation packages furnished by the
Bidder/C&I system/Sub-Supplier Page No ......... Sec. No.......
1.02.03 Brief description regarding manufacturing
facilities of the Bidder and DDC-MIS
manufacturer. (Please furnish details of floor
area, number of engineers, workers,
manufacturing facilities, special equipment
for manufacture andtesting etc.) Page No .......... Sec. No.........

CLAUSE NO.
Bidders Name ..

STAGE-II (2X660 MW)
SECTION - VI
PART-G

DC-01
C&I DATA
REQUIRMENTS

PAGE
4 OF 13

1.03.00 CONFIRMATION REGARDING Bidders's Response
BIDDERS PROPOSAL

1.03.01 Bidder/C&I System Sub-supplier to
furnish a list of bought out items
covered in his proposal along with
names of sub-vendors Page no .................. Sec No ..............

1.03.02 Bidder to confirm that all equipment
and System covered under this
specification shall be furnished as per
the requirements of this specification
and drawings / documents approved
by the Employer during contract stage .......................... Yes ....................

1.03.03 Bidder to confirm that all bought out
items shall be furnished as per make,
model and technical specifications
approved by the Employer during contract
stage within the quoted price .......................... Yes ....................

1.04.00 DISTRIBUTED DIGITAL CONTROL,
MONITORING AND INFORMATION
SYSTEM (DDCMIS)
1.04.01 General Technical Details and Drawings

i) DDCMIS manufacturers name ....................................;................

ii) Make / Model No. .......................................................

iii) Place of manufacture ........................................................

1.04.02 Detailed descriptions of Distributed Digital
Control, Monitoring and Information
System (DDCMIS) proposed by the Bidder
covering all salient features of hardware,
software, system configuration for each
system/ sub-system testing, documentation,
post commissioning support facilities, etc.
furnished at Page No .............. Sec. No.............

CLAUSE NO.
Bidders Name ..

STAGE-II (2X660 MW)
SECTION - VI
PART-G

DC-01
C&I DATA
REQUIRMENTS

PAGE
5 OF 13

1.04.03 Complete Bill of Materials including all
hardware items/equipment and accessories
(along with model no. of each item)
furnished at Page No ............Sec. No.............

1.04.04 Cabinet size/ Type ..

1.04.05 Cutout details of each type of cabinet
Furnished at

1.04.06 Layout drawings of Bidders cabinets for
CER / CR / RIO room furnished at ...

1.04.07 List of proprietary control systems not
offered as a part of offered DDCMIS. No. ............................................ ...........

1.04.08 Supporting documents furnished
for above. Page No .............. Sec. No.............

1.04.09 The offered HMIPIS is as per which alternative
Alternative - I / Alternative II

1.05.00 TG CONTROL SYSTEM
1.05.01 General

a) Control System functional grouping
diagram furnished at Page No ............ Vol.No..............

b) No. of functional groups (FGs)
offered .....................................................

c) Confirm that for each of the FGs,
separate sets of controllers, I/O
modules, communication controllers,
power supply packs/modules are Yes/No
provided
.....................................................
d) Confirm that Control System
shall function under environmental
conditions as per Sub-section Basic
Design Criteria, Yes/No
Part-B of Section-VI . .....................................................
CLAUSE NO.
Bidders Name ..

STAGE-II (2X660 MW)
SECTION - VI
PART-G

DC-01
C&I DATA
REQUIRMENTS

PAGE
6 OF 13

e) On-line simulation, testing, configura- Yes/No
tion & tuning of controllrs is possible .....................................................

f) Programs in controllers is stored
in (e.g. EEPROM/EPROM etc.) .....................................................

1.05.02 Please indicate make/model no. of
each of the control system indicated
below

i) TG Governing system .....................................................

ii) ATRS .....................................................

iii) TG C&I system (Turbine Protection) .....................................................

iv) TG C&I system (Non Turbine
Protection part) .....................................................

v) HP/LP Bypass .....................................................

vi) BFP TDBFP governing & protection .

vii) COLCTS

viii) SCS

ix) CPU .

x) LOPS

1.05.03 Turbine Protection System (TPS)

1. Whether all modules used in Yes/No
TPS are of fail safe design ....................................................

2. Whether that TPS meets all
applicable safety requirements
including those stipulated in
VDE 0116, section 8.7, VDE 0160/ Yes/No
8.83; DIN 57116 or IEC61508/IEC61511 .............................................

CLAUSE NO.
Bidders Name ..

STAGE-II (2X660 MW)
SECTION - VI
PART-G

DC-01
C&I DATA
REQUIRMENTS

PAGE
7 OF 13

3. Confirm that any single fault in
either primary sensor, input/output
modules, controller module etc.
will not result in loss of safety Yes/No
function .....................................................

4. i) Electronic protection channel in
2-out-of-3/ Or 1 out of 2
ii) Hydraulic protection channel
2-out-of-3/ Or 1 out of 2 Yes/No
. .....................................................

5. Confirm that all trip signal
inputs required for the safety
of the turbine will be based Yes/No
on 2 out 3 logic ( indicate exceptions) .....................................................

6. Confirm that redundant turbine trip Yes/No
solenoids one provided .....................................................

7. Make/Model no. of each type
module used in TPS

a) Input module .....................................................

b) Output module .....................................................

c) Controller module .....................................................

d) Communication controller
module .....................................................

e) Any other modules .....................................................

1.06.00 MAIN EQUIPMENT RELATED CONTROL & INSTRUMENTATION
1.06.01 Turbine Supervisory system (TSS)

1) All sensors, transmitters, conver-
ters, LVMs, measuring & amplifier
modules, power supplies etc. with
required accessories, special
cables (if any) etc. provided for all
types of measurements as specified Yes/No

CLAUSE NO.
Bidders Name ..

STAGE-II (2X660 MW)
SECTION - VI
PART-G

DC-01
C&I DATA
REQUIRMENTS

PAGE
8 OF 13

2) Distribution of signals and
interface with control system/
HMIPIS provided Yes/No

3) Make & Model (for sensors/
transmitters, converter/monitor
etc.)

i) Shaft Eccentricity ...........................................................

ii) Absolute & relative
shaft vibration ...........................................................

iii) Diff expansion of HPT,
IPT & LPT ...........................................................

iv) Overall Expansion of
HPT & IPT ...........................................................

v) Absolute bearing vibration
in each bearing ...........................................................

vi) Stator winding vibration ...........................................................

vii) Axial shift ...........................................................

viii) Turbine speed ...........................................................

ix) ESV/CV position ...........................................................

x) All metal steam & oil
temperature ...........................................................

xi) MS/HRH steam inlet
press ...........................................................

xii) Any other (Pl. list) ...........................................................

4) For Vibration measurement
Confirm That following
has been provided

a) Measurement provided in
both X & Y Directions Yes/No

CLAUSE NO.
Bidders Name ..

STAGE-II (2X660 MW)
SECTION - VI
PART-G

DC-01
C&I DATA
REQUIRMENTS

PAGE
9 OF 13

b) On-line spectrum/ Yes/No
harmonic analysis

c) Identification of exact Yes/No
nature of failure & direct
message on CRT

d) Storage & comparative
Analysis of vibration Yes/No

e) Generation/Analysis of
Bode plot /orbit plot &
time wave form /Nyquest
plot/shaft centre line plot/
coscade & water fall plot Yes/No

f) Shaft mounted reference
detectors and required
supervisory circuitry
provided Yes/No

5) All parameter fed to TCS
through hardwiring Yes/No

6) Test calibration jigs for site Yes/No
calibration provided

7) Detailed Technical literatures
for all TSS equipment
furnished at Page No. ........ Sec. No. .....................

8) Reference plant where
the offered TSS system
is in successful operation ...........................................................

9) Bill of material for entire
TSS system furnished at Page No............... Sec. No. ................

1.06.02 BFP Turbine Supervisory Instruments

1) All sensors, transmitters,
converters, LVMs, measuring
& amplifier modules, power
supplies etc. with required
accessories, special cables
CLAUSE NO.
Bidders Name ..

STAGE-II (2X660 MW)
SECTION - VI
PART-G

DC-01
C&I DATA
REQUIRMENTS

PAGE
10 OF 13

(if any) etc. provided for all types
of measurements as specified Yes/No

2) Distribution of signals
and interface with control
system / HMIPIS provided Yes/No

3) Make & Model (for sensors/
transmitters, converters
/monitors etc.)

a) Shaft Eccentricity ............................................................

b) Axial Shift

c) Differential expansion ............................................................

d) Overall Expansion ............................................................

e) Speed ............................................................

f) All steam & metal temp. ............................................................

g) Bearing pedestal vibration ............................................................

4) Test calibration jigs for site
calibration provided Yes/No

5) Detailed Technical literatures
furnished at Page No. ........ Sec. No. .................

6) Reference plant where the
offered system is in
successful operation ............................................................

7) Bill of material for entire
BFP Turbine Supervisory
System furnished at Page No.............. Sec. No. ................

CLAUSE NO.
Bidders Name ..

STAGE-II (2X660 MW)
SECTION - VI
PART-G

DC-01
C&I DATA
REQUIRMENTS

PAGE
11 OF 13

1.07.00 PROCESS CONNECTIONS AND PIPING (PCP)
a) Scope
Confirm that impulse pipes/tubes, sample pipes,
pneumatic pipes, required fittings, valves, valve
manifolds, condensing pots, balancing reservoirs,
air filter regulators, etc. and other accessories
for impulse piping and sample piping system
shall be furnished by the bidder on as required Yes/No
basis ..........................................

b) Detailed technical literature and data and Bill of
materials covering specification of each type of
impulse piping & tubing, sample piping,
pneumatic tubing fittings, instrument valves valve
manifolds and all other installation hardware &
accessories Page No ....... Sec No. ........

c) Details of skid mounted instruments considered
for mechanical equipments Page No ........ Sec No. ......
1.08.00 TG Auxillary Plant Control Functionalities
Control systems details make/ model/ type for
TG auxiliary control Page No ........ Sec No. ..........

1.09.00 PNEUMATIC CONTROL VALVES, ACTUATORS, AND ACCESSORIES
1.09.01 Pneumatic Control valve characteristic
Cv curves for all valves enclosed at Page No. ............ Sec. No. ...........
1.09.02 Control Valve Design Data
Control valve design data indicating
valve design specification sheets for all
valves, Technical literature for all
categories of valves included in the
proposal, Control valve sizing calculation
methods used and calculation sheets
for all valves including outlet velocity
calculations and noise calculations
and Details of special features of valve
design for

a) Cavitation services, Flashing
services and Low noise applications Page No. .......... Sec. No. ...........
CLAUSE NO.
Bidders Name ..

STAGE-II (2X660 MW)
SECTION - VI
PART-G

DC-01
C&I DATA
REQUIRMENTS

PAGE
12 OF 13

1.09.03 Control Valve Actuator Design Data
Actuator design specification for all
valves, Technical literature for each
type of actuator included in the
proposal and actuator sizing calculation
methods used and calculation
sheets for each type of actuator Page No. ............ Sec. No. ...........

1.09.04 Experience
1.09.05 Name and location of manufacturing Name ...........................................
1.09.06 Works Location .......................................
1.09.07 Separate reference lists of installations comparable to one specified herein where
the manufacturer at above has supplied the following equipment to power utilities
Control valves for flashing services, Control valves with anticavitation trims and
Other control valves for power station applications
Page No. ............ Sec. No. ...........
1.09.08 Microprocessor Based Positioners details

1. Make & Model No. ........................................................

2. E/P convertion & positioning
functions available Yes/No

3. Detailed diagnostic functions Yes/No
provided

4. Diagnostic & Historical infor- Yes/No
mation available via HART
interface

5. Position feed back (4-20mA) Yes/No
included

6. Characterisation via software Yes/No

7. Possible to stayput the valve Yes/No
or open/close or signal failure

CLAUSE NO.
Bidders Name ..

STAGE-II (2X660 MW)
SECTION - VI
PART-G

DC-01
C&I DATA
REQUIRMENTS

PAGE
13 OF 13

8. These are suitable for control Yes/No
dampers also

9. Detailed technical literature/ Page No.................. Sec No..............
catalogue furnished at

SECTION-VI
PART - G
STAGE-II (2X660 MW)
CHAPTER-II
TECHNICAL INFORMATION AND
DATA TO BE SUBMITTED AFTER
AWARD OF CONTRACT
CLAUSE NO.
Bidders Name ..

STAGE-II (2X660 MW)
SECTION - VI
PART-G
DC-02
POST AWRAD
TECHNICAL DATA

PAGE
1 OF 12

DC 02

POST AWARD TECHNICAL
DATA
REQUIRMENTS
CLAUSE NO.
Bidders Name ..

STAGE-II (2X660 MW)
SECTION - VI
PART-G
DC-02
POST AWRAD
TECHNICAL DATA

PAGE
2 OF 12

TECHNICAL INFORMATION AND DATA TO BE
SUBMITTED AFTER THE AWARD OF CONTRACT

1.00.00 GENERAL

A) For standard documentation requirement by the bidder please also refer
document list at Section VI, Part-B, IIIC-02 DDCMIS Clause no: 11.00.00

B) The minimum requirements of data, drawings and instruction manuals for
this package are indicated in this Part, in addition to the requirements of
various clauses of Technical Specification, Section-VI and other applicable
Sections/Sub-sections (to be submitted in multiple copies to the Employer
as per of GTC, Part-C of Section-VI).

The Contractor shall prepare an exhaustive Master Drawing List (MDL) of all
drawings/documents/manuals to be submitted during detailed engg. stage
(including those from sub-contractors). The MDL shall contain drawing/document
no., rev. no., title, scheduled date of submission, actual date of submission,
approval status (Category & date), etc. The exact format shall be as approved by
Employer. The Contractor shall furnish the MDL to Employer before Notification of
Award (NOA). This shall be discussed and finalized during pre-award discussions.
The MDL will be modified by Contractor periodically to take care of detailed
engineering requirements. The MDL shall be submitted by Contractor for
Employer's information every month with latest status. The MDL as well as each
drawing/document/manual submitted by Contractor/sub-contractor shall also have
provision for indicating Employer's drawing/document no. corresponding to each of
Contractor's/sub-Contractor's drawing/document/manual for document control at
Employer's end.

2.00.00 DISTRIBUTED DIGITAL CONTROL, MONITORING & INFORMATION SYSTEM
(DDCMIS):
(Refer sub-section DDCMIS, Part-B of Section-VI and other applicable clauses)

2.01.00 PHASE- I (Standard Documentation)

2.01.01 Detailed standard technical literature for all types of modules, peripherals of
DDCMIS.

2.01.02 User guide/details of

(i) diagnostic stations & diagnostic facilities

(ii) programming stations & programming facilities

(iii) system documentation facilities
CLAUSE NO.
Bidders Name ..

STAGE-II (2X660 MW)
SECTION - VI
PART-G
DC-02
POST AWRAD
TECHNICAL DATA

PAGE
3 OF 12

2.01.03 List of all types of software used in HMIPIS, Control system, Programming &
Documentation Stations, etc.

2.01.04 Details of all types of functional software blocks available in the system for
developing control loops/logics.

2.01.05 Details of standard & customised applications in HMIPIS.

2.01.06 Details of symbols used in graphic displays/mimics in HMIPIS.

2.01.07 Contractor's standard formats for database and other displays for Employer's
inputs.

2.02.00 PHASE-II (Preliminary Design Documents)

2.02.01 Overall configuration diagram of DDCMIS showing all components/modules.

2.02.02 Detailed functional grouping diagram of Control System showing distribution of
drives, calculations showing capabilities (including spare capacity) of each group.

2.02.03 Detailed configuration diagram of HMIPIS showing all peripherals and network
connections.

2.02.04 Preliminary Bill of Material (BOM) of DDCMIS indicating no. of system cabinets,
marshalling cabinets, relay cabinets, peripherals etc. with weight, heat load, degree
of protection of each item.

2.02.05 Outline & mounting drawings for all types of cabinets, peripherals in DDCMIS.

2.02.06 NOT USED

2.02.07 Preliminary write-up & recommendation for closed loop controls as well as interlock
& protection room main equipment manufacturers (including TPS, EHTC, TSCS
etc.)

2.02.08 Preliminary control loop & logic diagram of control system (covering total TG -C&I).

2.03.00 PHASE-III (Detail Design Documents)

2.03.01 Functional Design Specification for DDCMIS containing :

(i) Design philosophy for DDCMIS indicating how the specification
requirements are translated in Contractor's system, implementation
philosophy, redundancy features, etc.

CLAUSE NO.
Bidders Name ..

STAGE-II (2X660 MW)
SECTION - VI
PART-G
DC-02
POST AWRAD
TECHNICAL DATA

PAGE
4 OF 12

(ii) Write up on the system offered and as configured & customized for this
project.

(iii) Write up on HMIPIS elaborating

(a) System/operator functionalities for displays, logs, calculations,
historical storage, long term storage etc.

(b) Various application engineering details.

(c) System security

(d) Redundancy features

(e) Parametric requirements

(f) Programming requirements

(g) Diagnostic facilities

(h) Connectivity with LAN/WAN

(i) Interfaces for other systems like PLCs, off-line LAN/WAN of
Employer, etc.

(j) Alarm reporting

(iv) NOT USED

(v) NOT USED

(vi) Write-up on time synchronising scheme for master & slave clock system( IN
EMPLOYER'S SCOPE)

2.03.02 Single line diagram for power supply requirements and distribution scheme of
DDCMIS.

2.03.03 Grounding Scheme for DDCMIS.

2.03.04 Standard O&M manuals & programming guides e.g. for data base, mimics, logs,
HSR, etc. in HMIPIS.

2.03.05 Calculations to show how system spare capacity & expandability requirements as
specified are being met in Contractor's system.

CLAUSE NO.
Bidders Name ..

STAGE-II (2X660 MW)
SECTION - VI
PART-G
DC-02
POST AWRAD
TECHNICAL DATA

PAGE
5 OF 12

2.03.06 Calculations to show how system parametric requirements as specified are being
met in Contractor's system.

2.03.07 Calculations to show how system availability requirements are being met in the
offered configuration of DDCMIS and details of MTBF/MTTR figures for each
component of Contractor's system.

2.03.08 Detailed BOM of DDCMIS with main & mandatory spares quantities for each of the
subsystems of DDCMIS. The detailed BOM shall be furnished for each cabinet &
peripheral indicating quantity, make, model, part no., ordering code for each
part/component so that based on this information Employer can procure these
parts/components.

2.03.09 Detailed I/O list giving complete connectivity of input & outputs. This shall include
tag no., TB no., cable no., marshalling rack/pin no., functional group, system
cabinet no., I/O module location, channel no., related loop/logic drawing no.,
process range, alarm limits, set points, use of signal for interlock/protection/
sequence/control loop/SOE/annunciation/information only etc., destination details
for output signals including system cabinet no., I/O module no., channel no., Cable
no., etc. The exact no. of fields in the list shall be as approved by Employer during
detailed engg. stage.

2.03.10 Implemented control loop & logic diagrams for control system (covering TG-C&I
systems).

2.03.11 Displays, mimics, logs, reports, etc. for HMIPIS.

2.03.12 Methodology of testing including details of testing facilities available, model test for
control loops etc.

2.03.13 General Arrangement, Internal Arrangement of all cabinets (including card layout).

2.03.14 Interfacing details indicating interfacing arrangement of various sub-systems of
Contractor's system with other systems not in Contractor's scope.

2.03.15 Interconnection schedule (ICS) for connecting all equipment/cabinets in
Contractor's scope.

2.03.16 Schematic/wiring drawings for all cabinets/systems.

2.03.17 Safety requirements for grounding, interlocks, safety control circuits, etc.

2.03.18 Site handling, storage requirement/recommendations.

CLAUSE NO.
Bidders Name ..

STAGE-II (2X660 MW)
SECTION - VI
PART-G
DC-02
POST AWRAD
TECHNICAL DATA

PAGE
6 OF 12

2.03.19 Fuse/MCB characteristics of all types of fuses/MCBS used in the system, fuse
coordination, make/model nos. of all fuses/MCBs.

2.03.20 NOT USED

2.03.21 Detailed drawings showing complete system connectivity right from field
instruments/ devices/MCC/SWGR/actuators to individual channels of input
modules and system outputs from individual output channels to relay
cabinets/MCC/SWGR/actuators, etc. irrespective of scope of supply of
instruments/devices/actuators & cables.

2.03.22 a) Flow charts, program description and explanatory notes for all system
software, standard application software package. (Listings of all PROMs
and micro programs shall also be provided, wherever applicable).

b) Source listing of all application S/W & project specific files.

2.03.23 Detailed System Generation (Sys-Gen) procedures, i.e. the process of finally
integrating all programs and data modules in to a single system module.

2.03.24 Pre-ATS and ATS test documents including :

(i) Details of tests conducted on all modules, procedures followed, test data
used, results and interference drawn on all software modules.

(ii) Test plans for components performance checks that shall be performed by
Contractor on components/equipment before final assembly.

(iii) ATS test plan, preliminary ATS test procedures and test results and final
ATS test procedure to be conducted at works.

2.03.25 Any other design data, drawings and documents prepared for this project but not
specifically listed above.

2.04.00 PHASE-IV (Along with Equipment Dispatch)

2.04.01 Operation and maintenance manuals and diagnostics/trouble shooting guides for
all equipment/devices of DDCMIS. The manuals shall include all information
required for trouble-shooting, repair and maintenance information regarding all the
equipment furnished for the completeness of the system including on-line
insertion/removal of all types of modules.

CLAUSE NO.
Bidders Name ..

STAGE-II (2X660 MW)
SECTION - VI
PART-G
DC-02
POST AWRAD
TECHNICAL DATA

PAGE
7 OF 12

2.04.02 Installation & Commissioning manuals.

2.04.03 Detailed instruction manuals for all systems/modules of DDCMIS, which shall
include all standard technical literature and drawings/documents, approved by
Employer.

2.04.04 Application software listings including source floppy discs/CD-ROMs for
application system software and any changes from system software earlier
submitted, system generation discs, on-line/off-line diagnostics programs, software
system maintenance manuals, special to project data files and any other document
not listed specifically here but required to understand, trouble-shoot, repair,
maintain the offered system.

2.04.05 Consolidated detailed BOM of all devices/equipment as approved, approved
datasheets bound together.

2.05.00 Phase-V

2.05.01 All changes made to the system after its dispatch from the works shall be reflected
in the related documents and those revised documents shall be handed over to the
Employer in required number of copies. (As-built drgs)

3.00.00 TG RELATED MEASURING INSTRUMENTS (Refer Sub-section- TG related
Measuring Instruments, Part-B of Section-VI and other applicable clauses)

3.01.00 Turbine Supervisory System

3.01.01 Data Sheets of various Supervisory Instruments and their accessories.

3.01.02 Consolidated BOM.

3.01.03 Installation and mounting drawing for each sensor and other accessories.

3.01.04 Technical Write-up explaining the operating principle for each Supervisory
Instrument.

3.01.05 Total Schematic giving interconnection between various system components,
power supply etc.

3.01.06 Interconnection scheme and cable schedule.

3.01.07 Technical details and User manual for the On-line Spectrum and Harmonic
Analysis system

CLAUSE NO.
Bidders Name ..

STAGE-II (2X660 MW)
SECTION - VI
PART-G
DC-02
POST AWRAD
TECHNICAL DATA

PAGE
8 OF 12

3.01.08 Detailed Technical Literature giving system description, all technical parameters,
installation procedure & precautions, trouble-shooting and maintenance procedure
etc.

3.02.00 BFP Turbine Supervisory System

Same as Turbine Supervisory System above.

4.00.00 MEASURING INSTRUMENTS (PRIMARY AND SECONDARY)
(Refer Sub-section-MEAS INST, Part-B of Section-VI and other applicable clauses)

a) General

1. Complete Bill of material for all instruments including all necessary
accessories etc.

2. Specification sheets/Data sheets for all instruments including
accessories provided.

3. Instruction manual covering instructions for installation, calibration,
commissioning, normal operation, trouble shooting and
maintenance for all instruments furnished by the Bidder.

4. Outline and mounting drawings, detailing all necessary dimensions
for each category of instrument, thermowell etc,

5. Installation drawings for instruments and measurement systems
furnished along with details of erection material furnished.

6. Power supply distribution- single line and wiring diagram wherever
applicable.

7. Applicable internal wiring diagram and interconnection diagram for
each type of instrument furnished.

8. External connection and interconnection wiring diagrams.

9. Name-plate design and engraving.

b) Design calculations for thermowells and flow elements etc.

CLAUSE NO.
Bidders Name ..

STAGE-II (2X660 MW)
SECTION - VI
PART-G
DC-02
POST AWRAD
TECHNICAL DATA

PAGE
9 OF 12

c) Additional requirement for Vibration Monitoring System

a) Vibration monitor cabinet/rack, GA, internal arrangement, floor
opening etc.

b) Transducer mounting pad drawing, showing mounting hole and
other mounting details.

d) Instrument installation detail drawing showing instrument location, mounting
within enclosure/rack, floor opening (if any).

5.00.00 ELECTRICAL POWER SUPPLY
(Refer sub-section-Power Supply, Part-B of Section-VI and other applicable
clauses)

5.01.00 Design specification sheet for each type of system hardware/instrument.

5.02.00 Write up on DC system including descriptions for start-up/shut down procedures,
normal operation etc.

5.03.00 Total schematic diagrams showing connections between various
devices/instruments, for all DC system including feeder ratings.

5.04.00 General arrangement, layout & mounting drawings for all cabinets/enclosures,
including AC & DC distribution boards.

5.05.00 Calculations for sizing of batteries, battery charger, transformer etc.

5.06.00 Complete Bill of Materials for all DC power supply system equipment and system
components including associated accessories.

5.07.00 Wiring diagrams for the DC power supply system cubicles & battery.

5.08.00 All terminal board drawings required to define input/output connections for the
Power Supply System.

5.09.00 Interconnection diagram and cable schedule for DC power supply system and all
connected input and output system.

5.10.00 Detailed circuit diagrams (Including component level details) of the chargers,
inverters, static switches etc., including the circuit diagrams of various printed
circuit boards for facilitating maintenance of Power supply systems by Employer.
This shall include Specifications, ratings etc., of various components/devices
including international code numbers which will enable the Employer to procure
these components/devices from sources other than the original system supplier.
CLAUSE NO.
Bidders Name ..

STAGE-II (2X660 MW)
SECTION - VI
PART-G
DC-02
POST AWRAD
TECHNICAL DATA

PAGE
10 OF 12

5.11.00 Instruction manual covering instructions for installation, testing, commissioning,
normal operation, trouble shooting and maintenance for each type of DC power
supply system hardware furnished and for the system as a whole.

6.00.00 PROCESS CONNECTIONS AND PIPING
(Refer Sub-section-PCP, Part-B of Section-VI and other applicable clauses)

6.01.00 Detail installation drawings showing parts and material specification for process
connection, instrument valves, valve manifolds, fittings, etc.

6.02.00 Detail technical specification including material specification, dimensional details of
each type of impulse piping, sample piping, pneumatic piping/tubing, fittings,
flexible hoses, instrument valve, Air line valves, valve manifolds Cond. pot. and all
other required accessories.

6.03.00 Bill of Materials for impulse piping, sample piping, pneumatic tubing, fittings,
instrument valves, valve manifolds, tubing trays and all other accessories required
for erection.

6.04.00 Drawings indicating complete tray system, supports, etc., giving construction and
design features.

6.05.00 Drawings and documentation required for ensuring installation and commissioning
of all instruments and systems furnished under this specification as per intent and
requirements of this specification.

6.06.00 Instruction for inspection and erection of process connection, fittings, hydraulic and
leakage test methods and procedures.

6.07.00 Local Transmitter Enclosures/Racks

Following data/drawings shall be submitted for the transmitter enclosures/racks:

a) Outline and mounting drawings for transmitter enclosure/racks.

b) Drawing showing construction details for transmitter enclosures/racks.

c) Transmitter enclosures & racks piping drawing.

d) Tubing and electrical wiring layout drawings for transmitter
enclosures/racks.

e) Transmitter power supply wiring diagram.

CLAUSE NO.
Bidders Name ..

STAGE-II (2X660 MW)
SECTION - VI
PART-G
DC-02
POST AWRAD
TECHNICAL DATA

PAGE
11 OF 12

f) Instrument installation detail drawing showing instrument location, mounting
within enclosure/rack, floor opening (if any).

7.00.00 INSTRUMENTATION CABLE, INTERNAL WIRING AND ELECTRICAL
FIELD CONSTRUCTION MATERIAL
(Refer sub-section-Inst. Cable, Part-B, Section-VI and other applicable clauses)

7.01.00 Data sheets for cables, conduit, junction boxes etc.

7.02.00 Cable cross sectional drawings.

7.03.00 Complete Bill of Materials for all types of instrumentation cable and electrical field
construction material and accessories.

7.04.00 Cable interconnection diagrams & cables schedules for all cables furnished by the
Contractor.

7.05.00 Instruction for laying, pulling, inspection tests and termination procedures for
cables and erection of electrical field construction materials, instruction of
continuity, identification, circuit checking and testing of cables.

8.00.00 CONTROL VALVES AND ACTUATORS
(Refer Sub-section-Control Valve, Part-B of Section-VI and other applicable
clauses)

8.01.00 Data sheets / specification sheet of each control valve & its accessories.

8.02.00 Sizing calculation of each control valve

8.03.00 General arrangement, dimensional and edge preparation drawings.

8.04.00 Complete bill of material of control valves & accessories.

8.05.00 Technical details of control valves.

8.06.00 Interconnection schemes & wiring details

8.07.00 Piping & tubing diagrams.

8.08.00 Instructions for installation, settings & maintenance.

9.00.00 Not applicable

CLAUSE NO.
Bidders Name ..

STAGE-II (2X660 MW)
SECTION - VI
PART-G
DC-02
POST AWRAD
TECHNICAL DATA

PAGE
12 OF 12

10.00.00 CONTROL & INSTRUMENTATION FOR AUX. PLANT
(Refer Sub-section-Aux. Plant Ctrl., Part-B of Section-VI and other applicable
clauses)

10.01.00 Technical data sheets for all measuring instruments & accessories.

10.02.00 Complete bill of material of main and mandatory spare quantities.

10.03.00 Other applicable details as referred in clause 4.00.00 above.

10.04.00 Configuration drawings for PLC system (including its MMI).

10.05.00 Bill of material for PLC system (including MMI) and its accessories.

10.06.00 General arrangement drawing of PLC panels with complete BOM of panel mounted
items.

10.07.00 Control schemes and functional write-up of control system including hardware and
software details.

10.08.00 Wiring and termination details.

10.09.00 Interconnection cable schedules and diagrams.

10.10.00 Powers supply single line diagram.

10.11.00 NOT USED

10.12.00 Interfacing details & diagrams of control systems with station wide LAN and signal
exchange.

10.13.00 Detailed I/O list including tag nos, process range, alarm limits, set points, cable no.
TB no. etc.

10.14.00 Details of software used in PLCs, symbols in graphic displays etc.

11.00.00 TYPE TESTS
(Refer Sub-section-C&I Type Test, Part-B of Section-VI and other applicable
clauses)

11.01.00 Type test procedures for items for which tests are to be conducted .

11.02.00 Type test certificates / results for all identified items.

Tanda-II Specification - Technical

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Drive Turbine Tests as per relevant portion of specification

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