Section C

SPEC. NO.
TCE-5607A-C-811-08
BHUBANESHWAR POWER PRIVATE LIMITED

Consultant: TATA Consulting Engineers Limited
SECTION: C 1 SHEET 1 OF 20
AIR-CONDITIONING AND VENTILATION SYSTEMS
1.0 1.1.1
TECHNICAL DESCRIPTION AIR CONDITIONING SYSTEM The following are the areas to be Air-conditioned (i) Main control rooms, electronic cubicle rooms, UPS rooms, shift in charge engineers room, maintenance engineers room and other areas such as Analyser room in TG building for Units-1 & 2. Common Electrostatic precipitator (ESP) control room. Switch yard relay panel room. Service building
(ii) (iii) (iv) 1.1.2
The following are the various Input data considered in the Design of Airconditioning system: (i) Outside design conditions : DRY BULB TEMPERATURE SUMMER MONSOON WINTER (ii) 47.7 C 37.8 0C 19 0C
0
WET BULB TEMPERATURE 26.8 C 26.3 0C 16.7 0C

0
Inside design conditions to be maintained in Air-conditioned area: a) b) Dry bulb temperature summer & monsoon Relative Humidity in : 24 0 C 1.5 0 C : 55 5% for all areas served by centralized AC/PAC : To maintain minimum 230C DBT
c) 1.1.3
Winter
For Air conditioned areas, fresh air would be provided at the rate of one (1) air change per hour or 25 cu.m per hour per person inline with ASHRAE-62, whichever is higher. Make-up water for A/c equipment (cooling tower and expansion tank) is supplied from service water through strainer for AC plant of TG building and some quantity will be supplied to air washers of TG building.
ISSUE R0
1.1.4
SPEC. NO. TCE-5607A-C-811-08

1.2
REFERENCE CODES AND STANDARDS All materials and equipments provided shall comply with the following Standards: ASHRAE 15 ASHRAE 30 ARI 430 ARI 410 IS 277 IS 325 IS 655 IS 7613 ARI 550 IS 4671 IS 3588 IS 4894 UL 555 Safety code for mechanical refrigeration Methods of testing Liquid chilling package Central station Air Handling Units Forced Circulation Air-Cooling and Air Heating coils Galvanised Steel Sheets Three phase induction motors Metal Air ducts Method of testing panel type air filters for air-conditioning and Ventilation process. Water chilling package using the Vapour compression cycle Expanded polystyrene for thermal insulation purposes. Electric axial fans Centrifugal fans Fire dampers
IS 7098 Power cables Part-1 IS 1554 Control cables Part-1 IS 4237 IS 6875 Control panel MCC PB Stations Individual electrical components conform to respective IS
ISSUE R0
SPEC. NO. TCE-5607A-C-811-08

1.3 1.3.1
DESCRIPTION OF THE SYSTEMS Air-Conditioning Systems a) Water cooled Chilled water air conditioning system with rotary screw compressors and number of equipment (1 Working + 1 Standby) are to be considered to meet the air conditioning requirements of Main control room ESP control room and switchyard relay panel room. The various areas to be air-conditioned and approximate equipment heat load to considered are given in Appendix I. Officers cabins, conference room, I & C lab and electrical lab of service building shall be air-conditioned by air cooled non ductable split air conditioners with suitable numbers working. The capacity and quantity required shall be finalised by the bidder. 10% margin in equipment capacity over peak heat load calculated considering solar load and all internal loads due to equipment, lighting, fresh air, occupants, etc have to be considered.
b)
c)
1.3.2
AC Plant : Central Chilled Water Plant catering A/c areas of TG building & ESP Control building The central chilled water plant catering for air-conditioning of Main control rooms, electronic cubicle rooms, UPS rooms, shift in charge engineers room, maintenance engineers room and other areas such as SWAS room, Analyser room in TG building for Units-1 & 2, ESP control room and switchyard relay panel room. The Central chilled water plant, comprising Rotary screw refrigerant compressors with drive motors, water cooled condenser and chillers, condenser water and chilled water pump sets and associated equipment would be centrally located in the plant room. The location of plant room would be at EL. 0.0 m outside A row and between columns 10 & 12 of the TG building. Chilled water at 7 0C from these units would be supplied to Air handling units located in the AHU room adjacent to different areas to be Air-conditioned. Chilled 0 water from the air handling units after picking up heat load will be at 12 C approx. which will be returned to the chiller units for cooling and recirculated to air handling units. If any AC area will be located at a far off location from the AHU room, then it will be air-conditioned with ducted supply from AHU location and the return will taken through insulated return air duct back to the AHU room. The cool air is supplied to the A/c area from AHU through ducting and the warm
ISSUE R0
SPEC. NO. TCE-5607A-C-811-08

air from the A/c area after heat pick is taken to the AHU room through space between false ceiling and roof. In the AHU room, the warm the air is cooled by the chilled water at the cooling coil of AHU and the cooled air is supplied to the A/c area and the process repeats. The cooling towers along with expansion tank for the Air-conditioning plant would be located on the roof of Air washer room at EL 12.00 m outside A row and between columns 10 & 12 of the TG building. The AC plant (common for both units) would essentially comprise of the following equipment : i. Two (2) nos. (1 Working + 1 Standby) water Chilling units (minimum 135 TR capacity each) with R134a Refrigerant Rotary screw compressors in built with micro processor controller. Two (2) nos. (1 Working + 1 Standby) Chilled water pump sets of adequate capacity to match chilling unit chilled water flow rate. Two (2) nos. (1 Working + 1 Standby) condenser water pump sets of adequate capacity to match chilling unit condenser water flow rate.
ii. iii.
iv. Two (2) nos. (1 Working + 1 Standby) Induced draft FRP Cooling towers of adequate capacity to match chilling unit. v. Three (3) nos. (2 Working + 1 Standby) Air handling units for common control room, electronic cubicle room, UPS room, shift in charge engineers room, maintenance engineers room and other areas such as SWAS room, Analyser room for Unit - I located at AHU room at EL. 16.50 m in BC bay between columns 7 & 9 of TG building.
vi. Three (3) nos. (2 Working + 1 Standby) Air handling units for electronic cubicle room, UPS room, shift in charge engineers room, maintenance engineers room and other areas such as SWAS room, Analyser room for Unit - II located at AHU room at EL. 16.50 m in BC bay between columns 15 & 17 of TG building. vii. Two (2) nos. (1 Working + 1 Standby) Air handling units for ESP control room located at AHU room at EL. 0.00 m of ESP control building. viii. Two (2) nos. (1 Working + 1 Standby) Air handling units for Switchyard relay panel room located at AHU room of Switchyard control building. ix. Air distribution system comprising ducting, diffuser / grilles, thermal and acoustic insulation for ducting. x. Main control panel, local control panel and local push button station
ISSUE R0
SPEC. NO. TCE-5607A-C-811-08

xi. SINTEX Expansion tank insulated complete with vent, makeup water connection, overflow and drain line. xii. Electrical strip heaters with controls. Humidification package with pan/steam humidifiers (if required) for system. xiii. Piping, valves and specialities, necessary supports for piping and instruments for chilled water and condenser cooling water systems with thermal insulation for chilled water systems. xiv. Make up water for the air-conditioning system to be supplied to the cooling tower sumps and to expansion tank from service water at one terminal point and strainers. xv. Fresh air system consisting of pre filters, fine filters, tube axial fan, ducting, volume control dampers etc., shall be provided in the AHU rooms. The efficiency of pre-filters shall be 90% down to 10 microns and that of fine filters shall be 99% down to 5 microns. xvi. Necessary drain piping up to the nearest floor drain for each AHU with thermal insulation. xvii. Monorail with hoist will be provided in the A/c plant room for handling. xviii. Vibration isolators for chillers, chilled water pumps, condenser water pumps and cooling towers. 1.4 1.4.1 EQUIPMENT TO BE SUPPLIED Screw Chilling unit AC plant The capacity of chilling unit will be based on the following : i) ii) iii) iv) v) vi) Fouling factors - Cooler : 0.0001 hr.ft2.F/BTU Fouling factors - Condenser : 0.00025 hr.ft2.F/BTU Chilled water In / Out temperature : 12 deg C / 7 deg C Condenser water In / Out temperature : 31 deg C / 36 deg C Chilled water flow rate : 0.7 M /hr / TR Condenser water flow rate : 1.0 M /hr / TR
3 3
Each Screw chilling unit shall comprise of the following :

ISSUE R0
SPEC. NO. TCE-5607A-C-811-08

a) Microprocessor controlled water cooled water chiller package suitable for R134a having semi hermetic compressor, motor, unit mounted starter, crankcase heater, automatic stepless capacity control etc. I) Shell and tube type water cooled condensers complete with hot gas inlet, liquid outlet, relief and purge connection for refrigerant, water inlet and water outlet connection, drain connection with valve suitable for above selected capacity.
II) One (1) no. Shell and tube type / flooded / DX type water chiller suitable for above selected capacity complete with liquid inlet, Vapour outlet connection for refrigerant, water inlet and water outlet connection, drain connection with valve and chiller insulation. III) Thermostatic expansion valve, Refrigerant piping, valves and fittings interconnecting Chiller, compressor, condenser and expansion device and refrigerant piping including insulation etc IV) Refrigerant piping, valves and fittings interconnecting Chiller, compressor, condenser and expansion device. V) First charge of refrigerant gas and oil, base frames, vibration isolation pad, integral wiring and unit mounted isolator / fuse switch. VI) Flexible connection (Corirubber with retainer rods and flanges suitable to operate at the design pressure) between chilling unit and piping. VII) Lot-Controls comprising the following: i) HP/LP cutouts
ii) Oil pressure failure switch iii) Solenoid valve iv) Antifreeze thermostat v) Cooling thermostat vi) Water flow switch at the outlet of condenser and chiller. vii) Vibration isolators for chillers and cooling towers.
ISSUE R0
SPEC. NO. TCE-5607A-C-811-08

1.4.2
Centrifugal water pump set The centrifugal pump set shall be Horizontal split casing centrifugal pump set and each centrifugal water pump set shall comprise of the following : a) One (1) no. Horizontal split casing centrifugal pump. b) One (1) no. adequately sized Induction motor suitable for 415 V, 3 phase, 50 Hz supply. c) One (1) set of base plate, coupling guard, anti vibration pads and foundation bolts. d) Chilled water pump set will include thermal insulation of pump. e) Flexible connection (Corirubber with retainer rods and flanges suitable to operate at the design pressure) between pump and piping. f) Drain piping from pump to nearest floor drain
1.4.3
Air Handling Unit (AHU) The AHU shall be of double skin construction with Filter section, cooling coil section and fan section. Each AHU shall comprise of the following: i) Removable panels with double skin and sand witched insulation to make internal parts easily accessible for service and inspection, 25mm thick polyurethane foam (puff) insulation of minimum 40Kg/m3 density to prevent heat transfer to colder sections.
ii) Fan section complete with forward curved/Backward curved Double Inlet Double Width (DIDW) centrifugal fan and motor mounted on spring type vibration isolators. Fan outlet velocity not to exceed 11 m/s. Entire AHU assembly mounted on vibration rubber pads. iii) One (1) no. adequately sized Induction motor suitable for 415 V, 3 phase, 50 Hz supply with drive package comprising of fan pulley and V-belt. iv) Cooling coil section with suitably sized chilled water cooling coil made of copper tubes and aluminium fins complete with purge valve at top and drain plug at bottom. Velocity across cooling coil not to exceed 2.5 m/s. v) Filter section containing washable synthetic type air filters having GSS frame. Pre filters (efficiency 90% down to 10 microns) and fine filters (efficiency 99% down to 5 microns) shall be provided inside the AHU.
ISSUE R0
SPEC. NO. TCE-5607A-C-811-08

vi) Drain piping from AHU to floor drain vii) Flexible connection between fan and ducting. viii) Electrical strip heater package of suitable capacity complete with contact, humidistat, safety thermostat, heater box with insulation etc for monsoon reheat mounted inside the A/c plenum / duct. ix) Pan/steam humidifier kit comprising SS tank, immersion heater, humidistat etc. x) Controls comprising : i) One (1) no. 3 way mixing valve with actuator for each AHU. ii) One (1) no. proportionating thermostat for each AHU 1.4.4 Cooling Tower a) Design wet bulb temperature : 27.5 Deg C b) Approach : 4 deg C c) Hot water inlet temperature : 36 Deg C The cooling tower shall be Induced draft (single cell) FRP cooling tower and shall comprise of Fan, fan motor, drive package, FRP basin, FRP / HDGS louver, fills, drift eliminators, nozzles, make-up connection, over flow connection, drain connection, ladder and supporting structure. 1.4.5 Non ductable Split Air Conditioners Air cooled Non ductable split air conditioners shall be provided for the following areas Officers cabins, conference room, I & C lab and electrical lab in service building. 1.4.5.1 Construction Features a) Condensing Unit i) Cabinet The condensing unit cabinet will be of anodized aluminium or GI or Heavy gauge steel suitably treated with two coats of zinc chromate primer and three coats of epoxy paint and will be suitable for mounting in open space i.e. on terrace.
ISSUE R0
SPEC. NO. TCE-5607A-C-811-08

ii) Compressor The compressor will be hermetic and will be mounted on vibration absorbers. Necessary crank case heaters will be provided. iii) Condenser The air-cooled condenser will be with copper tubes and aluminium fins with maximum 75 db noise fans. Speed of axial fans will not exceed 960 rpm for fans with impeller diameter above 450mm and 1440 rpm for fans with impeller diameter 450mm and less b) Evaporator Unit i) The evaporator unit cabinet will be of GI or aluminium and thermally insulated, suitable drain connection will be provided for removal of condensate collected in the drain pan. The drain piping will be properly designed, insulated and routed up to ground floor. U-trap will be provided in the drain line to avoid ingress of unwanted air into the system.
ii) Air Handling Fan The fan of GI / aluminium will be centrifugal type with forward curved impeller. The impeller will be statically and dynamically balanced. iii) Cooling Coil And Filter The cooling coil will be direct expansion type with copper tubes and aluminium fins. This will be minimum three (3) rows deep and with minimum three fins per centimetre. The air before it enters the cooling coil will be filtered by dry and cleanable type filter. 1.4.5.2 Refrigeration Piping And Controls a) The refrigeration piping will be complete with externally equalized thermostatic expansion valve, liquid line strainer, dehydrator and liquid line shut off valve. b) For refrigerants R-134a/R-410a, copper tubes to IS 10773 will be used. Fittings, flanges and pipe joints will conform to the requirements of ANSI B31.5 c) The piping will be designed for an internal pressure representing the most severe condition of coincident pressure and temperature expected in normal operation.
ISSUE R0
SPEC. NO. TCE-5607A-C-811-08

d) Piping will be designed for not less than the internal pressure given in Table-1. For refrigerants not listed in Table1 the design pressure for the higher pressure side will not be less than the saturated vapour pressure of refrigerant at 600C for air cooled systems. For low pressure side the design pressure will 0 not be less than the saturated vapour pressure of the refrigerant at 32.5 C. For refrigerants not listed in the table-1 and having a critical temperature below 550C, the design pressure for the high pressure side will not be less than 1.2 times the critical pressure and design pressure for low pressure side will not be less than 2 kg/cm2(g). TABLE- 1 Refrigerant Number Refrigerant Name Minimum Internal Design pressure High Pressure Side Low pressure (kg/cm2 ) side(Kg/cm2 ) R-134a R -410a Tetraflouro ethane 17.5 8.55 15
Difluoro methane, 31 Pentafluoro ethane
e) Test pressure for piping will be 1.1 times of the design pressure. The pressure will be gradually increased until gauge pressure which is the lesser of one-half of the test pressure and 1.75 kg/cm2(g) is attained and preliminary leak checks will be carried out. Thereafter, the pressure will be gradually increased in steps until the test pressure is reached. The pressure will then be reduced to the design pressure and leakage examination will be made. The design pressure will be maintained for 48 hours to 72 hours. A pressure relief valve/device will be provided on test pressure line having a set pressure slightly above the test pressure. Nitrogen will be used as a test medium. Oxygen or any combustible mixture of gases will not be used within the piping for testing. Water or water solutions will not be used as a test medium. f) Vacuum testing will be done for medium vacuum of around 40mm of Hg absolute and held with vacuum pump in operation for at least 4 hours. Thereafter unit will be sealed and vacuum held for at least 12 hours. Vacuum break will be done using refrigerant and pressure raised to standing pressure in refrigerant cylinder. g) The Bidder will submit test certificate confirming to clauses (d) and (f) above along with the supply of equipments. h) ON-OFF thermostat with adjustable setting will be provided for temperature control. A selector switch enabling the running of the air handling fan alone or fan with cooling will be provided such that compressor can start only after
ISSUE R0
SPEC. NO. TCE-5607A-C-811-08

starting the air handling fan. Provision will also be made to interlock the compressor with air-cooled condenser fan motor. Safety devices such as high/low pressure stat, hermetic motor winding thermostat etc. will be provided. H.P cut out will be manual reset type while L.P cut will be auto reset type. 1.4.5.3 Capacity Calculations Bidder shall furnish calculations for selection of the capacity of the Split Air conditioners and required number of Split Air conditioners shall be provided for each of the areas mentioned in Cl. 1.4.5. 1.4.6 Piping and Valves i) Piping shall be
ERW, Black, IS-1239 heavy class for pipe sizes up to 150 NB ERW, IS 1978 or API 5L GR B (ERW) or IS 3589 fabricated from IS 2062 plates for pipe sizes 200 NB to 450 NB ii) Isolating valves shall be butterfly valve type for valve size 50 NB and above. iii) Isolating valves shall be gate valve type for valve size below 50 NB. iv) Strainers shall be Y-type v) Chilled water and Condenser water Piping shall be designed such that, for pipe sizes of 50 NB and under, maximum velocity is 1.2 m/s and friction rate is not exceeding 250 Pa/m. For pipe sizes above 50 NB, maximum velocity is 3 m/s and friction rate is not exceeding 400 Pa/m. vi) Isolating valves shall be provided at inlet and outlet piping of Chilling units, pumps, cooling towers and Air Handling Units. vii) Strainers shall be provided at the inlet piping to AHU and Pump. viii) Non return valves shall be provided at the outlet of Pumps. 1.4.7 Air distribution system a) Rectangular Duct: GSS supply air ducting and return air ducting with Zinc coating 180 gms /sq.m or better. b) The material thickness of the ducting shall be as following considering the industrial duty conditions
ISSUE R0
SPEC. NO. TCE-5607A-C-811-08

Large side of rectangular Duct (mm) 0 - 750 751 - 1500 1501 and 2100 2101 and above
Thickness (mm) 0.63 0.80 1.00 1.25
c) The supply air ducting to be designed based on equal friction method to have an initial velocity not exceeding 9.0 m/s and friction rate 0.8 Pa/m. d) The return air ducting to be designed based on equal friction method to have an initial velocity not exceeding 7.5 m/s and friction rate 0.66 Pa/m. e) Duct aspect ratio for rectangular ducts. Not exceeding 1:4. f) Maximum neck velocity for supply air diffusers 2.5 m/s.
g) Maximum neck velocity for return air diffusers 1.5 m/s. h) Maximum face velocity for supply air grills 2.5 m/s. i) j) Maximum neck velocity for return air / exhaust grilles 1.5 m/s. Maximum airflow velocity across flat type pre filters (90% efficiency down to 10 microns) shall be 2.5 m/s.
k) Maximum velocity across louvers 3.0 m/s. l) Motorized fire dampers to be provided in the supply air duct, return air ducts, all wall and floor crossings to isolate the area in the event of fire. The space around the ducts and pipes to be sealed with fire retardant material.
m) Volume control dampers shall be provided in all branch ducts and in the main ducts from AHU/PAC to throttle the air volume. 1.4.8 Thermal and Acoustic insulation a) Thermal insulation of ducting: Entire supply air duct will be thermally insulated with 25 mm thick fibre glass of density 32 kg/cu.m and covered with aluminium cladding. b) Acoustic insulation for first 6 m length from AHU outlet with 25mm thick resin bonded fibre glass wool of density 48 kg/cu.m covered with 30 G perforated
ISSUE R0
SPEC. NO. TCE-5607A-C-811-08

Aluminium sheet. c) Chilled water piping shall be thermally insulated with expanded polystyrene of density 20 kg/cu.m and finished with sand cement plaster. The thickness of piping insulation shall be as follows: 1.4.9 Pipe diameter upto 25 NB : 40 mm thick insulation Pipe diameter above 25 NB and up to 125 NB : 50 mm thick insulation Pipe diameter 150 NB : 75 mm thick insulation
Hangers and Supports - Ducting a) All ductwork shall be provided with adequate hangers to ensure rigid support and to prevent vibration. b) Hangers shall be attached to the ceiling by anchor / expansion bolts or welded to the plate inserts. Hangers shall be trapeze type with self constructed from ISA 35x35x5 and hung from two steel rods of adequate size. c) The fixing and supports interval shall not exceed 3 metres. The supporting and fixing arrangement shall be approved by the PURCHASER/Consultant.
1.4.10
Hangers and supports - Piping a) All piping supports, guides, anchors, rod' hangers, spring hangers, rollers, with incidental structural sub-framing shall be furnished and erected by the VENDOR. The fabrication of the hangers, anchors and materials shall conform to the requirements ASME B 31.1 latest edition. b) Spring hangers I supports shall be provided for all piping systems operating at above or below the ambient temperature at such locations where vertical movements of the pipe lines exists. c) Springs for spring hangers shall be helical compression type and shall be provided with means to prevent misalignment, buckling and eccentric loading. It shall be provided with stops for excessive travel. d) The spring constants shall be selected so as to limit variation of load in hot and cold conditions of pipe line to maximum of 25% of the rated load. If the variation exceeds 25%, constant load hanger shall be provided. Constant load hangers shall have a field load adjustment of 10% of the load specified. All spring hangers shall be provided with travel stop for field hydro testing. e) The diameter of hanger rods for piping NB50 and below shall not be less than 10.0 mm and for piping NB 65 & above, the rod diameter shall not be less than
ISSUE R0
SPEC. NO. TCE-5607A-C-811-08

13.0 mm. f) All piping shall be suspended, guided and anchored with due regard to general requirements and to avoid interference with the other pipes, hangers, electrical conduits and their supports, ducts, structural members and PURCHASER's equipment. It is the responsibility of the VENDOR to avoid all interference while locating hangers and supports. g) Anchor and l or guides for pipelines or for other purposes shall be provided, when specified, for holding the pipeline in position or alignment. Hangers shall be designed, fabricated and assembled in such a manner that they cannot become disengaged by any movement of the support pipe. h) All hangers shall be furnished -with beam clamps, rods, pipe and all other materials required for the attachment of the hangers to the building structure or the VENDOR's supplementary hanger supporting steel, as the case may be. Welding to structural members shall be made under the supervision of PURCHASER's engineers and in no case shall welding be permitted across the bottom of flange of main structural members. Parts of hangers-'which move relative to the pipe during expansion and contraction shall be connected to the pipe clamps and lugs in such a way that these parts shall lie entirely outside the insulation. When medium or heavy brackets are bolted to walls, back plates of adequate size and thickness shall be furnished to distribute the load against the wall. Where the use of back plate is not practicable, the bracket shall be fastened to the wall in an approved manner. 1.4.11 Pressure gauges Direct reading, pipe mounted Dial type Pressure gauges with Six (6) inch phenolic dial (White dial with black numerals). And will have to be provided at : a) One (1) each at Suction and discharge side of each pump set. b) One (1) each at chilled water inlet and outlet of each AHU. c) One (1) each at chilled water inlet and outlet of each chilling unit. d) One (1) each at condenser water inlet and outlet of each chilling unit. 1.4.12 Temperature gauges / Stem type thermometer Direct reading, field mounted Six (6) inch dial (White dial with black numerals) temperature gauge. And will have to be provided at :
ISSUE R0
SPEC. NO. TCE-5607A-C-811-08

a) One (1) each at chilled water inlet and outlet of each chilling unit. b) One (1) each at condenser water inlet and outlet of each chilling unit. c) One (1) each at condenser water inlet and outlet of each cooling tower. d) Steam type thermometer at chilled water inlet and outlet of each AHU. e) Steam type thermometer at condenser water inlet and outlet of each PAC. 1.4.13 Fresh air unit One (1) no. Fresh air unit each for AHU room supplies fresh air to the AHU room and is located in the AHU room. Each fresh air unit shall comprise of : a) One (1) no. Tube axial fan with motor b) Pre filter with HDPE media having 18 G GSS frame. The efficiency of the filters shall be 90% down to 10 microns. Maximum Velocity across pre filter shall be 2.5 m/s. c) Fine filter with HDPE media having 18 G GSS frame. The efficiency of the filters shall be 99% down to 5 microns. Maximum Velocity across Fine filter shall be 2.5 m/s. d) Fresh air Louver, Volume control damper and connecting duct. 1.4.14 Louvers / Wall Cowl with bird screen Louver / Wall Cowl with bird screen shall be provided for supply air inlet and for exhaust with Tube Axial fans. The louvers shall consist of parallel metallic blades. For louvers, the minimum projected width of blades in horizontal plane shall be 150mm with the blades inclined at minimum 35 degrees. Design face velocity for louvers is 3.0 m/s. Bird screen of 10 sq.mm and minimum 16 G wire mesh is to be provided on the outer face of Louvers. 1.4.15 Expansion tank SINTEX expansion tank insulated complete with vent, make-up water connection, overflow and drain line. 1.5 1.5.1 CONTROL PHILOSOPHY FOR AC SYSTEM PLC based control system is envisaged for AC plant in TG building.
ISSUE R0
SPEC. NO. TCE-5607A-C-811-08

1.5.2 1.5.3 1.5.4
One collective fault signal from each AC plant control system shall be hardwired to DDCMIS for annunciation in UCR. All operations are to be performed by the operator, control system will take care of safety and protection interlocks. Description of control system for each AC plant : (i) PLC based local control system shall be provided for the operation and control of following AC plant auxiliaries: a) Chiller water pumps b) Condenser water pumps c) AHU d) Fresh air fan e) Temperature and humidity control inside A/C area. (ii) The control system will consist of necessary operating and safety controls, pushbuttons, indicating lamps, annunciator for annunciating trip of each auxiliary in AC plant etc. All auxiliaries mentioned above can be operated from the control panel, in addition each drive shall be provided with local push button station for start & stop, the stop push button shall be lockable. Each Chiller unit shall have its own skid mounted microprocessor based control system. It consists of unit-mounted starter, crankcase heater, automatic capacity control etc. This integral control system shall have following minimum protective cutouts : a) HP/LP cutouts
(iii)
(iv)
b) Oil pressure failure switch c) Antifreeze thermostat d) Water flow switch at the outlet of condenser and chiller. e) Any other control recommended by the vendor. 1.5.5 Chiller control system will be complete with instruments and cabling to perform above functions.
ISSUE R0
SPEC. NO. TCE-5607A-C-811-08

1.5.6 1.5.7 1.5.8 1.5.9 1.5.10 1.6 1.6.1
Chiller control system shall have necessary signal exchange with AC plant control panel to build required safety interlocks. Chiller unit can not be started unless chiller water pump, condenser water pump, and AHU are started. Each AHU shall be provided by PLC based local control panel which shall be suitably interfaced with A/c Plant main control panel A/c Plant room main control panel shall accept fire alarm signal from fire detection system and shall trip all A/c plant on fire alarm and shall close fire dampers. Fire damper controls shall be implemented in AHU local control panel. Fire damper position shall be indicated on LCP with the help of limit switches. MATERIAL OF CONSTRUCTION Chilling Unit:
Shell - condenser Shell cooler End Cover Tube sheets Tubes
: Carbon steel : Carbon steel : Carbon steel : Carbon steel : Seamless copper
1.6.2
Air Handling Unit:
AHU casing Cooling coil Fan casing Fan shaft
: 0.63 mm thick GSS : Copper tube and Aluminium fins : Galvanized steel : EN 8
1.6.3
Centrifugal Pump Set:
Casing Impeller Shaft
: Cast iron, IS:210 Gr. FG 260 : Bronze IS 318 Gr 2 : EN 8

ISSUE R0
SPEC. NO. TCE-5607A-C-811-08

Base plate
: Fabricated MS
1.6.4
Cooling Tower:
Casing Air inlet Louver Fill Nozzles Cold water basin
: FRP : FRP / HDGS : PVC : Bronze/Polypropylene : FRP
1.6.5
Air Distribution system:
Ducting Diffuser Grille Volume control damper blade & frame Fire damper blades and frame Louver Frame Louver Blade
: GSS Zinc coating 180 gms /sq.m or better : Aluminium powder coated : Aluminium powder coated : 18 G GSS : 16 G GSS : 16 G GSS : 20 G GSS
1.6.6
Piping and Valves: Pipe sizes upto 150 NB Pipe sizes 200 NB to 450 NB : ERW, Black, IS-1239 heavy class : ERW, IS 1978 or API 5L GR B (ERW) or IS 3589 fabricated from IS 2062 plates :Gun metal construction or Bronze : Cast Iron, IS 210 Gr FG 220
Valves 50 NB and Below Valves above 50 NB
ISSUE R0
SPEC. NO. TCE-5607A-C-811-08

APPENDIX - I A/C LOAD BREAK-UP SL no Name of the Area Area(m2) Equip. Load (kW) TR CFM
1 1
Centralized chilled water plant Main control rooms, electronic cubicle rooms, UPS rooms, shift in charge engineers room, maintenance engineers room and other areas such as Analyser room in TG building for Units-1 & 2. ESP control room Switchyard relay panel room Total 820 105
Based on Summer conditions By Bidder By Bidder
2 3
100 150
20 6
By Bidder By Bidder By Bidder By Bidder
3 1
Air cooled split air conditioners Officers cabins, conference room, I & C lab and electrical lab in service building Note Later Later By Bidder By Bidder
1 2
The Bidder shall indicate the capacity of strip heaters and humidifier for winter heating. Equipment heat load indicated above are tentative.
ISSUE R0
SPEC. NO. TCE-5607A-C-811-08

APPENDIX - II BUILDING CONSTRUCTION DETAILS * SL.NO. 1.0 Roof (*) Cast insitu Roof 150 mm thick RCC +50 mm to 100 mm screed + water proofing 150 mm thick RCC + 50 mm thick floor finish. 150 mm thick RCC + 50 mm thick floor finish. ITEM CONSTRUCTION
2.0
a) Floor ( RCC ) b) Floor in station building ( steel beams with RC floor )
3.0
Outside walls
230 mm thick brick wall + 13 mm thick inside plaster + 20 mm thick outside plaster Single sheet plain glass 6 mm thick
4.0
Glass for window and partition (except unit control room) Glass for unit control room (partitions)
5.0
Double plate glass 6 mm thick towards facing T.G hall for unit control room area and single sheet plain glass 6 mm thick for other partitions.
(*) Considered in the calculation of A/c load Roof of all AC areas and AHU rooms / PAC rooms will be insulated on the underside by 50 mm thick standard thermal insulation. The under deck insulation of exposed roof slab is to be carried out by Civil Bidder.
ISSUE R0
SPEC. NO. TCE-5607A-C-811-08

2.0 2.1 2.1.1
TECHNICAL DESCRIPTION - VENTILATION SYSTEM AREAS TO BE VENTILATED TG Building and Electrical bay Evaporative cooling ventilation system is envisaged for Turbine building and Electrical bay. The inside temperature not exceeding 5 0C less than ambient dry bulb temperature during peak summer considering all heat loads shall be maintained.
2.1.2
Ventilation of other areas: The following are the other areas proposed to be ventilated (Dry ventilation). a) AC plant room b) Switchgear room & Cable gallery in ESP control building c) Switchgear room & Cable gallery in Switchyard control building d) Battery and battery charger rooms in main control room & switchyard control building e) SWAS (wet panel) room f) Workshop
g) All toilets in TG building, service building, ESP & Switchyard control building. h) Stores in TG building, service building, ESP & Switchyard control building. i) Elevator machine rooms in TG building & service building.
For all the above mentioned areas, the supply air fans/louvers and exhaust air fans/roof extractors or combination shall be provided. The ventilation system for each area shall be sized based on either air flow rate calculated considering a room temperature of 3 0C (Maximum) above ambient DBT during peak summer considering all heat loads or air flow rate calculated considering minimum number of air changes / hour as mentioned else where in the document, whichever results in higher air flow rate shall be considered. 2.1.3 The list of areas to be ventilated and type of system is detailed under Appendix III
ISSUE R0
SPEC. NO. TCE-5607A-C-811-08

2.1.4
The following are the various Input data considered in the Design of Ventilation system: Outside design conditions: DRY BULB TEMPERATURE SUMMER MONSOON WINTER 47.7 0C 37.8 0C 19 C
0
WET BULB TEMPERATURE 26.8 0C 26.3 0C 16.7 C

0
2.2
REFERENCE CODES AND STANDARDS All materials and equipments provided shall comply with the following Indian Standards IS 277 IS 325 IS 655 IS 7613 IS 2312 IS 3588 IS 4894 UL 555 IS 7098 Part-1 IS 1554 Part-1 IS 4237 IS 6875 Control panel Galvanised Steel Sheets Three phase induction motors Metal Air ducts Method of testing panel type air filters for air-conditioning and Ventilation process. Propeller type AC ventilation fans Electric axial fans Centrifugal fans Fire dampers Power cables Control cables MCC PB Stations Individual electrical components conform to respective IS
ISSUE R0
SPEC. NO. TCE-5607A-C-811-08

2.3
DESCRIPTION OF THE SYSTEMS a) Three (3) nos. suitable capacity and minimum of 75-mmWC static pressure Evaporative cooling system for Ventilation of TG building is to be provided. b) Ambient Air Ventilation (Dry) system for miscellaneous areas.
2.3.1 2.3.1.1
Evaporative Cooling System for T G Building and Electrical Bay (BC Bay) Air-washers of adequate capacity shall be provided for Evaporative cooling of various floors of Turbine building (during Unit in operation) including electrical Bay. Each Spray type air-washer system shall consist of an air-tight chamber or casing containing air distribution plates, spray nozzle system arranged in a single bank or multiple banks, a tank for collecting the spray water, eliminators for removing entrained drops of water from the air, flooding nozzles for cleaning eliminators, two (2) nos. Centrifugal fans (both working) and three (3) nos. centrifugal circulating water pumps (2 working + 1 standby) with piping, valves and specialties for recirculation water at higher rate than the evaporation rate. The tank is provided with drain, overflow, make-up water and quick-fill connections. Drain sump with suction Screens are provided in tank. The hot air is exhausted by power roof extractors for TG building and wall mounted tube axial fans for Electrical bay. With this system the dry bulb temperature within the 0 turbine building shall be maintained 5 C less than ambient dry bulb temperature at all times of the year. The air-washer capacity is to be decided based on either the conditions as specified below or number of air changes as indicated in Appendix III which ever is higher: a) Total internal heat load within the turbine building, inclusive of electrical bay and maintenance bay and considering the heat dissipated by various electrical switchgear, motors, equipment hot surfaces, steam piping as well as the dissipated heat, solar transmission through the building wall and glass, and any other sources of heat. b) Summer ambient conditions as furnished to be considered. c) Efficiency of air-washer shall be 90% with two banks opposed type spray system.
2.3.1.2
Each air washer comprising Two (2) no. Double Inlet Double Width (DIDW) type centrifugal fan of suitable capacity and minimum 75 mm WC static pressure. The impeller shall have die formed blades welded to the rim and back plate and blade shall be of backward curved type. Power roof extractors / Hybrid turbo ventilators each of suitable capacity mounted on TG hall roof for exhausting the hot and ventilated air. The number of Power roof extractors on the turbine building as well as wall mounted tube axial exhaust fans provided for Electrical bay to be sized so as to exhaust about
ISSUE R0
2.3.1.3
SPEC. NO. TCE-5607A-C-811-08

70% of the total air supplied. Remaining 30% of air is exhausted through window openings/ventilators/rolling shutters/floor hatchers. 2.3.1.4 Re circulated water flow rate is 0.53 M3/Hr for a single bank and 1.34 M3/Hr Or double or multiple banks per 1,000 M3/Hr of air flow rate. Air resistance varies from 6mmWC to as high as 25 mmWC. Spray nozzle pressure varies from 1.4 to 2 2 2.8Kg/cm g, whereas flooding nozzle operates at 0.2 to 0.3 Kg/cm g pressure. Generally, specified air face velocity through the air washer internals i.e. distribution plate, spray nozzles and the eliminators is 2.5 M/sec.Tank has a minimum depth of 600 mm with 450 mm water level. The distance between air distribution plates and spray bank as well as spray bank and eliminator plates is 400 to 600 mm. The distance between the two spray banks is 800 to 1,400 mm. normally; air washer tank is extended beyond eliminators by 500 mm. An air-tight inspection door is provided on the chamber or casing along with a marine light and catwalk inside the spray section, to facilitate cleaning of spray and flooding nozzles during maintenance. A level switch is provided to safeguard the pump. The system comprises of the following equipment : i) Three (3) nos. air washer units of following capacities. a. One (1) nos outside A-row of minimum capacity 250000 m3/hr. b. Two (2) nos. at El. 21.50 m of BC bay of minimum capacity 150000 m3/hr each. Bidder to note that the Air washer capacities indicated above are minimum and shall be considered only for bidding purpose. ii) Each air washer comprising Two (2) no. ( Double Inlet Double Width (DIDW) type centrifugal fan of suitable capacity and minimum 75 mm wc static pressure, Three (3) nos (2 Operating and 1 standby ) circulating water pumps of Horizontal split casing type / End suction top discharge type, each of adequate capacity.
iii) Spray type Air washers with water distribution arrangement etc. iv) Pre filter with HDPE media having 18 G GSS frame. The efficiency of the filters shall be 90% down to 10 microns. v) Inlet louvers and bird screen.
vi) Air distribution system comprising of GSS ducting, dampers, Grilles etc vii) Thirty four- (34) nos.(for both TG buildings) power roof extractors/Hybrid turbo ventilators each of suitable capacity and minimum 15 mm static pressure mounted on TG hall roof for exhausting the hot and ventilated air.
ISSUE R0
SPEC. NO. TCE-5607A-C-811-08

viii) Wall mounted tube axial fans for switchgear room and cable gallery in BC bay. ix) Necessary blow down/makeup arrangement to ensure proper water quality. The method of air distribution will be as follows : a) One (1) nos. of 250000 m3/hr minimum capacity air washer is located adjacent to A row wall of TG building at 5.50 EL b/w grids 10 and 12, catering TG hall of both Unit I & II. The supply air from the fan outlets shall be collected in a plenum adjacent to A row wall. From this plenum, various branches are tapped at various levels to ventilate the following areas as below. + 0.00 M floor of AB bay + 5.50 M floor of AB bay + 11.00 M floor of AB bay b) Two (2) nos. each of 150000 m3/hr minimum capacity air washers are located at 21.50 EL in BC bay b/w grids 7 &10 and 15 & 18, catering TG hall, Electrical room & Cable gallery of both Unit I & II. The supply air from the fan outlets will be collected in a plenum adjacent to B row wall. From this plenum, various branches are tapped at various levels to ventilate the following areas as below. + 0.00 M floor of BC bay and AB bay + 3.50 M floor of BC bay + 5.50 M floor of AB bay + 8.00 M floor of BC bay + 11.00 M floor of AB bay c) Thirty four- (34) nos. (for both Units) adequate capacity and minimum 15 mm static pressure power roof extractors/Hybrid turbo ventilators mounted on TG hall roof for exhausting the hot and ventilated air from TG hall. d) Wall mounted tube axial fans of adequate capacity for exhausting hot and ventilated air from Switchgear room and cable gallery in BC bay.
ISSUE R0
SPEC. NO. TCE-5607A-C-811-08

2.3.2 2.3.2.1
Ambient Air Ventilation (DRY) System for Miscellaneous Areas For Ventilation of other miscellaneous areas, the ambient Mechanical Ventilation system shall be designed to maintain Dry bulb temperature not exceeding 3 0 C above ambient Dry bulb temperature or based on number of air-changes/hr, whichever results in higher air flow rate will be provided. All Dry ventilated areas, shall be provided with supply system comprising supply air fans or supply air intake louvers (without fan) and exhaust system comprising wall mounted exhaust fans OR roof extractors mounted on the roof of the respective building, depending upon the layout of the building. The type of system is detailed under Appendix-III. The ventilation system for the various areas shall be designed duly considering the factors such as temperature, relative humidity and maximum allowable concentration of gases present in the rooms, corresponding to international guidelines. For hazardous areas, fans with anti-spark characteristics to be provided. For Battery rooms, air intake is through louvers and exhaust by means of 20G MS Epoxy painted ducted exhaust by exhaust fans shall be provided. Higher exhaust air flow rates compared to supply air flow rate shall be maintained within the Battery room to maintain negative pressure. All fans, motors, ducting and grilles in this area shall be given acid and epoxy painted. The fans shall be of anti spark construction with flame proof motors. Pressurised Ventilation Switchgear rooms / MCC rooms & cable gallery: Filtered air is supplied to Switchgear rooms / MCC rooms through ducting and grilles by means of supply air fan and the air is exhausted through gravity dampers, axial flow fans of suitable capacity will be added if necessary. For elevator machine room, filtered air shall be supplied by supply air fan. Exhaust shall be through gravity dampers. Start up & commissioning spares and tools for maintenance shall be included. Painting of all equipment and structures shall be provided and the colour & quality shall be subject to approval by the PURCHASER / Engineer.
2.3.2.2
2.3.2.3
2.3.2.4 2.3.2.5
2.3.2.6
2.3.2.7 2.3.2.8 2.3.2.9
2.3.2.10 List of essential spares to be included as enclosed.
ISSUE R0
SPEC. NO. TCE-5607A-C-811-08

2.4 2.4.1
EQUIPMENT TO BE SUPPLIED Air Washer for TG Building & Main Control Building Design wet bulb temperature : 27.0 Deg C Saturation efficiency: 90% Each Air washer comprises of the following : a) Two (2) no. (2x50% capacity) Double Inlet Double Width (DIDW) type centrifugal fan of suitable capacity and complete with drive package and motor. b) Three (3) nos (2 Operating and 1 standby ) circulating water pumps of Horizontal split casing type, each of adequate capacity c) Evaporative spray nozzle water distribution arrangement with multiple banks, a tank for collecting the spray water, eliminators for removing entrained drops of water from the air, flooding nozzles for cleaning eliminators. d) Pre filter with HDPE media having 18 G GSS frame. The efficiency of the filters shall be 90% down to 10 microns e) Inlet louvers and bird screen. f) Sump complete with make-up connection, over flow connection, drain connection and water level switch. g) Controls comprising the following: Sump Level switch, to trip pump at low water level in the sump.
h) Monorail with hoist for handling centrifugal fans (To be provided in each air washer room). 2.4.2 Centrifugal water pump set The centrifugal pump set will be Horizontal split casing / End suction top discharge centrifugal pump set and each centrifugal water pump set shall comprise of the following : a) One (1) no. Horizontal split casing centrifugal pump. b) One (1) no. adequately sized Induction motor suitable for 415 V, 3 phase, 50 Hz supply.
ISSUE R0
SPEC. NO. TCE-5607A-C-811-08

c) One (1) set of base plate, coupling guard, anti vibration pads and foundation bolts. d) Flexible connection between pump and piping. e) Drain piping from pump to nearest floor drain 2.4.3 Centrifugal Fan The centrifugal fan shall be designed for : i) Fan RPM : Not exceeding 1000 RPM
ii) Fan type : Backward curved DIDW / SISW iii) Fan outlet Velocity: Not exceeding 12 m/s. Each centrifugal fan comprises of : a) One (1) no. adequately sized Induction motor suitable for 415 V, 3 phase, 50 Hz supply with drive package comprising of fan pulley and V-belt. b) Common base frame with spring type vibration isolators. c) Inlet guard, outlet damper and flexible connection between duct and fan 2.4.4 Axial fan The Axial fan shall be designed for : i) Fan type: Tube Axial / Propeller.
ii) The impeller shall have blades of an aerofoil design. iii) The speed of the fans shall be 1500 rpm for impeller diameter 450 mm or less and 1000 rpm for impeller diameter above 450 mm. Axial fans will be of propeller type, for fans with 5 mm of WC fan static pressure and Tube Axial type for fans with static pressure above 5 mm of WC. Each Axial fan comprises of fan, fan motor, inlet and outlet cone (for Tube axial), Louvered shutter (exhaust fans), bird screen and supporting arrangement. 2.4.5 Power Roof Extractor The Power Roof Extractor shall be designed for :
ISSUE R0
SPEC. NO. TCE-5607A-C-811-08

i)
Fan type : Tube Axial
ii) The impeller shall have blades of an airfoil design iii) The speed of the fans shall be 1500 rpm for impeller diameter 450 mm or less and 1000 rpm for impeller diameter above 450 mm. iv) Hood shall be hinged type. Each Power Roof Extractor comprises of fan, fan motor, hood with disconnect switch and supporting arrangement. 2.4.6 Air distribution system a) Rectangular Duct: GSS supply air ducting and return air ducting with Zinc coating 180 gms /sq.m or better. b) The material thickness of the ducting shall be as following considering the industrial duty conditions Large side of rectangular Duct (mm) 0 - 750 751 - 1500 1501 and 2100 2101 and above Thickness (mm) 0.63 0.80 1.00 1.25
c) The supply air ducting will be designed based on equal friction method to have an initial velocity not exceeding 12 m/s and friction rate 0.8 Pa/m. d) The exhaust air ducting will be designed based on equal friction method to have an initial velocity not exceeding 8 m/s and friction rate 0.66 Pa/m. e) Ducting outside the served premises of air washing unit shall be insulated with 40mm (minimum) thick fibre glass insulation with aluminium cladding of thickness 24G. f) Supply air grilles will be with volume control damper g) Return air grilles will be without volume control damper h) Neck velocity for supply air grille and return air grille will be 3.75 m/s (max) and 2.5 m/s (max) respectively.
ISSUE R0
SPEC. NO. TCE-5607A-C-811-08

i)
Motorized fire dampers to be provided in the Ventilation supply air duct crossing wall / slab opening in Electrical bay of TG building.
j) Fusible link type fire dampers shall be provided in the supply air ventilation duct and return air ventilation duct crossing wall / floor. 2.4.7 Hangers and Supports a) All ductwork shall be provided with adequate hangers to ensure rigid support and to prevent vibration. b) Hangers shall be attached to the ceiling by anchor / expansion bolts or welded to the plate inserts. Hangers shall be trapeze type with self constructed from ISA 35x35x5 and hung from two steel rods of adequate size. c) The fixing and supports interval shall not exceed 3 metres. The supporting and fixing arrangement shall be approved by the PURCHASER/Consultant. 2.4.8 Piping and Valves a) Piping shall be ERW, Black, IS-1239 heavy class for pipe sizes up to 150 NB ERW, IS 1978 or API 5L GR B (ERW) or IS 3589 fabricated from IS 2062 plates for pipe sizes 200 NB to 450 NB b) Isolating valves will be butterfly valve type for valve size 50 NB and above. c) Isolating valves will be Gate valve type for valve size below 50 NB. d) Strainers will be Pot strainer type e) Air washer circulating water piping shall be designed such that, for pipe sizes of 50 NB and under, maximum velocity is 1.2 m/s and friction rate is not exceeding 250 Pa/m. For pipe sizes above 50 NB, maximum velocity is 3 m/s and friction rate is not exceeding 400 Pa/m. f) Isolating valves will be provided at inlet and outlet piping of pumps. g) Strainers will be provided at the inlet piping to pump. h) Non return valves will be provided at the outlet of Pumps.
ISSUE R0
SPEC. NO. TCE-5607A-C-811-08

2.4.9
Pressure gauge Direct reading, pipe mounted Dial type Pressure gauges with Six (6) inch phenolic dial (White dial with black numerals) and will be provided at One each at Suction and discharge side of the pump set.
2.4.10
Temperature gauge Direct reading, field mounted Six (6) inch dial (White dial with black numerals) temperature gauge and will be provided at Air washer circulating water pump discharge header.
2.4.11
Louvers / Wall Cowl with bird screen Louver / Wall Cowl with bird screen will be provided for supply air inlet and for exhaust with Tube Axial fans. The louvers shall consist of parallel metallic blades. For louvers, the minimum projected width of blades in horizontal plane shall be 150mm with the blades inclined at minimum 35 degrees. Design face velocity for louvers is 2.5 m/s. Bird screen of 10 sq.mm and minimum 16 G wire mesh is provided on the outer face of Louvers.
2.5 2.5.1 2.5.2
CONTROL PHILOSOPHY FOR VENTILATION SYSTEM Microcontroller/PLC based control system shall be envisaged for ventilation system. Following control function are to be proposed : 5.2.1 5.2.2 5.2.3 5.2.4 Tripping of Air washer circulating water pumps at low water level in the air washer sump. Annunciation on the status of Run/trip status of Air washer pumps and Air washer fans. Air washer pump and fan shall be provided with local lockable start/stop push button. Air washer and all the ventilation fans shall be interlocked with fire protection system to trip under fire condition and associated motorised fire dampers shall close.
ISSUE R0
SPEC. NO. TCE-5607A-C-811-08

2.6 2.6.1
MATERIAL OF CONSTRUCTION Air Washer Internals

Spray nozzles Air distribution plates Eliminator plates Flooding nozzles Suction screen
: Brass/Bronze : 18G GSS : 24G GSS / PVC : Brass : 24 G brass / SS
2.6.2
Centrifugal Pump Set:
Casing Impeller Shaft Base plate
: Cast iron, IS:210 Gr. FG 260 : Bronze IS 318 Gr 2 : EN 8 : Fabricated MS
2.6.3
Air Distribution system:

Ducting Grille Volume control damper blade & frame Fire damper blades and frame Louver Frame Louver Blade
: GSS Zinc coating 180 gms /sq.m or better : Aluminium powder coated. : 18 G GSS : 16 G GSS : 16 G GSS : 20 G GSS
2.6.4
Piping and Valves: Pipe sizes upto 150 NB Pipe sizes 200 NB to 450 NB : ERW, Black, IS-1239 heavy class : ERW, IS 1978 or API 5L GR B (ERW) or IS 3589 fabricated from IS 2062 plates
ISSUE R0
SPEC. NO. TCE-5607A-C-811-08

2.6.5
Valves 50 NB and Below Valves above 50 NB
: Gun metal construction or Bronze : Cast Iron, IS 210 Gr FG 220
Centrifugal Fan: Casing Impeller Shaft Outlet damper Fan supports, frames and structure : Mild steel sheets / plate to IS 2062 Grade B and 3.15 mm thick : Mild steel sheets / plate to IS 2062 Grade B and 3.15 mm thick : EN 8 : GSS : Mild steel plate to IS 2062
2.6.6
Axial Fan: Casing Impeller Shaft Inlet Cone / Outlet cone : Mild steel plate to IS 2062 : Cast Aluminium : EN 8 : Mild steel
2.6.7
Roof Extractor: Casing Impeller Shaft Hood : Mild steel plate to IS 2062 : Cast Aluminium : EN 8 : MS
2.6.8
Pre filter: Filter Media Frame : High Density Poly ethylene (HDPE) media. : 18 G GSS
ISSUE R0
SPEC. NO. TCE-5607A-C-811-08

2.7
NOISE & VIBRATION The design of air-conditioning and ventilation equipment and accessories shall ensure maintaining of noise and vibration levels within the limits as per latest applicable codes and standards.
ISSUE R0
SPEC. NO. TCE-5607A-C-811-08

(APPENDIX III) The following is the type of Ventilation system to be provided

SL. NAME OF AREA NO
TYPE OF DESIGN CONDTIONS VENTILATI ON SYSTEM Evaporative 50C below ambient cooling during peak summer system
EQUIP. AIR SUPPLY AIR LOAD CHANG SYSTEM (kW) * ES/HR
EXHAUST AIR SYSTEM
TG Building A B Bay - El.0.0m, 5.50 m & 11.0 m
1350
From Air washer Roof through ducting extractors
Cable vault at El. 0.0 Evaporative 50C below ambient m at BC bay in TG cooling during peak summer building for Unit I & system with pressurization 2-3 II mm WC Switch gear room at Evaporative 50C below ambient El. 3.50 m at BC bay cooling during peak summer in TG building for system with pressurization 2-3 Unit I & II mm WC Cable vault at El. Evaporative 5 C below ambient 8.00 m at BC bay in cooling during peak summer TG building for Unit system with pressurization 2-3 I & II mm WC Battery and battery charger room at El. 11.00 m at BC bay in TG building for Unit 1 Battery and battery charger room at El. 11.0 m at BC bay in TG building for Unit 2 Ambient Air Ventilation (DRY) System Not exceeding 30C above ambient temperature with negative pressurization
0 0
140
15
From Air washer through ducting Tube axial exhaust fans
70
15
100
15
20
Tube axial Fresh air through Louvers exhaust fans with ducting
Ambient Air Ventilation (DRY) System
Not exceeding 3C above ambient temperature with negative pressurization

0
20
Fresh air Tube axial through Louvers exhaust fans with ducting
Switchgear room at Ambient Air ESP control building Ventilation (DRY) System
Not exceeding 3C above ambient temperature with pressurization 2 3 mm WC

0
20
20
Filtered air supplied by supply air fan
Tube axial exhaust fans
Cable vault at ESP control building at
Ambient Air Not exceeding 3C Ventilation above ambient
40
20
Filtered air supplied by
Tube axial
ISSUE R0
SPEC. NO. TCE-5607A-C-811-08

El.0.0 m.
(DRY) System
temperature with pressurization 2 3 mm WC Not exceeding 3C above ambient temperature with negative pressurization Not exceeding 30C above ambient temperature with negative pressurization exchange
0
supply air fan
exhaust fans
10 Battery and battery charger room in Switchyard relay panel building 11 Switchyard MCC room
Ambient Air Ventilation (DRY) System Ambient Air Ventilation (DRY) System
20
Tube axial Fresh air through Louvers exhaust fans with ducting
12
20
Fresh air Tube axial through Louvers exhaust fans with ducting
12 AC plant room
Ambient Air General air Ventilation ventilation (DRY) System Ambient Air General air Ventilation ventilation (DRY) System
20
Fresh air Exhaust fans through Louvers
13 Toilets in TG building, service building, ESP control building & Switchyard relay panel building 14 Stores in TG building, ESP control building & Switchyard relay panel building 15 Elevator machine rooms
exchange
20
Through door undercuts/door louvers
Propeller fans
Ambient Air General air Ventilation ventilation (DRY) System Ambient Air General air Ventilation ventilation (DRY) System Ambient Air General air Ventilation ventilation (DRY) System
exchange
20
Propeller Fresh air through Louvers fans
exchange
20
Gravity dampers
16 Workshop
exchange
20
Tube axial exhaust fans
*The equipment heat loads indicated are tentative.
ISSUE R0
SPEC. NO. TCE-5607A-C-811-08

3.0
SHOP INSPECTION AND TEST REQUIREMENTS Minimum shop inspection requirements for different AC and Ventilation equipment are furnished below. All inspection shall meet the enclosed standard in Section-D
3.1
Information to Vendors for quality plans and general inspection requirement Shop inspection and test procedures Chilling package (a) Screw compressor (b) Condenser & chiller
TCE.M4-185-01
3.2 3.3
TCE.M4-904
TCE.5607A-C-811-08 TCE.M4-185-72 TCE.M4-185-32 TCE.M4-185-10 TCE.M4-185-68
3.4 3.5 3.6 3.7
Pumps Axial & radial fans Filters Air handling units (a) Fans (b) Filter (c) Cooling coil
TCE.M4-185-10 TCE.M4-185-68 Review of material test certificates of cooling coil and witnessing of pneumatic/hydraulic test on each coil
(d) Visual inspection for dimensional check with respect to general arrangement drawings to be furnished earlier. (e) Run test to be witnessed.
ISSUE R0
SPEC. NO. TCE-5607A-C-811-08

3.8
Cooling towers
TCE.M4-185-76
For FRP lining Following tests on raw material to be witnessed. (a) Glass percentage (b) Tensile & flexural strength (c) Barcol hardness (d) Lap shear strength tests (e) Bond strength tests 3.9 3.10 Piping Valves TCE.M4-185-38 TCE.M4-185-17 TCE.M4-185-18 TCE.M4-185-30 TCE.M4-185.13 TCE.M4-185.71
3.11 3.12 3.13
Duct Thermal Insulation Air Washer Internals (a) (b) Visual inspection of various internals.
Measurements to establish air washer efficiency (This test will be done at site). Material test certificates for air washer internals.
(c) 3.14
Packaged Air Conditioners (a) (b) (c) Visual inspection for dimension / finish etc. Witnessing run test. Test certificate.
3.15
Motors (a) Routine test as per IS 325. (b) Type test certificates as per IS 325 for all motors. Control Panels (a) Functional test and routine test as per relevant IS standard
3.16
ISSUE R0
SPEC. NO. TCE-5607A-C-811-08

4.0 4.1 4.1.1 4.1.2
GUARANTEES AND ACCEPTANCE TESTS Guarantee Requirements The specified inside design conditions shall be guaranteed by the BIDDER. Satisfactory operation of the equipment offered shall be guaranteed for 12 months from the date of commissioning. Bidder shall undertake to repair or replace any part which is defective due to faulty materials, design or workmanship.. All equipment supplied shall have capacities / performance not less than those specified in section C1 & C2. If BIDDER feels that higher capacity equipment is required to meet the specified conditions, the same has to be substantiated by the BIDDER with supporting calculations. Acceptance Tests After completion of the installation, VENDOR shall balance the system and make necessary adjustments for all equipment until all guaranteed performance requirements are satisfied. After completing the adjustments, VENDOR shall conduct acceptance tests of the installation in the presence of BPPL during which the installation shall meet the guaranteed performance requirements to the satisfaction of BPPL and all inside design conditions specified shall be maintained, within the specified tolerances. If the performance is not achieved by the VENDOR, VENDOR shall be given the option of making adjustments after which the tests shall be repeated at the VENDORs expense. The repeat test shall be carried out within the stipulated time. All instruments and services required for the above tests shall be provided by VENDOR. The test reports shall be submitted for BPPLs approval before handing over the plant. VENDOR shall ensure that all instruments installed in the air-conditioning and ventilation systems as well as all instruments required for conducting acceptance tests shall be only calibrated instruments. VENDOR shall ensure that calibration of all instruments shall be carried out by any certified laboratory having traceability to national standards. VENDOR shall submit such calibration certificates meeting the above requirements to BPPL for approval prior to installations/ conducting of acceptance tests
4.1.3
4.2 4.2.1
4.2.2
4.2.3
4.2.4
4.2.5
ISSUE R0
SPEC. NO. TCE-5607A-C-811-08

5.0 5.1
BID EVALUATION/PENALTY BIDDER shall comply with the AIR-CONDITIONING & VENTILATION equipment specifications laid out in various sections. No credit will be given in tender evaluation if parameters better than those specified are offered by the BIDDER. In case the BIDDERs recommendation is different from the specification in regard to any aspect, the BIDDER shall quote basically in line with the specification indicating price change for adopting his recommendation, failing which his bid will be summarily rejected. BIDDER shall ensure that there are no deviations from technical specifications. In case BIDDER takes major deviations from the specifications, his Bid will be summarily rejected. In case there are minor deviations the BIDDER shall absorb the same within the price quoted by him already. No deviation after award of contract from the agreed technical specification will be permitted. Any such deviation noticed by the BPPL at any stage after the award of Contract will not be permitted and the VENDOR shall carry out necessary modifications to bring the system in line with agreed technical specification at no extra cost. The BIDDER shall furnish the information called for in the Schedule of motor with guaranteed power consumption for continuously running equipment giving ratings and number of all electrical equipment, etc., under the scope of contract. BIDDER shall also furnish all the data called for in Data Sheet-B of various equipment of Section-D. Offers which do not contain all the data will be treated as incomplete and are liable for rejection. Cost loading for differential power consumption will be Rs.2.18 Lakhs per kW. In case the energy consumption of the drive of any equipment exceeds the energy consumption figures furnished by the BIDDER during bid stage, the BIDDER will be penalised at the rate of Rs. 2.18 Lakhs /kW differential.
5.2
5.3
5.4 5.5
ISSUE R0
SPEC. NO. TCE-5607A-C-811-08

6.0 6.1 6.1.1
MISCELLANEOUS SERVICES SPARES & TOOLS BIDDERs shall include and quote for list of spares separately as per Table-1 enclosed and also furnish unit prices, which shall be included in the basic quoted price. BIDDER shall include and quote for list of maintenance and erection tools and tackles as per Table-2 enclosed, which shall be included in the basic quoted price. Start-up and commissioning spares as required during startup and commissioning till handing over the plant to the BPPL shall be supplied by the BIDDER and included in the basic quoted price. Training of BPPLs Personnel The VENDOR shall undertake to train a reasonable number of engineers selected and sent by the BPPL. The engineers shall be given special training in the shop, laboratory and drawing office of the VENDOR where the Equipment will be designed and manufactured and in any other power plant where similar capacity equipment design, manufactured and supplied by him is under installation, test, operation and maintenance, to enable the engineers to become fully familiar with the Equipment to be supplied under this Contract. The VENDORs supervisory personnel at Site shall continuously and intensively instruct and train adequate number of BPPLs operating and maintenance personnel at Site during erection and commissioning of the Plant to enable them to take over the proper operation and maintenance of the Plant after commissioning. Grouting of all equipment base plate / foundation bolts shall be included in VENDORs scope. PERFORMANCE TESTS Performance test shall be carried out in the presence of BPPL / CONSULTANTs to prove the guarantee indicated by the VENDOR/BIDDER. Satisfactory operation of control interlock and sequential operation of the control scheme shall be demonstrated at site. All instruments and services required for the above tests shall be provided by VENDOR. The test reports shall be submitted for BPPLS / CONSULTANTs approval before handing over the plant. PAINTING Painting of all the equipment and structures shall be as per section C-13:
ISSUE R0
6.1.2 6.1.3
6.2 6.2.1
6.2.2
6.3 6.4 6.4.1
6.4.2
6.5 6.5.1
SPEC. NO. TCE-5607A-C-811-08

6.6
ERECTION, TESTING AND COMMISSIONING The VENDORs scope of work shall include complete erection, testing and commissioning of the air-conditioning and ventilation systems, which will include initial and trial operation of the both systems. The VENDORs supervisory personnel shall be stationed at the plant for supervision of operation till the commissioning and handing over of the air conditioning and ventilation plants. It is responsibility of VENDOR to meet the guaranteed performance requirements to the satisfaction of BPPL and all inside design conditions specified shall be maintained, within the specified tolerances.
ISSUE R0
SPEC. NO. TCE-5607A-C-811-08

TABLE - 1 LIST OF SPARES AIR CONDITIONING SYSTEM
Sl.No. 1.
Equipment Screw refrigerant compressor
Quantity a) b) c) d) e) One (1) set of sensors of each type One (1) set of valves of each type One (1) set of sight glass One (1) set of filter driers One (1) set of any other critical parts based on manufacturers recommendation to be included. CONTROLS f) g) h) One (1) oil pressure failure safety switch One (1) HP / LP cut-out One (1) thermostatic expansion valve
2.
Water cooled refrigerant condensers(for each model) Refrigerant chillers Air handling units (for each model)
a) Two sets of gaskets
3. 4.
b)
Two (2) sets of gaskets
a) One (1) set VEE belt b) Two (2) sets of blower bearings c) Two (2) sets of blower motor bearings d) Filters One (1) set for one AHU of each model/size e) One (1) motor for each size of AHU
ISSUE R0
SPEC. NO. TCE-5607A-C-811-08

5.
Horizontal centrifugal pumps (for each model)
a) One (1) impeller for each size of pump b) One (1) set of shaft sleeves for each model c) One (1) set of bearings for each model d) One (1) set of bearings for motor of each pump model
6.
Induced draft FRP cooling tower
a) One (1) no Gear box b) One (1) no fan blade assembly c) Two (2) sets of fan bearings d) Two (2) sets of motor bearings e) 50% of total requirement of oil seals and O-rings f) 10% of total requirement of spray nozzles
Cables and Accessories
a) Termination kit for each size of cables b) Lugs- 10% of total with at least one of each size whichever is higher
LIST OF SPARES VENTILATION SYSTEM
Sl.No. 1.
Equipment Horizontal Centrifugal Pumps (for each model) 1. 2. 3. 4.
Quantity One (1) impeller for each size of pump One (1) set of shaft sleeves for each model One (1) set of bearings for each model One (1) set of bearings for motor of each pump model
ISSUE R0
SPEC. NO. TCE-5607A-C-811-08

2.
Air Washer
1. 2. 3. 4.
Two (2) water strainers * Nos. spray nozzles * Nos. flooding nozzles Two (2) set of brass suction screen One (1) set V-belts One (1) set of blower bearings One (1) set of blower motor bearings Two (2) sets of gaskets One (1) set of fan bearings One (1) set of fan motor bearings One (1) set of motor for each size of fan Termination kit for each size of cables Lugs 10% of total with atleast one of each size whichever is higher
3.
Centrifugal fans (for each size)
1. 2. 3. 4.
4.
Axial fans / Roof Extractors (for each size)
1. 2. 3.
5.
Cables and accessories
1. 2.
*- BIDDER TO INDICATE.
ISSUE R0
SPEC. NO. TCE-5607A-C-811-08

TABLE 2 LIST OF MAINTENANCE AND ERECTION TOOLS AND TACKLES
Sl.No. 1.
Item Imperial wide range flaring tool (45) for 9 sizes from 1/8 to : OD flooring Double ended spanner Tube cutter Bearing puller Alley key set Screw driver set (6 Nos.) with insulated handles Pulley puller Open type wrench 6 mm to 30 mm Valve key Adjustable wrench 15 cm Wratchet wrench Box spanner set Leak detector Tube bender spring set Hacksaw frame with blade Steel cabinet for tools Pressure gauge Compound gauge 6.35 cm Flexible gauge connection
Quantity 4 sets
2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19.
1 set 1 No. 1 No. 1 set 1 set 1 set (each type) 1 set 1 No. 1 No. 1 No. 1 set 1 set 1 No. 1 No. 1 No. 1 No. 1 No. 1 No.
ISSUE R0
SPEC. NO. TCE-5607A-C-811-08

Sl.No. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40.
Item Spring balance 0.20 kg Ring spanner set of 6 pieces Gas charging kit Long brushes with extension rods and locking arrangement for cleaning condenser Refrigerant pipes pressure testing kit Thermometers well type Sling psychrometer Vacuum pump HP Anemometer Plier combination Hammer kgs Chisel flat 19 mm Centre punch File flat smooth 200 mm File round bastard 200 mm File brush Flexible steel tape 2 mts. Feeler gauge Spirit level 8" Fuse wire set Test lamp holder
Quantity 1 No. 1 No. 1 No. 3 Nos. 1 No. 2 Nos. 1 No. 1 No. 1 No. 1 No. 1 No. 1 No. 1 No. 1 No. 1 No. 1 No. 1 No. 1 No. 1 No. 1 No. 1 No.
ISSUE R0
SPEC. NO. TCE-5607A-C-811-08

Sl.No. 41. 42. 43. 44. 45.
Item Insulating tape roll Flare nuts "SAE Adaptor for refrigerant cylinder " FPT x " SAE Gauge adaptors 1/8" FPT x " SAE Portable multirange meter
Quantity 1 No. 6 Nos. 1 No. 2 Nos. 1 No.
ISSUE R0
SPEC. NO. TCE-5607A-C-811-08

7.0 7.1
ELECTRICAL REQUIREMENTS SCOPE OF WORK The BIDDER shall include design, detailed engineering, supply, erection, installation, testing and commissioning till handing over of all the electrical equipment and systems required for HVAC handling system and its auxiliaries in the scope of works. a) b) c) d) e) 400 V switchgear All necessary AC LT Drive Motors for the system All motor operated valves required for the system All Power, Control and instrumentation cables between equipment supplied by the BIDDER and all required Special cables. Cabling system with cable raceway system with necessary fire barriers, fire proof sealing and coating systems and other accessories like glands, lugs, gland plates, etc. required for cables that are included in the scope. Local Control Panels, Ventilation distribution board, Junction boxes, ACDBs, Adaptor boxes and Marshalling boxes as required Local push button stations for all the motors/ System Equipment earthing All the foundation accessories including base plates/channels, foundation bolts, wall/column inserts/supports, anchor bolts, etc. as may be required for all electrical equipment Commissioning spares and essential spares for 2 years trouble free operation. Any other items required completing the electrics of HVAC handling system and its auxiliaries are in the scope of the BIDDER.
f) g) h) i)
j) k)
7.2 7.3 7.3.1
Deleted. LOW VOLTAGE SWITCHGEAR LV switchgear required for feeding all the loads and systems pertaining to HVAC handling system loads like air washer fans, pumps etc are included in the scope.
ISSUE R0
SPEC. NO. TCE-5607A-C-811-08

7.3.2
The switchgear shall be 400V AC rated 4 wire system, indoor, metal enclosed, fully draw-out and compartmentalized and shall be as per the enclosed specification TCE.M4-219-11 in section-D which forms an integral part of this specification. Scheme wiring diagrams for module types referred in TCE.M4-21911 are not enclosed with this specification. Instead specific design requirements are spelt in this section. Based on this, Bidder to furnish the wiring schemes for Purchasers approval. Each switchgear shall be complete with all fittings and accessories as detailed in Section -C, Section D and Data Sheet -A1 as well as those required for normal working even though not explicitly called for in this specification. All mounting accessories like base channels, cross angles if required, bolts, nuts etc. shall be supplied by the BIDDER under the scope of this contract. CODES AND STANDARDS The Equipment and system shall comply with the requirements of the latest versions of National and International Codes and Standards and as specified in Data Sheet-A2 of Section-D. DESIGN AND PERFORMANCE REQUIREMENT The metal enclosed switchgear shall be designed to operate continuously under the conditions specified in Data Sheet-A of Section-D and under site conditions enumerated in Section-B. SPECIFIC REQUIREMENTS Switchgears shall be fully draw out type, floor mounted and of modular design. All AC switchboards shall be with TPN bus bars. Switchgears shall be completely fuse free. The continuous current rating of the bus bars, incomers, bus couplers of the switchgear fed from 400 V station service switchgear shall be based on the total load size selected. The continuous current rating of the bus bars, incomers, bus couplers of the switchgear fed from other switchgears shall be the maximum load on the total switchgear due to all the running auxiliaries during any operation condition plus 20% margin rounded off to the next higher standard rating. For the load calculation, load factors to be considered shall be 0.8 for continuous loads, 0.2 for intermittent loads. All air circuit breakers (ACBs) and moulded case circuit breakers shall be of short circuit performance category P2 as per IS: 13947 Parts I & II.
ISSUE R0
7.3.3
7.3.4
7.3.5 7.3.5.1
7.3.6 7.3.6.1
7.3.7 7.3.7.1
7.3.7.2
7.3.7.3
7.3.7.4
SPEC. NO. TCE-5607A-C-811-08

7.3.7.5 7.3.7.6 7.3.7.7
The MCCBs shall be of current limiting type. Generally the switchgear shall be designed for bottom entry of cable. All Power and control terminals shall be stud type (ELMEX make) only. ELMEX make terminals type CATDM4 shall be used for CT connections. At least 10% spare terminals for PURCHASERs external connection shall be provided in each terminal block. For all external cables, including power cables, only stud type terminals suitable for eyelet type cable lugs shall be provided terminals suitable for pin type terminal lugs is not acceptable. Cable terminations shall be arranged such that it shall be possible to attend to any termination without having to disturb / switch off any other feeder or its constituents. Adequate clearance shall be provided for terminating power cables especially incomers without having to resort to cable boxes etc. Minimum of one NO and one NC spare contacts of all contactors, relay devices shall be wired to terminal block. 15% spare terminals shall be provided for each module.
7.3.7.8 7.3.7.9
7.3.7.10 For CT & VT circuits disconnecting type of terminals shall be provided. 7.3.7.11 IPRs shall be provided for remote control and shall be located in the switchgear panel itself 7.3.7.12 All current transformers shall have 1A secondary and all relays and meters shall be suitable for 1A operation. 7.3.7.13 400V PTs shall be of three (3) single-phase type only. 7.3.7.14 For AHU in ESP and switchyard control room, power and control supply will be in purchasers scope. Power and control cables from purchaser MCC to bidders equipment will be bidders scope. 7.3.8 7.3.8.1 FEEDER DETAILS Each of the switchgear shall be provided with two bus sections, two Incomers and a bus coupler rated for 100% rating of the switchgear as worked out in cl.7.3.8.2 & 7.3.8.3. The switch gears shall be provided with suitable number and type of outgoing feeders for the respective auxiliary loads of the system/area, power supply feeders to various panels, space heating panels, control cabinets and all other loads encountered in the plant. In addition, following feeders shall be provided in each switchgear.
7.3.8.2
ISSUE R0
SPEC. NO. TCE-5607A-C-811-08

(a) Spare feeders: Minimum of one no. module of each size in each type (for outgoing feeders - motor and MCCB feeders only) (b) Bus VT module: 1 No. / section. (c) 400 / 230V transformer for 230V, 1 phase, panel & motor space heating: 1 No. per each section (d) 400/110V, 2 X 100% control transformer for 110V Control supply module for motor feeders. (e) Feeder for purchaser use. 7.3.8.3 The incomer & bus coupler rated 400A and below shall be MCCB controlled and those rated above 400A shall be ACB controlled. Bus coupler shall be 4 pole MCCB/ACB. ACB controlled Incomers & Bus Couplers 400V system shall be 3 Phase, 4 wire, and solidly grounded system. The incomer modules shall be interlocked with their upstream breaker such that they can be closed only when upstream breaker is closed and trip automatically when the upstream breaker is tripped. For this, 86 lockout relay contact of upstream to be hard wired in the trip circuit of circuit breaker Separate current transformers shall be provided for metering and protection purpose. Accordingly, one ammeter on Y- phase and one volt meter with selector switch also shall be provided on the panel for local metering. For remote metering 3 numbers of current transducers and three number of voltage transducers to be provided. KW meter to be provided for each incomer. R, Y, B lamp indications for line side on each incomer shall be provided Each circuit breaker cubicle shall be complete with following minimum accessories:(a) One spring return TNC switch. (b) Large size cluster LEDs for following condition of breaker/contactor:(i) (ii) (iii) ON(Red) OFF (green) Trip relay supervision (White).
ISSUE R0
7.3.9 7.3.9.1 7.3.9.2
7.3.9.3
7.3.9.4 7.3.9.5 7.3.9.6
SPEC. NO. TCE-5607A-C-811-08

(iv) (v) (vi)
Spring charged (Blue) Line voltage healthy signal for each incomer DC supply supervision (Violet)
(c) Limit switch for test and service position interlocking. (d) Double pole switch for DC control supply and spring charging motor with HRC fuses. (e) Anti pumping relay. (f) Sufficient terminal blocks. (g) Auxiliary relays as required for contact multiplication (Electrical reset type). (h) Breaker operation counter. (i) Protective relays along with trip circuit supervision relay and master trip relay. (High speed trip relay) (j) Meters as indicated elsewhere. (k) Required CTs/PTs/CBCTs. (l) Space heaters. (m) Other associated equipment. 7.3.9.7 7.3.9.8 N/V relay on each bus to be provided for implementing auto changeover scheme in the PLC. Numerical relays for protection functions shall comprise 3- phase inverse time over current and earth fault protection (with communication facility through serial link cable to PLC). Trip circuit supervision relay shall be provided (to be wired at the end of the trip circuits). Separate U/V relay on each bus to be provided for tripping ACB operated motor. U/V relay shall be electrical reset type from PLC.
7.3.9.9
7.3.9.10 All numerical relays watch-dog contact (IRF) shall be wired for alarm. 7.3.9.11 Independent MCB protected circuit shall be provided for numerical relay, closing circuit, tripping circuit and indication circuit. For each switchgear, for breaker control 2 Nos. 220V DC control supply shall be provided with a manual
ISSUE R0
SPEC. NO. TCE-5607A-C-811-08

selection for changing over to either supply. Necessary voltage monitoring relays for remote alarm and local indication shall be provided. 7.3.9.12 For remote PLC monitoring & control, provision for the following shall be provided in the switchgear typically. Breaker open / close status in service position Lockout relay operated (86) Individual protective relay operation Trip relay failure Bus under voltage, no voltage Bus PT fuse failed Trip supervision relay operated Bus PT not in service. DC supply failure status Two incomers paralleled beyond preset time Local / Remote switch in remote position Service / test position of breaker Spring charging trouble
7.3.9.13 Closing, opening, auto change over and trip selector switch logic for incomer & bus coupler will be developed in PLC. For this, provision of all the required signals / contacts is included in this BIDDER scope. Same shall be wired till the terminal block in the switchgear. 7.3.9.14 Type and number of contacts required for Cl.3.10.12 & 3.10.13 will be worked out and finalized during detailed engineering. 7.3.9.15 Double tier arrangement shall not be provided for incomers and bus coupler. In case of motor feeders, double tier arrangement may be provided but two breakers of same application motor shall not be provided in one vertical.
ISSUE R0
SPEC. NO. TCE-5607A-C-811-08

7.3.10
MCCB controlled Incomers & Bus Couplers
7.3.10.1 MCCB shall be considered instead of Isolation switch and Fuse indicated in the drawing. 7.3.10.2 Two (2) Incomers & bus coupler modules with MCCB shall be provided with mechanically operated MCCBs. MCCBs shall be provided with castle key interlock in such a way that only 2 out of 3 breakers can be closed at a time. MCCBs shall be provided with inbuilt over current, short circuit and earth fault releases. 7.3.10.3 Shunt trip to be provided for remote tripping on each MCCB 7.3.10.4 Current transformers, Bus PT shall be provided for metering purpose. Accordingly, one ammeter on Y- phase and one volt meter with selector switch also shall be provided on the panel for local metering. Trip LED indication lamp on panel to be provided. 7.3.10.5 R, Y, B lamp indications for line side on each incomer shall be provided. 7.3.10.6 One current transducer for each MCCB incomer and 1 voltage transducer for each bus shall be provided for remote metering. 7.3.11 Motor feeders a) All 400 V motors rated 100 kW and below will be Contactor controlled and shall be suitable for DOL starter. Motors rated above 100 kW shall be ACB controlled. b) All the motor feeders shall comply with Type -2 co-ordination as per IS-13947. c) The motor feeder modules shall be depending on the service of motors. (i) (ii) (iii) 7.3.11.1 Motor Protection: i) Below 100kW: Overload protection with 3-pole bi-metallic relay, with inbuilt single phasing, trip-free mechanism and ambient temperature compensation to be provided.
ISSUE R0
K module For Non Essential, Non reversible DOL control L module For Essential, Non reversible DOL control R module For Non Essential, Reversible DOL control
SPEC. NO. TCE-5607A-C-811-08

ii)
Above 100kW ACB with composite motor protection numerical relays with associated CTs (on all three phases) to be provided. Overload, short circuit ambient temperature compensation, negative phase sequence, earth fault protection, blocked rotor protection, and provision for hot & cold withstand characteristics matching with motor characteristics shall be provided. Short circuit protection in the three phases through MCCBs for item (i) above shall be provided.
iii)
7.3.11.2 For motors greater than 30 kW, 240V, 1ph space heating shall be provided. 7.3.11.3 Control voltage supply : a. Independent control transformer for each module is not to be provided. b. Motor winding heating supply is not to be provided for the motors rated below 30kw. c. Local ammeter (Y phase) and current transducer (Y phase) for remote metering in PLC shall be provided for motors above 30kw. Metering CT, if required, to be provided. d. Protection relays shall be as specified in this Section. e. IPR for remote control shall be located in switchgear. Rating of IPR and its contact rating shall match the requirement of PLC. f. Current Transducer shall be powered from 110V AC motor control supply.
g. MCCB trip indication LED to be provided 7.3.11.4 ACB Controlled motor feeders: ON, OFF and Fault indicating shall be provided. Provision for remote control, metering & monitoring shall be provided for all the ACB controlled motor feeders. All relevant sub clauses of 7.3.10 above apply.
ISSUE R0
SPEC. NO. TCE-5607A-C-811-08

7.3.11.5 Motor Control supply : a. Automatic change over between two control supplies shall be provided instead of manual selector switch. However, provision to block auto changeover in case of fault should be provided. 7.3.11.6 Switch & contactor ratings for various motor starter modules shall be selected such that their rating is at least 20% higher than the circuit rating. 7.3.11.7 For motors rated > 30 kW and some essential motor irrespective of their motor rating, a current transducer shall be provided, one CT & one ammeter are required in the switchgear. 7.3.11.8 The control, interlocks, indications and fault alarms for the motors of the auxiliaries as covered in the specification as part of C&I requirements, Section C8 also to be provided. 7.3.12 Essential Service Feeders
7.3.12.1 During auto changeover of the supply the contactors in the affected bus would have dropped off. The services, which shall be restarted immediately without time lapse to keep the unit running, are considered essential services (For e.g. Air heater motor, etc.). Such auxiliaries shall restart automatically without any action by the operator after an auto changeover. These modules shall have additional hardware like timer, aux. Contactors and associated circuitry in the module. Such essential services shall be identified during the detailed engineering stage and suitable module/scheme shall be provided. 7.3.12.2 The essential service feeders like air heater motor etc, shall be provided with a CT, ammeter and a current transducer for remote metering in CRT in control room irrespective of their kW rating. 7.3.12.3 For emergency shut down condition, hardwired, on-off control of emergency drives to be provided from a centralized control panel. 7.3.13 VT modules Each bus section of main switchboard and MCCs shall be provided with a us VT module along with one voltmeter with selector switch and energy meter. The accuracy class of VT shall be 1.0 with adequate VA burden. (i) Bus VT modules shall be provided with suitable 400/3 / 110/3 V VTs with primary and secondary fuses.
(ii) VT modules in 400V main switchboard/MCC shall be provided with all necessary relay devices for auto changeover function like under
ISSUE R0
SPEC. NO. TCE-5607A-C-811-08

voltage relays (2 nos) voltage available relays (2 nos.), under voltage timer, fuse failure relay, 220V DC control supply switch & fuses. (iii) In case of fuse failure, the under voltage timer operation shall be blocked. 7.3.14 The current, voltage, power measurements for each bus shall be available both on PLC as indicated in this section and elsewhere in the specification. Also for specific motors where the current transducers are indicated, the measurement shall be available at the PLC. Terminal arrangements shall be such that all terminals at switchgear ends, which are to be connected to remote alarms and indication at PLC, shall be separated out and shall be kept isolated from other terminals. 230V AC, 110V AC, 220V DC & other voltages shall be segregated to avoid mix up of voltages to C&I low voltage systems. Switchgear shall be suitable for easy extension on both the sides. It shall be possible at a later stage to add cubicles on both sides of the switchgear by extending the bus bars. For CT & VT circuits disconnecting type of terminals shall be provided. All meters to be of digital type The transducers for switchgears shall be located in respective switchgears. The supply for the transducers shall be derived from 230V control supply. The transducers shall comply with the following requirements 7.3.20 7.3.21 Minimum two galvanically / optically isolated O/P Accuracy class 1.0 4-20mA output
7.3.15
7.3.16
7.3.17 7.3.18 7.3.19
Terminals required (to be worked out during detailed engineering) for remote PLC monitoring, alarm, SOE interlock etc., shall be provided in each module. No control & metering equipment should be mounted on breaker compartment door (i.e., access to control & metering equipment should be available at all time without opening breaker compartment door) The cable terminations inside the cable alley shall be completely shrouded so that it shall be possible to work on any one of the terminations by switching OFF the corresponding feeder switch only.
ISSUE R0
7.3.22
SPEC. NO. TCE-5607A-C-811-08

7.3.23
In case of copper to aluminium connections, proper treatment shall be given to minimise the bimetallic effect. That is, all joint surfaces at aluminium to copper joints shall be silver / tin plates, alternatively cu-al washers (Bimetallic washers) can be used. The requirement indicated above for LV switchgear are minimum. BIDDER shall provide all necessary controls, indications, interlocks and devices as required for the electrical system described therein. Also, the BIDDER shall provide any additional requirements arising during detailed engineering without any additional cost to the owner. TESTS
7.3.24
7.3.25
7.3.25.1 Switchgear shall be subjected to all tests as per relevant standards along with following tests: a) b) c) d) Mechanical operation test Insulation resistance and 500V DC before/after 1 minute HV test Electrical control, interlock and sequential operation tests Verification of wiring as per approved schematic
7.3.25.2 BIDDER shall submit all type test reports as per IS 13947 of similar switchgear. Also, calculations of temperature rise shall be submitted for approval. 7.3.25.3 Routine tests shall be carried out on all associated equipment supplied with switchgear as per relevant standards. Type test certificates of all major equipment shall be furnished. 7.3.25.4 Certified copies of all type and routine test certificates shall be submitted by BIDDER before despatch of the switchgear. 7.4 7.4.1 DRIVE MOTORS All motors rated 200 kW and below shall be suitable for 400V, 3 phase 50 Hz AC supply. Motors above 200 kW shall be suitable for 6.6 kV, 3 phase 50 Hz AC supply. All motors shall be EFF1 class. The motor rating shall be arrived at considering 15% margin over the duty point input or 10% over the maximum demand of the driven equipment, whichever is higher, considering highest system frequency. The motors being supplied under this contract shall comply with the following specific requirements.
ISSUE R0
7.4.2
7.4.3
SPEC. NO. TCE-5607A-C-811-08

7.4.4
Referring to the specification TCE.M4-203-01, following may be noted. a) Supply condition I under clause 4.1 is deleted. Supply condition II is applicable. b) Table I indicating sizes of cables and terminal boxes etc. is only for guidance. Suitable cable glands and terminal boxes shall be supplied based on the final cable sizes to be worked out during detailed engineering. c) Cl.4.3.1 of M4.203.01 shall read as: Motors shall be capable of starting and accelerating the load with the applicable method of starting without exceeding acceptable winding temperature, when the supply voltage is in the range of 80-110% of the rated voltage.
7.4.5 7.4.6
All motors covered under the scope of this specification shall be designed to withstand at least 5% harmonics in supply voltage. The minimum phase to phase and phase to earth clearances for 400V in the respective terminal boxes shall be as follows : Phase - Phase 25.4mm Phase - Earth 19.0 mm motors
7.4.7
For 400 V Motors With speed upto 1500 rpm Above 1500 rpm and upto 3000 rpm 40 microns 15 microns
7.4.8 7.4.9
Maximum noise level measured at a distance of 1.0M from the outer surface of any motor shall not exceed 85 db(A). MOTOR OPERATED VALVE ACTUATORS All the motor operated valve actuators along with their motors specified under this specification shall comply with the specification TCE.M4-203-06.
7.5 7.5.1
230V, UPS AND DISTRIBUTION BOARD 230 V UPS supply required for PLC shall be in purchaser scope. Bidder shall provide details of the feeder requirement for PLC.
ISSUE R0
SPEC. NO. TCE-5607A-C-811-08

7.6 7.6.1
CABLES Scope: The scope of supply and installation of cables includes if equipments at both ends are supplied by Bidder as well as if end equipment by Bidder and other end by purchaser. Supply and installation of Power, control & instrumentation cables from the field equipment/instruments upto the switchgear, MCC,Junction Boxes/Marshalling Boxes located near the main equipment and special cables if any is in BIDDERs scope including supply and installation of accessories. Supply and installation of control and instrumentation cables from BIDDER supplied equipment (JBs/MBs) upto PURCHASERs equipment will be by the BIDDER. The BIDDER shall suitably group and terminate all control & instrumentation cables required for interconnection with PURCHASERs equipment in Junction boxes/Marshalling boxes which shall be located near the main equipment. Necessary Junction Boxes/Marshalling Boxes for this purpose shall be supplied and installed by the BIDDER. Supply and installation of all special cables if any from BIDDERs equipment upto PURCHASERs equipment is in BIDDERs scope. The following technical specifications will form an integral part of this specification. TCE.M4-208-01 Cables
7.6.2
7.6.3
Power Cables LT Power cable for 400V AC system, 230V AC, 220V DC system shall be 1100 V grade, single / multicore with stranded & compacted aluminium conductor, grade H4, Class 2 as per IS 8130, extruded XLPE insulated, extruded PVC (Type ST 2) inner sheath, extruded (Type ST 2) FRLS PVC outer sheathed, conforming to IS 7098 (Part I). The cables used for DC system shall be of single core type. Minimum conductor cross section of power cables shall be 6 sq.mm Al or 2.5 sq.mm Cu. However, 2C, 3C, 4C, 2.5sqmm power cables shall be copper conductor, PVC insulated as per description in clause 7.6.4 below. All cables laid on trays will be unarmoured.Hard drawn aluminium wire / strip armour to be provided for all cables buried in ground.
7.6.4
Control Cables 1100 V grade, multicore, minimum 1.5 sq.mm cross section (2.5 sqmm or higher for CT circuits and others based on voltage drop), annealed stranded copper conductor, class 2 as per IS: 8130, PVC insulated inner PVC sheathed, galvanised steel wire / formed wire & outer sheath made of FRLS PVC compound. The cables shall conform to IS:1554 (Part-1) 1998 / IEC502(1983). All cables laid on trays will be unarmoured.Hard drawn aluminium wire / strip armour to be provided for all cables buried in ground.
ISSUE R0
SPEC. NO. TCE-5607A-C-811-08

7.6.5
Instrumentation cables All instrumentation cables shall be 600V grade, 0.5/0.8 sq.mm cross section stranded copper conductor, PVC insulated, in twisted pairs, overall screened (for digital signals) and individual & overall screened (for analog signals) and inner PVC sheathed, galvanised steel wire / formed wire armoured & outer sheath made of specially formulated FRLS PVC compound meeting the requirements as specified above. The cables shall conform to IS: 1554 (Part 1) 1998 / IEC502 (1983 in all other respects. All cables laid on trays will be unarmoured.Hard drawn aluminium wire / strip armour to be provided for all cables buried in ground.
7.6.6
Cables for single-phase loads The cables for single-phase loads shall be two core cables identical to 1.1kV grade power cables described as above.
7.6.7 7.6.8
The outer sheath shall meet the following performance requirements as indicated in the clause no. 5.0 of TCE.M4-208-01, cables. The cables shall be suitable for continuous operation and satisfactory performance for the following power supply conditions. a) Variation in power supply voltage () 10% b) Variation in supply frequency () 5% c) Combined Voltage & frequency 10% variation The quantity of cables shall be decided by BIDDER.
7.6.9
Cables for DC system: The cables shall be XLPE insulated cables. All DC cables shall be single core cables, including following cables, to eliminate the chances of the positive to negative faults in the cables: a. All feeders from DC board to various panels, switchgears, DC motors.
7.6.10
DESIGN CRITERIA FOR CABLE SIZING
7.6.10.1 Power cables In general, Power Cables are sized to satisfy the following three criteria:
ISSUE R0
SPEC. NO. TCE-5607A-C-811-08

i)
Full load current carrying capacity under installation conditions (ie. With suitable derating factors to cover site conditions such as ambient temperatures, and cable laying configuration). Short circuit current withstand capacity for applicable fault current and duration. Maximum voltage drop limits (max. 2.5% from board to equipments) under steady state and voltage dip during starting. Maximum voltage drop for 220V DC feeders from DC board to any feeder shall be 3%. In case of 24V DC system, the total voltage drop of 7.5% is recommended ( 2.5% between board and charger / battery, 5% between board and individual loads)
ii) iii) iv)
7.6.11
CABLING ACCESSORIES All cable glands shall be of double compression brass/stainless steel type. All lugs shall be of tinned copper type.
7.6.12
CABLE TERMINATION
7.6.12.1 All cables shall be terminated at both ends. BIDDER shall clearly note that all charges for connecting cables to various equipment shall not be included under individual equipment installation charges, and shall be included under unit prices for cable terminations. Cables shall be additionally supported near the entry point of equipment in order to avoid the whole weight of the cables, coming on to the gland plate / cable box. The BIDDER shall quote unit prices for termination of cable at one end, for each type / size of cable. 7.6.12.2 The scope of termination at each end shall include dressing, and connecting all the cores of the cables. The following shall be included in the scope of work : (a) Making the requisite holes on the gland plate of the switchgear / any other panel, fixing glands, terminating the cables in the cable boxes, mounting of core balance CT on the cable where called for, earthing the cable armour, crimping of cable lugs on each, neatly clamping the cables inside switchgear / panel cable alleys, wiring troughs and connecting to terminals. The cable and core identifying tags and core identifying ferrules respectively shall be supplied and installed by the BIDDER as a part of cable termination work. 7.6.12.3 The equipment will be generally provided with undrilled gland plates for cables / conduit entry. The BIDDER shall be responsible for punching, drilling of gland plates, painting and touching up. Holes shall be made by gas cutting / drilling.
ISSUE R0
SPEC. NO. TCE-5607A-C-811-08

7.6.12.4 Requirements for internal panel wiring, Inter panel wiring & Field to Junction box cabling shall be as per enclosed specification TCE.M4-299-02 in section-D. 7.7 Cable carrier system For cables in Bidders scope entire cabling system is included. Sub trays till Purchasers main cable trays along with laying and termination of cables is included in Bidders scope. GI cable trays shall be provided for laying. Cable tray covers for top most tray shall be provided for all outdoor cable racks. 7.7.1 The cable carrier system shall be designed considering the following : (a) (b) (c) (d) (e) (f) (g) (h) Facility for easy laying of cables. Access to maintenance. Neat and aesthetic appearance. Safety of equipment & personnel. Ground water seepage. Interference with drainage system for oil and water. Cable entry to switchgears and panels. Following cable carrier system shall be adopted in various areas as indicated below in general. All cable routing layouts shall be submitted for OWNERs / ENGINEERs approval. The list below is for BIDDERs guidance only. It is not the intent of this specification to specify the required arrangement for all areas. Control room: - False floor (as applicable) (ii) (iii) (iv) (v) Switchgear room Road crossings Cable carrier system connecting outlying areas Off-site buildings and utilities : Cables to be laid on the cable support arm : Cable trays / Cable trench : Duct banks : Overhead trench Cable rack / Cable
(i)
: Overhead Cable trays / Cable trench
ISSUE R0
SPEC. NO. TCE-5607A-C-811-08

7.7.2
The Bidder shall prepare detailed cable routing diagram, cable tray layouts, cable schedules, interconnection schedules for all cables being supplied under this contract. It is anticipated that a few cables-supplied outside this contract would be required to be routed in the cable carrier system being provided by this Bidder. The details of these cables would be made available to the Bidder to prepare integrated cable layout/routing drawing considering the cable being installed by others. Cable Trench Preferred working space between the cable support arms and the wall are as follows. Bidder shall design the trenches accordingly. Trench depth 1500 mm (5 tiers) 1200 mm (4 tiers) 1000 mm (3 tiers) 700 mm (2 tiers) Width of Trays 600 mm 600 mm 600 mm 300 mm Working Space 750 mm 750 mm 750 mm 350 mm
7.7.3
7.7.4
Cable Trays and Covers Cable trays of ladder (for Power and Control cables) and perforated types (for Instrumentation cables) with the associated accessories such as coupler plates, tees, elbows, etc., shall be fabricated from 14 gauge (2.0 mm thick) galvanised mild steel sheets. Cable tray covers shall be fabricated from 16 gauge (1.60 mm thick) galvanised mild steel sheets. In battery room, the cable trays, accessories and covers shall be corrosion proof. The spacing of rungs for ladder type of trays shall be not more than 250 mm. Cable trays, accessories and covers shall be hot dip galvanised. Galvanising thickness shall be minimum 75 microns.Vertical raceways shall be formed by either structural members and slotted angles or by running the prefabricated trays vertically.
7.7.5
Conduits & Pipes (i) Galvanised steel conduits shall be used for size upto 63.5 mm. The conduits shall be manufactured by electric resistance welding process and shall be hot dip galvanised. The conduits and fittings shall comply with IS: 1653, 3837, and 2667. Galvanised steel pipes shall be used for sizes from 80mm onwards. They shall be medium duty class-B type as per IS. The pipes shall be manufactured by electric resistance welding and hot dip galvanised. The pipes and fittings shall comply with IS.
ISSUE R0
(ii)
SPEC. NO. TCE-5607A-C-811-08

(iii)
Flexible steel conduits shall be manufactured with electro galvanising process. The flexible conduits and their fittings shall comply with IS:3480, 4649. The hume pipes/RCC pipes shall comply with IS:458.
(iv) 7.7.6 7.7.6.1
Cable/Cable tray supports Cable tray supports shall be fabricated from standard steel structures of different sizes. The sizes selected shall be adequate for the weight of cables/trays encountered. The steel members shall be cleaned thoroughly for rust and painted as follows : For indoor - One shop coat of red oxide zinc chromate primer and two site coats of aluminium alkali paint. For outdoor & corrosive areas like battery room - Hot dip galvanised.
7.7.6.2
7.7.7 7.7.7.1
Cable Carrier Installation practice Minimum level difference between two tiers of horizontal cable trays in building, trenches, shall be 275 mm. In vertical raceways with multi tiers the tiers shall be located atleast with 400 mm intervals. In trenches & tunnels the width of the cable tray shall be limited to 600 mm. Separate cable trays/tiers shall be provided for 6.6 kV power, 400V/240V power, control cables and instrumentation cables. Cable trays shall be supported at every 1000 mm interval. Cable trays shall be welded to the mounting/carrier structures. All outdoor cable trays shall be erected in vertical plane. Vertical trays (raceways) and all outdoor cable trays shall be provided with removable 16 gauge galvanised MS sheet covers. Each continuous laid out length of cable tray shall be earthed at minimum two places by MS flats of minimum size 25mm x 6 mm, the distance between earthing points shall not exceed 10 metres. When cables are taken in vertical raceways /trays and they pass from one floor & other floor pipe sleeves in concrete shall be provided.
7.7.7.2 7.7.7.3 7.7.7.4 7.7.7.5 7.7.7.6
7.7.7.7
7.7.7.8
ISSUE R0
SPEC. NO. TCE-5607A-C-811-08

7.7.7.9
At least 300mm clearance shall be maintained between the top tray and beams, piping or other obstacles to facilitate installation of cables in the tray. A working space of not less than 600mm shall be maintained on atleast on one side of each tray.
7.7.7.10 In heat zone areas as far as possible the cables shall be taken away from that area to avoid heat. If Cabling in heat zones cannot be avoided, the cables shall be terminated in a junction box of IP 67 protection class away from the heat zones and small length of cables may be laid from junction box to the respective equipment to facilitate easier replacement in case of fire. Bunching of cables in the heat zones and boiler areas shall be avoided and laid in separate groups. 7.7.8 7.7.8.1 Cable Installation Cables to each circuit shall be laid in one continuous length. Cable jointing and splicing shall be avoided. Jointing shall be allowed only for the cases where the route length is more than the maximum possible drum length. Outdoor cable installation (a) Where cables cross roads and water, oil, gas or sewage pipes, the cables shall be laid in hume or steel pipes. For road crossings, the pipe for the cable shall be buried at not less than 600 mm. Hume pipes shall be preferred to steel pipes from the point of view of corrosion. The cables shall be tied to tray rungs by means of 3mm dia. nylon cord at an interval of 5000 mm and also at bends. For good sealing arrangement at entry points, suitable pipe sleeves, adequate in number and of adequate sizes shall be provided in building walls/slabs for passage of cables into a building from cable trays/racks/cable trenches located outside the building.
7.7.8.2
(b) (c)
7.7.8.3
Cables in Trays / on Racks (a) Different voltage grade cables shall be laid in separate trays. When trays are arranged in tiers, HV cables shall be laid in top trays and cables of subsequent voltage grades in lower tiers of trays. Deleted. 1100V grade power cables of 120mm size and above shall normally be laid in single layer in trays/on racks. Smaller 1100V grade power cables below 120 mm may be run in double layers, where required, due to space restrictions.
ISSUE R0
(b) (c) (d)
SPEC. NO. TCE-5607A-C-811-08

(e) (f)
Control and instrumentation cables can be laid upto a maximum of three layers in each tray/rack. Single core power cables for 3 phase AC circuits laid in trays/racks/ trenches in trefoil groups shall be held in trefoil clamps placed at an interval of 3 m. The trefoil groups of cables shall be additionally tied by means of 3 mm dia. nylon cord as follows: (i) (ii) At an interval of 1m when laid in cable trays/racks. At an interval of 750 mm when laid in trenches without cable trays.
(g)
Control cables and small power cables on racks shall be run in ladder type cable trays supported on rack carrier arms. The cables shall be tied to tray rung by means of 3 mm dia. nylon cord at an interval of 5000 mm and also at bends.
7.7.8.4
Bending radii for cables The bending radii for various types of cables shall not be less than those values specified by the cable manufacturer.
7.7.9
Earthing of cables (a) (b) Metallic sheaths, screens and armour of all multicore cables shall be earthed at both equipment and switchgear end. Sheath and armour of single core power cables shall be earthed at switchgear end only. For long lengths of cables multiple earthing may have to be adopted to safeguard against the presence of standing voltages under normal as well as fault conditions.
7.7.10
Fire proof sealing system (FPS)
7.7.10.1 Fire proof sealing system shall consist of (i) Fire-stops/fire-seals for sealing of cable/cable tray and conduit/pipe penetrations, both horizontal and vertical, through brick or RCC walls/floors, to prevent the spread of fire from one area, which is separated from others by fire-resistant barriers. `Fire-breaks' provided on long runs of cable racks/trays to prevent the propagation of fire along the cable rack, within a single fire-area or firezone.
(ii)
ISSUE R0
SPEC. NO. TCE-5607A-C-811-08

7.7.10.2 The FPS system shall also include all the necessary accessories and equipment required for supporting, holding in position, fixing and installation of the firestop/fire-break. 7.7.10.3 The FPS system shall comply in all respects with the requirements of the codes and standards listed below IEEE-634 ASTM-E-814 ANSI-IEEE-383 IEC-331 IEC-332 7.7.10.4 Fire Stop/Seal The FPS system adopted for cables or cable trays penetrating through walls and floor openings, or cables passing through embedded conduits/pipes/ pipesleeves, constitutes a `fire stop/seal', which is meant to prevent spreading of fire between areas separated by fire-resistant barriers. 7.7.10.5 Fire Break The fire proofing system, other than fire-stops, adopted to retard flame propagation along long runs of horizontal or vertical cable trays in the same fire zone or area, in an event of a fire, shall constitute a `fire-break' and shall be provided by applying a suitable fire-resistant coating on cables and cable trays for the required length, with or without a fire resistant panel, at the point of the fire break to obtain the fire-rating specified. 7.7.10.6 Performance Requirements (i) Requirement of fire stops The material, design and construction of the fire stops shall be such as to provide the fire-rating of 120 minutes for a fire on any side and meet all requirements listed in this specification and the relevant codes and standards. The materials used in the fire stops shall be non-hygroscopic, compatible with the type of cables.
ISSUE R0
SPEC. NO. TCE-5607A-C-811-08

The fire stops shall be suitable for retrofitting of cables through the penetration seal without disturbing the sealing of the cables already existing.
(ii) Requirements of fire breaks Each firebreak shall have a fire-rating of 30 minutes and shall be capable of withstanding for the duration specified, a fire on any side of the fire break.
7.7.10.7 Application of fire proof sealing system (i) Fire stops Fire stops shall be provided for cable penetration openings listed below The passage of cables/cable trays pipe sleeves/embedded conduits through walls / floors. Vertical raceways, which carry cables between successive floors, through openings provided in the RCC floor slab, shall be sealed by fire stops at each floor level. Cable entry through openings in floor slabs below HT/LT switchgear, MCCs, various control and relay panels and other bottom entry panels, shall be effectively sealed by fire stops.
(ii)
Location of fire breaks Firebreaks shall be provided on both cable rack and trenches at all cable tray intersections and tee-offs. On linear runs of cable trays between fire stops or fire breaks, fire breaks shall be provided at intervals of 15 metres on horizontal cable runs and 5 m on vertical cable runs. Fire breaks in linear runs of cable trenches between intersections and tee-offs shall be provided at intervals of 30 metres.
7.7.10.8 Bidder shall furnish the test certificates for the fire stops and fire breaks after award of contract for Owner / Owners Representative review. If the certificates are not satisfactory all the tests shall be conducted free of cost. The offered system i.e. fire stops and fire breaks shall be identical (or better) with the system which is successfully type tested for the specified rating i.e. the composition density of the material, thickness of coating in case of fire breaks and any other properties of the material / system offered shall be identical or better than the tested system and shall be subject to Owner / Owners Representative approval.
ISSUE R0
SPEC. NO. TCE-5607A-C-811-08

7.7.10.9 Performance Tests: Tests on Fire Stops (a) The fire stops shall be subjected to the following type tests: (i) (ii) (b) Fire Rating Test Hose Stream Test
Type tests shall be conducted on different fire stop test specimens described above as per IEEE-634. The sizes of the fire stop test specimens shall be similar to the largest of the sizes being used in the plant. Preconditioning of fire stop test specimens Before conducting the fire rating and hose stream tests, each test specimen shall be preconditioned for thermal ageing, water immersion and vibration.
(c)
(d)
Test on Fire Stops During the fire rating test, the transmission of heat through the cable penetration fire stop shall not raise the temperature on its unexposed surface above the self ignition temperature of the outer cable covering, the cable penetration fire stop material, or material in contact with the cable penetration fire stop, with a maximum temperature limit on the unexposed surface of 200oC.
(e)
Tests on fire breaks Firebreaks shall undergo the following tests as per ANSI-IEEE-383: (i) (ii) Ampacity test Flame test
7.8 7.8.1 7.8.2 7.8.3
JUNCTION BOXES (JBS) / ADAPTER BOXES / MARSHALLING BOXES The constructional features of JBs/ABs shall be as per the clause 3.0 of in the enclosed Specification TCE.M4-219-01. The junction boxes are required for terminating the cables from field instruments, thermocouples etc. and for further cabling to OWNERs equipment. The JBs and MBs shall be selected such that at least 20% spare terminals are available in each of these boxes after all the cabling is completed.
ISSUE R0
SPEC. NO. TCE-5607A-C-811-08

7.9 7.9.1
LOCAL PUSH BUTTON STATIONS (LPB) All motors under the scope of this specification shall be provided with local push button station. Mushroom type lockable emergency push buttons with key shall be provided for field motors. The stop push button shall be lockable in pushed position. PBs shall be shrouded type. LPBSs shall be metal enclosed suitable for mounting on wall/column. The enclosure shall be die cast aluminium or cold rolled sheet steel of 2.0 mm thickness and shall have IP-55 degree of protection. The LPBS shall be painted to shade 631 of IS-5 on the outside and the inside shall be painted glossy white. The LPBS shall be provided with two earthing terminals suitable for 8 SWG GS wire. LPBs shall be rated for 650V, 10 amps with 2NO+2NC potential free contacts for each LPB. LPBs shall include brackets, Civil works, bolts, nuts, etc. However, when the LPBs are mounted on a channel, the mounting channel will also be in BIDDERs scope. The LPBs shall be of the following types. a) LPB Type-A1 - With three push buttons for control of reversible motors outdoor type. b) LPB Type-A2 Same as above but suitable for indoor location. c) LPB Type-B1 - With two push buttons for control of non-reversible motors outdoor type. d) LPB Type-B2 Same as above but suitable for indoor location. e) LPB Type-C1 Single push button for D.C motors - outdoor type. f) LPB Type C2 Single push button for DC motors for indoor location.
7.9.2
Adequate number of stud terminals to be provided for terminations of cables from MCC, control panels etc.
7.10 7.11 7.12
Deleted Deleted EARTHING PROTECTION Equipment earthing for all equipment in Bidders scope is included. GI flats shall be provided. Electronic earthing shall be provided each for PLC located in HVAC handling system control room. Earthing shall be designed as per latest version of IS/IEEE standards. Sizing calculations and Layout drawings shall be furnished for Purchasers approval.
ISSUE R0
SPEC. NO. TCE-5607A-C-811-08

7.13
PLC INTERFACE FOR SYSTEM
ELECTRICAL SYSTEM OF HVAC HANDLING
All the measurements, monitoring, metering, control etc. of the HVAC handling system package is envisaged through PLC based Control System. The complete specification of the same is given in I&C volume. Necessary linking with main plant DCS is also under the scope. Control, metering, monitoring, measurement, annunciation, synchronising of complete electrical system supplied under this contract shall be possible from PLC based Control system through CRTs / keyboards. Minimum functional requirement of PLC based control system in respect of electrical system shall be as below: 7.14 7.14.1 PLC BASED SYSTEM - CONTROLS All 400V breakers/ Contactors in 400V MCCs shall be controlled from PLC based control system. Remote position, service position, breaker healthiness, permissive for interlocks, etc., shall be considered as input to the PLC based system. Control of incomers and bus-coupler breakers of 400V MCCs shall be possible from PLC based control system through necessary interposing / coupling relays. Inter posing relay shall be housed in the respective switchboards. Control of all breakers/contactors from PLC based control system shall be done through interposing relays. Any auxiliary relay required for linking with PLC shall also be provided in the modules. These interposing relays shall be mounted on the respective modules. Monitoring PLC based control system shall include the following functions: (1) (2) Indication-Status of breakers/vacuum contactors, position of Local/Remote selector switches, spring charged indication etc, Abnormal conditions to be considered for alarm inputs to CRT are: (i) LV System (400V) Breaker auto trip, individual protective relay operation, trip circuit failure, DC supply failure, bus under voltage, VT fuse failure. Successful/Unsuccessful changeover of 400V supplies.
7.14.2
7.14.3
7.14.4
ISSUE R0
SPEC. NO. TCE-5607A-C-811-08

7.14.5
Measurement The following analogue inputs from LT modules shall be communicated to the PLC system through transducers and shall be displayed in the CRT.
Feeder Description Incoming feeders Switchgears & MCCs Buscoupler switchgears 400V Buses breakers of 400V V (All phases), A (All phases), MW, MWh, 400V A (All phases)
of
V (All phases), F
Outgoing feeders ACBs, contactor A modules
7.14.6
Event logging shall be provided for all manual operations and relay operations as detailed below: a) b) c) Status of circuit breakers, Status of circuit breakers /contactors of 400V Switchgear/PMCC. Each feeder lock out relay operation. Event logger shall be a part of the PLC based control system with first up feature. It shall have a time resolution of 1 ms.
7.14.7
Trending of parameters during disturbance shall be with a resolution of 0.5/1.0 sec., and at 15 minutes during normal operation. The change from normal mode to disturbance mode shall be through threshold/gradient settings provided in the system for analogue quantities and external binary signals obtained from selected protective relays. Capturing of momentary values of all these parameters shall also be possible triggered either by a protective relay or by a manual keyboard command. All Sequence of event recorder (SER) signals shall be with time stamping in PLC based control system with 1 ms resolution. Further, all the control functions shall be achieved through interposing relays.
7.14.8
ISSUE R0
SPEC. NO. TCE-5607A-C-811-08

7.14.9
Synchronising 400V switchboard /400 V PMCC/ MCC incomer and bus coupler breakers shall have facility for dead bus and synchronising closure through PLC based control system.
7.14.10 The functional requirement indicated above are minimum, the Bidder shall provide all necessary controls indications, interlock s & devices required for the system offered by him. Also, any additional requirement arising during detailed engineering shall be provided by the Bidder without any additional cost to the Owner. 7.14.11 Interposing Relays The interposing relays required for the switchgear / equipment being supplied under this contract shall be located in the respective modules in Switchgear/MCC. 7.14.12 Bidder to furnish the I/O list for the Digital, Analogue and SER inputs from various systems to PLC based system for Purchasers approval.. 7.14.13 Numerical relay shall have modbus/IEC protocol compatible for communication to PLC. Serial link data cable shall be provided for fault monitoring of all the individual protection signals. For this numerical relays, relays shall be time synchronized to GPS clock. 7.15 7.15.1 ELECTRICAL LAYOUT REQUIREMENTS LT Switchgears, MCCs, ACDB, Distribution boards, Lighting transformers, MLDB etc. shall be located in the Switchgear room. Cabling for these panels shall be through cable trench of adequate depth. Cable trays shall be provided in the cable trenches/gallery for the panels located in Switchgear room. For outdoor area, pipe cum cable tray rack shall be employed for cable routing. All the rooms housing the electrical panels shall have minimum 2 nos. fire proof doors opening outside. Access to the rooms and doors provided shall consider movement of panels during erection and also later during maintenance/ replacement. The layout shall meet all the statutory requirements, Tariff Advisory Committee regulations and electrical inspectorate requirements. General requirements for all Layouts The layout of the switchboard shall consider the following aspects.
ISSUE R0
7.15.2
7.15.3 7.15.4
7.15.5
SPEC. NO. TCE-5607A-C-811-08

(a) (b) (c) (d) (e) (f) 7.15.6
Adequate space for movement of personnel with breaker/modules withdrawal. Adequate movement & operation space around Separate maintenance space Space for cable trenches Minimum statutory clearance requirements Space for additional panels that may arise during engineering
Following shall be considered as minimum spacing for various switchboards (electrical panels): (a) (b) 6.6kV switchgear facing 400V switchboard Two 400V switchboard or panels facing each other LV switchboard or panel front facing the wall LV switchboard / panels back side to the obstructions like column, raceways, walls if single front Space between the sides of two switchboard panels or switchboard panels and the wall. From top of switchboard / panels to nearest obstruction 2500 (Minimum) 3500 mm (Main switchboard), 1500mm (Battery chargers, LDB, UPS, etc.) 2000 mm (Main switchboard), 1500mm (battery chargers, LDB, UPS, etc.) 1000 mm or door opening space plus personnel movement whichever is higher 1000 mm
(c)
(d)
(e)
(f)
800 mm (min).
7.16
CONSTRUCTION POWER SUPPLY For construction power supply one (1) 400V, 250A, 3 phase 4 wire feeder will be provided by the PURCHASER at one point. The Bidder shall make all arrangements for further distribution of construction power wherever required. This shall include required power and control cables, distribution transformer, distribution boards, switch fuse units etc. All construction power feeders shall be provided with ELCB.
ISSUE R0
SPEC. NO. TCE-5607A-C-811-08

7.17
PAINTING: Surface preparation & painting requirement shall be followed for all the equipment covered in the scope. For surface preparation & treatment, 7 tank process shall be followed. 2 coats (30 Microns / coat) of epoxy based primer followed by epoxy based finish paint (30 Microns / coat) is included in the scope.
7.18
All equipment supplied and all work done including system design and detailed engineering shall also comply with the statutory requirements of the Government of India, the Government of Orissa and with the Indian Electricity Rules. It is not the intent to completely specify here-in, all details of design and construction of the equipment and system. However, the equipment and system shall conform to all applicable latest standards, codes, high standards of engineering, design and workmanship and shall be capable of performing in continuous commercial operation, up to the VENDOR'S guarantees in a manner acceptable to the PURCHASER, who will interpret the meaning of the design calculations, drawings and specifications submitted by the BIDDER for approval and shall have the power to reject any work or material which in his judgment is not in full accordance therewith. TERMINAL POINT (ELECTRICAL) The terminal point shall be the outgoing terminals of feeder breaker at PURCHASERs 400V station board located in main plant building. For UPS supply, outgoing terminals of breaker in UPS ACDB. For ESP AHU power and control supply terminal point shall be outgoing terminal of 400V ACB / MCCB in 400 V MCC of purchaser. For switchyard AHU power and control supply terminal point shall be outgoing terminal of 400V ACB / MCCB in 400 V MCC of purchaser. Terminal point for 220V DC shall be out going terminal of MCBs at purchasers DCDB. EXCLUSIONS (ELECTRICAL) 400 V MCC at ESP and switchyard control room. UPS for PLC. DC system Earth grid.
ISSUE R0
7.19
7.20 7.20.1 7.20.2 7.20.3 7.20.4 7.20.5
7.21 7.21.1 7.21.2 7.21.3 7.21.4
SPEC. NO. TCE-5607A-C-811-08

7.22 7.22.1 7.22.2
SPARES Commissioning Spare and start up spares till handing over is in the scope of BIDDER and the same to be included in the offer. BIDDER to quote separately unit prices for recommended spare including the essential spare listed in the equipment datasheets enclosed with this specification. BIDDER shall indicate the list of recommended spares with quantity required for two years trouble free operation for all the electrical equipment included in their scope. SUB- VENDOR LIST Approved sub vendor list for major electrical equipment is attached in the section D. Vendor list for items not covered in the list to be furnished by BIDDER for approval.
7.23
7.24
COMMISSIONING Detailed Field Quality Plan for equipment included under scope of this contract shall be furnished against the respective equipment for approval.
7.25
TESTS The BIDDER shall furnish the type test certificates for all electrical equipment to PURCHASER / CONSULTANT for review / acceptance. If the type test certificates are found to be inadequate by PURCHASER / CONSULTANT, the BIDDER shall conduct the type tests free of cost. In addition, the BIDDER shall carry out routine and acceptance tests on all electrical equipment as per latest relevant IS / IEC standards in presence of Purchaser/ or Purchasers representative. BIDDER shall furnish Quality Assurance Plans (QAPs) for all equipment in their scope for approval.
7.26
STATUTORY/ REGULATORY AUTHORITIES APPROVAL Statutory Approval of Electrical Inspector for the electrical installation in BIDDERS scope including drawing approval shall be in BIDDERS scope.
7.27
DATA REQUIRED FROM BIDDER ALONG WITH THE BID Detailed catalogues / drawings of LT switch gears including cubicle / compartment arrangements. Detailed catalogues / test reports of LT breakers.
ISSUE R0
SPEC. NO. TCE-5607A-C-811-08

Detailed write up / catalogues / drawings of transformers, isolators, protective relays. Typical transformer sizing calculation Typical cable sizing calculation Typical Earthing calculation. 7.28 DATA REQUIRED FROM BIDDER AFTER AWARD OF CONTRACT This is apart from that covered elsewhere in Section C and Section D Electrical Load List Concept note covering the equipment main parameters, design and operation philosophies including synchronising through auto synchroniser and manual synchronising gear sizing criteria, selection criteria, schemes proposed, operation, indication and alarm philosophies for 400V switchboard, motor control centre, DC system, UPS system, cabling system (cable carriers, layout, installation), earthing and lightning protection system, lighting system, electrical switchgear layouts. Calculations for all CT and PT Parameters Fault calculation Main one line diagram and single line diagrams, indicating parameters of all electrical equipment, CTs, PTs, location of meters, relays, etc.. Technical data sheet for all electrical equipment Plant and auxiliary power supply single diagram viz., 400V, 220V DC and UPS system. Standard / typical installation sketches for cabling, earthing, lightning protection and lighting Cable interconnection diagram Cable schedules format Control wiring diagram Electrical equipment layout drawings
ISSUE R0
SPEC. NO. TCE-5607A-C-811-08

Relay setting along with calculation and co-ordination curves. Control wiring : diagrams for each drive / auxiliary Showing the complete details of the switchgear module, external cable connection to motors, devices, control panels, system cabinets, etc., interconnection between panels related to the respective drives, cable nos., cable core nos.
Cable interconnection schedules / diagrams for all the cables showing the cable no., core no., cable size, terminal nos., on either side. Cable schedule showing the cable number, size and type, emanating and terminating points, cable lengths, routing, etc., to facilitate cable layout work and as a reference to monitor the work and later as a maintenance reference Bidder shall furnish the following drawings / data / information : Switchgear MCC (a) Outline dimensions and general arrangement, including plan, front elevation, rear elevation, side elevation and relevant crosssectional views. Schematic control circuit diagrams Detailed wiring diagrams including terminal block numbers, ferrule numbers and cable connections. Development diagrams of switches
(b) (c)
(d)
Motors (AC ) (a) (b) Dimensioned outline and general arrangement drawing of motor Internal view of terminal boxes showing connection of motor i.e., star / delta terminal markings, clearance between phases, disconnecting facilities and direction of cable entry and cable glands. Motor characteristics curves
(c)
ISSUE R0
SPEC. NO. TCE-5607A-C-811-08

Motor Operated Valve Actuators (a) Drawing indicating overall dimensions and mounting details of valve actuator on the valve Detailed internal wiring diagram of the actuator.
(b)
Control Cabinets (For all services) (a) Schematic diagram indicating terminal numbers for external connections and with a Bill of Material for all the equipment Control cabinet drawing showing outline dimensions, cable entry openings, floor / wall / pedestal fixing arrangement, padlocking arrangement, weights Inside view of distribution boards / panels showing mounting and wiring arrangement of various component equipments.
(b)
(c)
Fire Proof Sealing for Cable Carrier Systems (a) Detailed drawings including the constructional features, outline dimensions, general arrangement and cross-sectional views of the Fire Proof Sealing System to be provided in the areas specified in specification for each type of fire stop and fire break supplied. Type test certificates as per this specification for all types of fire stop / fire breaks included in the order.
(b)
DESIGN CRITERIA Standard voltage levels The standardised voltage levels as given in the Table below shall be adopted: S 1 2 3 Description A.C. Drive motors Metering Control & protection of switchgear LT Voltage level 400V, 3 phase, 3 wire 110 V, AC PT. Voltage 220V, DC 2 wire unearthed
ISSUE R0
SPEC. NO. TCE-5607A-C-811-08

Panel lighting heaters
and
space
240V, 1 phase, 2 wire 50 Hz, A.C. with one point earthed. 230V, 1 phase, 2 wires 50 Hz, A.C stabilized through inverter system 400V, 3 wire 50 Hz, A.C 24V, 1 phase, 2 wire, 50 Hz, A.C through suitable transformers.
PLC power supply
6 7
Welding socket outlets Special socket out lets for portable lamps for maintenance
Permissible variations: The system unit/plant equipment shall be designed suitable for variation in voltage and frequency as indicated in the table below: Variation in voltage and frequency: Sl. 1. Description Permissible variation with rated performance/rated current and control effectiveness maintained Permissible variations for control and regulation equipment with rated performance and control quality maintained. Permissible voltage dip at LT switchgear bus for starting of LT motors Voltage +10% to 10%, +10% to 10%, Frequency +5% to 5% for LT system +5% to 5% for HT system +5% to 5%
2.
+/ - 10%
3.
-10%
Symmetrical short circuit ratings The three phase symmetrical short circuit ratings of the switchgear at different voltage levels shall be as indicated in the Table below: Symmetrical short circuit ratings
ISSUE R0
SPEC. NO. TCE-5607A-C-811-08

Sl.
Voltage level
Symmetrical Breaking capacity 50 kA Min. 20 kA
Making Capacity
1. 2.
400 V 220 V DC
105 kA -
The rated short circuit withstand duration for switchgear of 400 V switchgear including MCCs it shall be 1 sec. Criteria for selection of voltage levels for motors A.C induction motors of ratings up to 200 kW shall be fed at 400 V, 3 phase, 50 Hz, with DOL starter. A.C motors of ratings larger than above shall be connected to the 6.6 kV system. Motor starting and permissible voltage dips: The electrical system shall be so optimised that Voltage dip on starting of the largest motor shall be limited to 15% of the nominal voltage at the motor terminals where as nominal running voltage dip shall be limited to 5%.
ISSUE R0
SPEC. NO. TCE-5607A-C-811-08

8.0 8.1 8.1.1
INSTRUMENTATION CONTROL EQUIPMENT REQUIREMENTS SCOPE OF SUPPLY All sensors and local instruments, transmitters shall be supplied, as required. The actual number of instruments shall be as per the Bidders PIDs to be approved by the Purchaser during detail engineering. BIDDER shall supply a redundant PLC based system with cabinets, processor cards, complete with I/O cards, Remote IO panels, power supply modules and other associated hardware and Application Software. The PLC system shall be provided with complete HMI Operation, Control & Monitoring of the HVAC plant with Annunciation system. Control panel in HVAC control shall be provided with HMIs, annunciation windows, critical safe shut down push buttons and all other specified hardware. Two nos PCs 24 (One engineering cum operating station and one operating station) shall be provided in HVAC control room. Entire HVAC system shall be controlled & monitored by these stations. Redundant 2x 100% 230VAC 1PH 50Hz UPS of adequate capacity along with suitable power distribution boards for PLC, TFTs and other I & C systems etc. Local control panels (control-cum-annunciation panel) for AHUs, Air washer rooms. All the local control panels shall be hardwire interfaced with Main PLC panel. The local control panel shall house all the operational and control hardware with adequate interface devices like interposing relays, contactors, etc. to suit the MCC requirements, multiplication of signals, etc.
8.1.2
8.1.3 8.1.4 8.1.5
8.1.6 8.1.7
8.1.8
Cables (Instrumentation, control, Data highway & pre fabricated cables, fibre optic cables, serial link cables and any special cables as required) along with cable accessories. For scope of Control cables, refer to clause no. 8.6 of this section. Complete engineering viz. Preparation of cable schedule, Interconnection schedule etc for bidders battery limits are in bidders scope. Complete Field Instrumentation including all field sensors, Cables, Erection hardware, Junction boxes etc., within bidders battery Limits.
8.1.9
8.1.10 Junction boxes, marshalling Cabinets, as required. 8.1.11 Local push button stations for all motor operated drives. 8.1.12 Instrument air distribution system as required for bidders system.
ISSUE R0
SPEC. NO. TCE-5607A-C-811-08

8.1.13 Any other I & C equipment not specified but necessary to meet the specified functional requirements of the system. 8.1.14 Erection, field calibration, testing and commissioning of all I&C equipments included in the scope of BIDDER as per standard methods and to PURCHASERs satisfaction. 8.2 8.2.1 CABLES All Instrumentation cables, Data highway cables, prefabricated cables, fibre optic cables, serial link cables and any other special cables related to the entire HVAC systems are under Bidders scope. All control cables between any two equipments supplied by Bidder shall be in Bidders scope. All control cables between any Bidders equipments and Purchasers equipments shall be in Bidders scope. Preparation of cable schedules, Interconnection cable schedule, for all the instrumentation and control cables is included in Bidders scope. 8.2.2 Cable Quantities All required quantities of cables for all services shall be supplied, installed and terminated by the BIDDER. It is the BIDDERs absolute responsibility to work out the quantities and supply, install and terminate the same. 8.2.3 Quality of Cables Only ISI certified cables of reputed make as approved by PURCHASER shall be acceptable. Each cable length shall have relevant ISI certification mark as stipulated by Bureau of Indian Standards. Cable manufacturers who have capability to develop tests and ensure timely supply of cables and have an arrangement for carrying out all tests including special test called for only shall be considered. The technical features of all the cables are subject to PURCHASERs approval. 8.2.4 Test Reports a) Routine test shall be carried out in the presence of PURCHASER and certificates for each drum of cable employed shall be forwarded to PURCHAER/CONSULTANT well in advance before delivery to site. Only those cable drums whose test certificates are cleared by PURCHASER/CONSULTANT shall be despatched to site. PURCHASER shall not be responsible for any delay on account of non-submission of test reports and rejected items.
ISSUE R0
SPEC. NO. TCE-5607A-C-811-08

b) Type test/special test shall be carried out in the presence of PURCHASER and the certificates shall be furnished for one drum out of every 10 drums or less for various cable sizes to the PURCHASER for approval. PURCHASER shall call for type test certificates for any other item at his discretion depending on the manufacturers various types of cables. 8.2.5 Cable Termination a) All control cables shall be terminated using crimping type lugs. b) Cable terminations for control cables shall include all items such as earthing clips, lugs, double compression type glands, earthing the armours, complete consumables required for installation practices mentioned elsewhere in the specification. 8.2.6 Cable Joints Only straight through joints of respective voltage classes are allowed. All the materials required for straight through joints including kits, consumables shall be included in BIDDERs scope. No marshalling of cables due to long runs are allowed. All termination cables due to long runs are allowed. All termination kits and jointing material shall be suitable for the environment in which they are intended to be used. 8.2.7 Cable joints shall be avoided to the extent possible. All joints shall be heat shrinkable type meeting specified short circuit withstand capacity of 40 kA for 1 second. However cable joints wherever unavoidable shall be subject to PURCHASERs approval. Only straight through joints shall be employed for all types of cables including control cables. Cable Installation and Accessories Cable shall be laid in pre-fabricated cable trays provided by PURCHASER in indoor areas. 8.2.9 Cable Glands Cable glands provided shall be of double compression type, with minimum 3 rings. Material of construction shall be brass. All the cable entries to the equipment shall be from bottom. However, if necessary, side entry may be adopted for motors with the permission of PURCHASER. Top entry shall not be adopted for any equipment in outdoor areas. Complete control system including sensors, relays, controllers, control wiring, fire stat (smoke detectors) shall be provided in the return air space (near the wall separating AHU room) to trip the air handling unit fans / A/C plants in the event of
ISSUE R0
8.2.8
SPEC. NO. TCE-5607A-C-811-08

a fire. Solenoid operated fire dampers (energised to close) to be provided in the supply air duct and return air wall/slab opening in order to isolate the respective AHU room from the a/c area in the event of fire. For cable specification, refer to clause no. 8.6. 8.3 LOCAL INSTRUMENTS / SENSORS ,SWITCHES AND TRANSMITTERS Necessary local instruments such as thermometers, temperature switches, level switches,level indicator, pressure transmitter, Differential pressure switch cum gauge, flow switch etc., shall be provided as required within the Bidders Battery Limits. The technical features and Sub - Bidders of the same are subjected to Purchasers approval. Bidder shall include in his scope 2 x 100% 230VAC 1PH 50Hz UPS power supply for I & C system Specification for UPS is included in Electrical Section. 8.4 OPERATION PHILOSOPHY FOR HVAC SYSTEM 1. Microprocessor based PLC control systems shall be envisaged for the complete Air conditioning system in HVAC control room ( also called AC plant room). HVAC control room is located in the Control building at the same elevation that of AHU room and Air washer room. 2. AHU of air conditioning system shall also have local control panel for local operation in addition to PLC based operations. a) Complete control system including sensors, relays, controllers, control wiring, fire stat (smoke detectors) shall be provided in the return air space (near the wall separating AHU room) to trip the air handling unit fans / A/C plants in the event of a fire. Motor operated fire dampers to be provided in the supply air duct and return air wall/slab opening in order to isolate the respective AHU room from the a/c area in the event of fire. b) Each control panel shall have start & stop push button for operation of respective drives and one lockable local / remote selector switch (individually) shall be provided. c) Each panel shall shave indication of open/close status of respective fire dampers in addition the status provided in HMI stations in HVAC control room. d) All the drives can be operated from OWS located in HVAC control room while selector switch is turned in Remote mode. e) In remote mode, further two selection shall appear in respective graphic page of OWS, i.e., Auto / Manual mode selection. If any drive fails to start
ISSUE R0
SPEC. NO. TCE-5607A-C-811-08

or during running any drive is tripped there shall be AHU system fault annunciation in OWS. Actual fault shall be indicated in alarms page and as well as in respective page of OWS. 3. Relay based local control panel operation shall be considered for Ventilation system. However critical hardwired signal shall be considered from HVAC PLC. 4. Chillers shall have skid mounted microcontroller based control system. Each skid mounted control system shall be complete in itself that, entire operation and monitoring of each chiller unit shall be done from skid only. However, Each skid mounted control system shall have hardwired interface with HVAC PLC system for important process parameters, alarm status, remote monitoring, remote operation, fault conditions, service parameters etc. When command from PLC is through, all the necessary interlocks shall be checked by its dedicated skid mounted control panel. All interlocks for start/ stop, main/ standby etc between the chillers shall be implemented in the HAVC PLC system. Provision for remote operation and monitoring of all the chillers shall be available at HAVC control room. Status, Fault conditions and alarms shall be made available in HAVC control room.
5. All drives (both AC plant & AHU room) shall have individually service/maintenance mode selection through OWS, but by default they shall be in service mode only. Operator shall be able to change the drive selection from service to maintenance mode or vice versa. 8.5 8.5.1 CONTROL PANEL (CONTROL-CUM-ANNUNCIATION PANEL) Local control operation shall be envisaged for Ventilation system AHU units (In addition to PLC operation) 8.5.2 Power supplies of different voltages, required for the satisfactory operation of the system offered by the Bidder shall be derived in the control panel using necessary equipment. The main power supply to the control panel shall be derived from the bidders AC MCC. Control supply shall be on 110 V AC and the same shall be derived from the .bidders power supply.
ISSUE R0
SPEC. NO. TCE-5607A-C-811-08

8.5.3
The make of all the equipments used in the control panel and also the make of the panel shall be reputed and reliable. These shall be subject to PURCHASERs approval without commercial implications. Ventilation control panel shall be located in HVAC PLC room and AHU local panels shall be located in AHU rooms. The panel shall include all the equipments required to start, stop, auto and manual control, ON-OFF indications, interlock and annunciation of the relevant system. Annunciation system shall be of facia type windows with hooter, acknowledge, test and reset push buttons and sequential fault annunciation. List of parameters that are to be annunciated shall be finalized during detailed engineering. 10% of total quantity of windows shall be left as spare windows for PURCHASERs use and the spare windows shall be completely wired. The technical features of annunciation system are subject to PURCHASERs approval.
8.5.4 8.5.5 8.5.6
8.6 8.6.1
SPECIFICATIONS FOR INSTRUMENTS (AS APPLICABLE) ARE AS FOLLOWS: Pressure Indicators Direct reading, pipe mounted Pressure gauges of Stainless Steel with 6 inch phenolic dial (white dial with black numerals), 316 SS Bourdon tube, AISI 304 movements and micrometer type adjustable aluminum pointer an accuracy of +/0.5% of span including accessories like siphons for steam services, snubbers for pump discharge applications and chemical diaphragm for corrosive and oil services and name plate, etc. Material of accessories shall be SS. IP65 or equivalent degree of protection for enclosure. Over range protection shall be 50% above maximum pressure.
8.6.2
Pressure Switches Non indicating type, field mounted Pressure Switches of aluminium casing (epoxy coated), and 316 SS element and accuracy of +/-1% of span, including accessories like siphons for steam services, snubbers for pump discharge applications and chemical diaphragm for corrosive and oil services, name plate & mounting brackets. Material of accessories shall be SS. Auto reset micro switch with internal adjustment for set values with 2 SPDT contacts rated for 0.2 A at 220 V DC. IP 65 or equivalent degree of protection for enclosure. Over range protection 50% above maximum pressure. Scale for setting shall be provided.
8.6.3
Thermometers Indicating type, field mounted, filled system with SS armour and six (6) inch dial (white dial with black numerals with micrometer pointer) housed in aluminium casing (epoxy coated) with an accuracy of +/-1% of span, response time of
ISSUE R0
SPEC. NO. TCE-5607A-C-811-08

2-4 seconds, auto temperature calibration, linear calibration over the range and SS bulb with 316 SS thermowell having a process connection of M33 x 2 thread or 150 RF flanged. Material of accessories (name plates, mounting brackets, etc.) shall be SS. IP 65 or equivalent degree of protection for enclosure. Thermowell with Hex head bar stock assembly. The thermowell construction shall meet the ANSI 19.3-1994 (latest) requirements. 8.6.4 Thermowells Pipe/equipment mounted temperature test wells of 316 SS with a process connection of M33x2 thread or 150 RF flanged. Accessories like name plate, plug with chain, etc. shall be provided. Material of accessories shall be SS. Thermowell shall be hex head of barstock assembly. In case flanged wells are required for any specific application, the same shall be supplied as required. The thermowell construction shall meet the ANSI 19.3 (latest) requirements. 8.6.5 Temperature Switch Non-indicating type, field mounted, filled system with SS armour housed in Aluminium casing (epoxy coated) with an accuracy of +/-1% span, auto temperature calibration, linear calibration over the range and SS bulb with 316 SS thermowell having a process connection of M33x2 thread or 150 RF flanged. The thermowell construction shall meet the ANSI 19.3 (latest) requirements. Micro switch with reset type with tamper proof externally adjustable set values with 2 SPDT contacts rated for 0.2 A, 220V DC. IP 65 or equivalent degree of protection for enclosure. Thermowell with hex head bar stock assembly. Material of accessories (name plates, mounting brackets, etc.) shall be SS. Scale shall be provided for setting. Repeatability shall be +/-0.5% of full scale. Wherever the ambient temperature shall approximate or exceed the switch set point, temperature switches designed for cross ambient operation shall be used. 8.6.6 Thermocouple Assembly Duplex , K - Type with accuracy of +/-0.5% of span, response time of 2 to 6 sec, Spring loaded mineral insulated thermocouple assembly with 316 SS thermowell housed aluminium casing (epoxy coated) having a process connection of M33 x 2 thread. Material of accessories (name plate, etc.) shall be SS. IP 65 or equivalent degree of protection for enclosure. Thermowell with hex head (with screwed cover & SS chain) bar stock assembly with ungrounded junction. For metal temperature measurement, thermocouple pads weldable to M.S pipes shall be provided with 15 m thermocouple extension wires. Element size shall be 18 AWG. Insulation resistance at 540 Deg C shall not be less than 5 M ohms. Temperature devices provided with thermowells shall be calibrated with the associated thermowell as an assembly. The thermowell construction shall meet the ANSI 19.3 (latest) requirements. All pent house
ISSUE R0
SPEC. NO. TCE-5607A-C-811-08

thermocouples shall be supplied with 15mts flexible extension length. All bed thermocouples shall have solid tungsten carbide or SS440 protecting sheath. 8.6.7 Resistance Temperature Detectors (RTD) Duplex type, PT 100, with accuracy of +/-0.5% of span, response time 1-2 seconds; Spring loaded mineral insulated three (3) wire RTD assembly with 316 SS Thermowell housed in aluminium casing (epoxy coated) having a process connection of M33 x 2 thread or 150 RF flanged. IP 65 or equivalent degree of protection for enclosure. Material of accessories (name plate, etc.) shall be SS. Thermowell with hex head with screwed cover & SS chain, barstock assembly. Element lead size shall be 18 AWG. The insulation resistance at 540 Deg C shall not be less than 5M ohms. Repeatability over full range shall be better than 0.02%. RTDs shall be ungrounded. RTD shall be supplied as an assembly complete with thermowells meeting ANSI 19.3 (latest) requirements. 8.6.8 Flow indicating switch Vane / Paddle type water flow detector, with switched output with time delay. Pneumatically controlled mechanical delay mechanism as applicable. 2 nos switch contacts rated for 10A, 240 VAC, 2.5A, 24 VDC. 8.6.9 Junction Boxes (JB) All JBs shall be Di Cast Aluminium. Wall/column mounted junction boxes having 32 (2x16) terminals and cable entry only at the bottom and sealed with fire proof compound; Screwed terminal type; IP 65 or equivalent degree of protection for enclosure. Separate terminal blocks shall be used for analog and digital signal and also for signals with different voltages. Removable gland plate shall be supplied. JB shall have single lockable door with gasket, able to open side ways, with common keys. Painting inside shall be glossy white & outside - IS-5 shade 631. Shield bus for screw connection shall be provided. Terminal size shall be suitable for 0.5 sq.mm to 2.5 sq.mm wire. Terminal blocks shall be vertical. JB shall have provision to add 10% additional terminals. Accessories like metal tag (SS), clamps, fixtures, bolts (SS), nuts (SS), gaskets (neoprene), lock & key, fire proof compound for sealing, etc. shall be supplied. The grouping of instruments in JBs is subject to Purchasers approval. All the field Junction boxes shall have single doors and provision for locking. The doors shall not have screwed type of locking, but turnable hinge based. The JBs are subject to approval prior to manufacturing All JBs shall be provided with individual canopies to avoid ingress of water. All the TBs used shall be 6.6 polymide to withstand corrosion and the metallic portion shall be coated against rust / corrosion.
ISSUE R0
SPEC. NO. TCE-5607A-C-811-08

8.6.10 Interposing Relays (IPR) Electro magnetic type IPRs with plug-in type connections, suitable for channel/rail mounting in cabinets; coil rating 24V D.C; 2 set of silver plated Change over contacts rated for 0.2A 220 V DC. Free wheeling diode across relay coil (copper) and self reset type status indicator flag (electronic) shall be provided. All relays shall be mounted in IPR cabinet & relay base (silver plated) internally wired to the external cabling termination block in IPR cabinet. Wiring connection shall be cage-clamp & termination shall be suitable for 0.5 sq.mm to 2.5 sq.mm size wiring. Facility to simulate relay operation manually shall be provided. Relays of different contact interrogation voltages shall be separated by a barrier in IPR cabinet. Accessories like name plate (SS) with tag & service inscription, relay base mounting rail/channel, nuts & bolts, etc. shall be supplied. Three nos. change over contacts shall be wired to external TB in the Interposing relay cabinet. Status/amps shall be provided. 8.6.11 Cables Individual pair shielded & overall shield twisted pair copper cables shall be used for analog signals & overall shielded cables shall be used for digital signals. All these cables shall be armoured. All the insulation including overall sheath shall be FRLS quality. The wire size shall be 0.5 sq.mm. Ferruling indicating terminal numbers on termination side shall be followed. Colour coding shall be as per Purchasers standard. Only sleeve type ferruling with printed terminal numbers shall be used. Cross ferruling shall be adopted. Instrumentation Cables Instrumentation cables shall be 600VAC grade, stranded high conductivity annealed, tinned copper, twisted pair (with min. 20 twists for meter) extruded PVC insulated with overall and / or individual screening, extruded PVC inner sheathed, galvanized steel wire armoured, extruded outer sheathed with FRLS PVC compound. The conductor size shall be minimu m 0.5 sq.mm. Triplex cables similar to instrumentation cables can be used for RTDs. Instrumentation cables carrying digital signals shall have overall screening along with drain wire and analogue signal carrying cables shall have each pair screening and overall screening along with each pair drain wire and overall drain wire. Control Cables Control cables shall be 1100V AC grade, multicore, minimum 1.5 sq.mm cross section, stranded copper conductor having 7 strands, PVC insulated, inner FRLS PVC sheathed of type ST-1, galvanized steel wire armoured and outer sheath made of FRLS PVC compound of type ST-1. In situations where accuracy of measurement or voltage drop in control circuit, warrant, higher cross sections as
ISSUE R0
SPEC. NO. TCE-5607A-C-811-08

required shall be used. For all the CT & PT cables, minimum 2.5 sq.mm cables shall be used. Solenoid valve Power supply cables shall be minimum 2.5 sq.mm. 8.6.12 System Cabinets These cabinets shall house signal-conditioning cards, input/output cards, processor cards & associated power supply units. Indoor located, free standing vertical type system cabinets with IP-32 enclosure and with 2 mm thick sheet metal of cold rolled steel; double doors with neoprene gaskets; antivibration pads of 15 mm thick; blower & louvers in each cabinet with brass mesh; fire proof compound (50 mm thickness) for sealing cable entry (bottom); fire detector for each cabinet. The racks in system cabinets shall have provision along with plug in sockets/back plane to house atleast 10% additional cards, to accommodate for engineering flexibility or future expansion. The color of the cabinets shall be indicated at detailed engineering stage. Doors shall have concealed type of o hinges and swing of 100 . Alternatively system cabinets with lift off type doors can be offered. The doors shall be provided both at the front and rear. A fault lamp shall be provided on the first or last (based on the control room layout to be decided during detailed engineering) cabinet, on the side to help the operator. Power supply distribution shall be provided on per cabinet basis with all associated MCBs, protections, etc. The system cabinets, racks in system cabinets, slots in the racks & the terminals shall have identification numbers. A stainless steel metal tag (plate) shall be fixed to the inside of the door & the layout of the racks, slots & details of the card type/service shall be inscribed on this metal tag. Each cabinet shall be provided with one each 3 pin receptacles for 240 V, 1P, 50 C/S and receptacles for +24V DC. Cabinet shall be delivered totally wired. All electronics shall be mounted & wiring connections at these hardwares shall be terminated by Bidder. Quantity shall be as required. All cabinets shall have common key for the locks . 8.6.13 Marshalling Cabinets Indoor located, free standing vertical type marshalling cabinets with IP-32 enclosure and with 2 mm thick sheet metal of cold rolled steel; single door with neoprene gaskets; anti vibration pads of 15 mm thick; fluorescent lighting; blower & louver in each cabinet with brass mesh; fire detection for each cabinet; fire proof compound (50 mm thick) for sealing cable entry (bottom, front, rear). The colour of the cabinets shall be indicated at detailed engineering stage. The type of terminal shall be Phoenix / Weid mueller / WAGO. The terminal blocks shall be cage clamp type. Fused terminal blocks hinged at one end to facilitate easy isolation shall be provided wherever necessary. All cabinets shall be provided with 20% spare terminals. The type of terminals for terminations from cabinets/panels shall match with the pre fabricated cables and pins supplied. The terminals for field cables shall be arranged in a logical order of equipment/system wise and shall be worked out by Bidder, subject to approval by Purchaser/ Consultant.
ISSUE R0
SPEC. NO. TCE-5607A-C-811-08

Door shall have concealed type hinges and swing of 180 Degree & lockable. The doors shall be provided both on the front and rear. Channels, bolts & nuts shall be zinc plated and passivated. Two coats of premier paint and black colour paint shall be applied. Fluorescent lamp of 40W shall be provided and shall be operated by the door switches as well as by manual switches. The marshalling cabinets, the terminal blocks, the terminals and the electronic hardware if any, shall have identification numbers. Each cabinet shall be provided with one each 3 pin receptacles for 240 V AC, 1Ph, 50 c/s and receptacles for +24V DC. A system cabinet and associated cabinets shall be supplied on a skid to avoid outside interconnecting cables. Cabinet shall be delivered totally wired. Preparation of interconnection schedule (ICS) between marshalling cabinets in Bidders scope & JBs in Bidder scope is in Bidders scope. The format of Interconnection Cable Schedule (ICS) shall be given to the Bidder during detailed engineering stage. Quantity shall be as required. All cabinets shall have common key for the locks. All the terminals shall have no screws and the cables shall be gripped by spring. All the cabinets shall have universal type of lock and key arrangement. Each terminal shall have LED indication with fuses to indicate and isolate earth faults. 8.6.14 Local Panels All the local panels shall be galvanised. Indoor/Outdoor located, free standing vertical type local panels with 2 mm thick sheet material of cold rolled steel; antivibration pads of 15 mm thick; fluorescent lighting; Double doors with neoprene gaskets at every 1.5 m; blower & louvers in each section with brass mesh; fire proof compound (50 mm thick) for sealing cable entry (bottom); fire detector for each section; space heater with thermostatic control for each section (strip type). IP 65 degree of protection for enclosure. Removable cover plates with locking facility shall be provided along the bottom of the front desk continuously to facilitate maintenance work. The length of each cover plate shall not exceed 1 m. Fluorescent lamp of 40 W shall be provided from one end of the panel to the other end at continuous length and shall be operated by the door switches as well as by manual switches. Name plates shall be provided for all instruments/inserts with Tag. No. & short description of service engraved. These shall be phenolic overlays (1.6 mm thick), black background with white lettering & shall be fixed to the panel by stainless steel screws (counter sunk). Each section of the panels shall be provided with one each 3 pin receptacles for 240V AC, 1P, 50 c/s & 110 V AC, 1P, 50 c/s. Panel shall be delivered totally wired. All instruments, inserts and annunciation windows shall be mounted & wiring connections at these hardwares shall be terminated at site by Bidder. Quantity shall be as required. All the Terminal Blocks shall be rust proof and corrosive resistant for outdoor mounted panels. Terminal Blocks housing material shall be 6.6 polyamide and metallic portion shall be coated against rust/corrosion.
ISSUE R0
SPEC. NO. TCE-5607A-C-811-08

8.6.15
Wiring, Termination and Accessories All the cables are to be treated with anti-rodent treatment.
8.6.15.1
Instrument wires : Wires carrying 4-20 mA DC or any other low voltage or current signals. Used for panel internal wiring, tinned copper conductor of 0.5 sq.mm cross section with seven strands and twisted pair with 20 twists/metre. Insulation material shall be PVC, heat resistant with flame retarding properties with thickness not more than 0.5 mm and voltage grade shall be 1100V AC. Control Wires: Wires used for power supply like 110V AC, 240V AC, 220V DC, + 24V etc. Used for panel internal wiring, tinned copper conductor of 1.5 sq.mm cross section with seven strands. Insulation material shall be PVC, heat resistant with flame retarding properties, voltage grade shall be 1100V. Prefabricated Cable : Used for interconnection between system/marshalling cabinets. Used for panel external wiring, tinned copper conductor of 0.5 sq.mm cross section with seven strands twisted pair with 20 twists/metre. Insulation material shall be PVC, heat resistant with flame retarding properties with thickness not more than 0.5 sq.mm. Voltage grade shall be 1100V AC. Each prefabricated cable shall have a minimum of 5 cores as spares and these shall not be connected to end connectors. Terminal Block (TB): Cageclamp type , 1100 V AC grade, vertically mounted, size of 0.5 sq.mm to 1.5 sq.mm for instrument wires and 1.5 sq.mm to 2.5 sq.mm for control wires. Clearance between TBs shall be 150 mm and between TB and bottom plate shall be 250 mm, flame resistant, non-hygroscopic, decarbonised. Insulation between adjacent terminals or between terminals & frame work shall be 2 KV RMS for 1 minute . Power supply and signal TB shall be separate. Signals shall be grouped in TBs in the same order as that in field junction box so as to provide neat cable layout and wiring. High voltage and low voltage signals shall be provided on separate TBs, which are mounted separately. TBs housing material shall be 6.6 polyamide and metallic portion shall be coated against corrosion. There shall be no double decker terminals.
8.6.15.2
8.6.15.3
8.6.15.4
8.6.15.5
Termination Details Maximum of 2 wires shall be terminated per terminal. Wiring raceways, strapes shall be flame retardant. All wiring shall be ferruled.(printed Partex type ferrule shall be used)Wires carrying power and signal wires shall be routed in separate raceways. Accessories like MCB, cable support fuses, etc. shall be supplied. Cable entries shall be cemented with fire proof compound.
ISSUE R0
SPEC. NO. TCE-5607A-C-811-08

8.6.16 Solenoid Valves Direct operated solenoid valves, pilot operated for higher sizes with shut of class (leakage) VI, body material of bronze, plunger material of 316 SS rated for continuous duty. IP 65 class for enclosure. Insulation class of 'F' for the solenoid. Body ratings shall suit the pressure and temperature conditions. 8.6.17 Illuminated push buttons (ILPB) a) Rectangular, twin block per assembly, One block for START/OPEN and second block for STOP/CLOSE operation; 2 lamps/block, one additional lamp for discrepancy indication per assembly, 2NO + 2NC contacts with 5A 230V AC rating, 110V AC/24V DC lamp rating, 3 watts, series resistance for lamps, colour red / green / amber b) Same single block with one lamp for forward/reverse/stop operation. 8.6.18 Push button (PB) Rectangular, single block, Momentary contact type with engraved inscription plates, 2NO + 2 NC contacts with 5A, 230V AC rating, colour red/green/amber. 8.6.19 Programmable Logic Controller (PLC)
SI. No 1.
DESCRIPTION
REQUIREMENT
Bidder response Logic
Type of Control system
Programmable Controller (PLC)
2.
Offered PLC System Latest system and system configuration and PLC configuration available / system hardware being marketed in the international market by the bidder/ collaborator with minimum 3 years of proven performance record. Operating System Windows based or Unix based
3.
4.
Hierarchical protection for At least 3 levels of security operator & engineer is required
ISSUE R0
SPEC. NO. TCE-5607A-C-811-08

SI. No
DESCRIPTION
REQUIREMENT
Bidder response
functions 5. UPS Any other voltage required for the PLC shall be derived from the UPS. Similarly, 24 V DC derived shall have redundant power packs. Two(2)
6. 7.
No of feeders Response time (Maximum) for
250 m sec Analog input RTD Digital Input / output Loop cycle time inclusive of controller processing time 8. Auto switchover backup/redundant component at time to Instantaneous and bumpless (Bidder to indicate the time) b) Communication level a) within 50 milisecond c) Power supply level 9. Display Call up time in HMI 1-2 sec monitor Dynamic update time of parameters in the HMI monitor for measurement 1-2 sec and control Spare capacity required in the control processor
ISSUE R0
1 sec 25 - 50 m sec 250 m sec (Analog); 100 m sec (Digital)
a) Processor level
10.
11.
SPEC. NO. TCE-5607A-C-811-08

SI. No
DESCRIPTION
REQUIREMENT
Bidder response
considering spare I/O Minimum 40 % channels and future I/O modules to be located in the spare I/O slots 12. Output status on controller Configurable in Engineering failure station Output status supply failure on power Configurable for switching to fail safe mode
13.
14.
Status indication for each LED indication required channel in DI / DO card Power supply healthiness LED indication required status in all modules Optical Isolation for DI / DO Galvanic isolation for AI / AO Required Required
15.
16. 17. 18.
Fuse Protection for AI / DI Required modules Individual fuse for each DO Required
19. 20.
All I/O module status Required monitoring in PLC system MMI Self diagnostics for all PLC Required modules Control processor with 32 bit processor , RISC floating point arithmetic based capability Capacity of RAM Spare capacity in RAM 256 MB minimum Minimum 40 % including spare I/O
21.
22.
ISSUE R0
SPEC. NO. TCE-5607A-C-811-08

SI. No
DESCRIPTION
REQUIREMENT
Bidder response
Processor Redundancy
Dual redundant hot standby, Physical cable connectivity between primary and secondary controllers, loading of programs in primary controller alone.
23.
Primary and secondary LED indication required indication on controllers Memory expandability Battery back up for RAM 150% of offered capacity Rechargeable Ni. Cd
24. 25.
Duration of battery back up 72 Hrs for dynamic memory 26. 27. Closed Loop Control Non-redundant I/O modules
Open loop control ( Logic , Non-redundant I/O modules Protection & Interlock) Maximum number of channels in I/O modules 8 Channels Analog I/O modules 16 Channels RTD, Thermocouple 16 Channels Digital I/O modules
28.
29.
Power supply to the field Analog input module shall transmitters drive the connected field transmitter on 2 wire loop Interrogation voltage Digital signals Concept of I/O grouping for 24 V DC
30.
31.
a) No two identical / similar equipment shall be

ISSUE R0
SPEC. NO. TCE-5607A-C-811-08

SI. No
DESCRIPTION
REQUIREMENT
Bidder response
grouped in the same I/O module b) I/Os related to an equipment and I/Os related to its associated auxiliaries shall be connected to different modules. c) Inputs and outputs shall not be combined in a single module. d) Where ever 2oo3 logic is involved, the redundant inputs shall be connected to different modules. 32. Displays on HMI monitor Process mimic displays, trend displays, system status, alarm displays, logs / reports etc
33.
Minimum no of plant mimics 75 configurable Time activated logs Periodic logs, shift report, daily report, status change log, Control system fault log - 1 NO. - Intel Core2 Duo, Minimum 3.6 GHz processor or higher - 24 TFT Monitor - 2 GB RAM min or better
34.
35.
Operator Station:
ISSUE R0
SPEC. NO. TCE-5607A-C-811-08

SI. No
DESCRIPTION
REQUIREMENT
Bidder response
- 250 GB HDD - DVD R/W Drive - QWERTY Keyboard -Optical Mouse - Workstation model - USB ports 4 Nos. 36. Engineering Station Operator Stations cum -1 No. -Operator Station having Engineering capability and pass word protection. - Workstation model. 37. 38. Annunciation System Printers Integral to the PLC One A4 laser color and one A3 size black and white laser jet printer (600 DPI resolution) shall be provided. plant Bi-directional, OPC link redundant
39.
Interface with DCS(redundant) Spare I/O modules
40.
10 % (wired up ) spare modules for each type of I/O module.
41.
Spare Channels in each I/O 10 % (wired up ) spare Module channels over the entire population of each type of module. Spare slots in the I/O rack 20% additional slots in each rack
ISSUE R0
42.
SPEC. NO. TCE-5607A-C-811-08

SI. No 43.
DESCRIPTION
REQUIREMENT
Bidder response
Fuse for I/O channels
- Individual for analogue signals - Group of max 8 for digital channels
44.
Interposing Relays
24 V DC with free wheeling diode across the coil Relay contact rating 5A at 240 V AC Self Standing type maximum height 2200mm with of
45.
Panels / Cabinets
46.
Mechanical features
a) Minimum 2mm thick CRCA 3mm removable gland plate b) 2.5 mm thickness for double doors c) Panel - door switch d) Fans e) Paint RAL 7035 f) Illuminated lamp push buttons Enclosure
g) Suitable Protection
h) Anti vibration pad of minimum 15mm thickness. 47. Panel Earthing Safety earth for enclosure and Electronic earth for PLC system.
ISSUE R0
SPEC. NO. TCE-5607A-C-811-08

SI. No 48. 49.
DESCRIPTION
REQUIREMENT
Bidder response
Control room Quality Assurance
Air Conditioned. As per quality plan to be approved by the Purchaser / Consultant Factory Acceptance Test as per procedure approved by the Purchaser / Consultant. The communication shall be redundant b/w the control processors and HMI as well as across processors and transmission rate shall be 100 Mbps. Also communication b/w control processors and I/O shall be redundant. 1.Siemens(S7) 2. GE Fanuc 3. Alan Bradely 4.ABB 5.Schneider Electric
50.
Inspection Requirements
51.
Communication
52.
Make of PLC
8.7
General a) The equipment supplied shall have the maximum reliability. Only the reputed and the proven makes and type of equipment/components shall be supplied. Instrument system to be supplied under this contract shall be of reliable make. The makes and models of all instruments, PLC, HMI, etc., supplied by Bidder shall be subject to Purchasers approval. b) All the technical features of all instruments, local panel, cables, junction boxes etc., shall be as per relevant clauses in the specification.
ISSUE R0
SPEC. NO. TCE-5607A-C-811-08

c) Technical features and sub-bidders of I&C equipment are subject to Purchasers approval. d) All the system / instrument in the Bidders scope shall work satisfactorily taking into account all the required interconnections. e) BIDDER shall furnish set points for all instruments mounted on his pipes/equipment. f) Any other Instrumentation & Control not specifically included but required for successful operation of the system shall be supplied as required.
g) The extent of supply under this contract includes all items shown in the drawings, notwithstanding the fact that such items may have been omitted from the specifications or schedules. Similarly, the extent of supply also includes all items mentioned in the specifications or schedule, notwithstanding the fact that such items may have been omitted in the drawings. 8.8 SELECTION OF RANGES FOR INSTRUMENTS The ranges of the instruments shall be selected based on the following philosophy (a) For pressure measurements, the maximum operating pressure shall be within 70 to 80% of the maximum scale range. The operating range for transmitters shall be 30 - 80% of the specified range of the instrument. (b) For temperature measurement, the maximum operating temperature shall be within 80 to 90% of the maximum scale range. (c) For pressure switches and temperature switches, the set points shall fall within 40% to 70% of the scale range selected. (d) For level measurement, the maximum of the range shall cover the very high point and the minimum of the range shall be stacked with overlap to cover permissive, alarm and trip levels. (e) For flow measurement, the maximum range shall be fixed at about 10 to 15% above the maximum operating flow. 8.9 SIGNAL EXCHANGE WITH PURCHASERS SYSTEM a) Bidder shall provide potential free contacts for the following signals for connection to purchasers system. PLC fault, which shall be a grouped contact covering all the faults in HVAC plant including the sub system Faults.
ISSUE R0
SPEC. NO. TCE-5607A-C-811-08

b) Redundant bi-directional OPC link shall be envisaged between Bidders PLC to Purchasers DCS. The offered PLC system shall include all the hardware, software, cable etc., as required to establish this serial link. Bidder shall lay the cable upto Purchasers DCS cabinet in the main control room. The offered PLC based system shall include all the hardware, software, cable, implementation etc., as required to establish link to Purchasers DCS. c) Two no. time stamping signal shall be provided from Purchasers GPS master clock to Bidders PLC. The format of the GPS time signal shall be informed during detailed engineering. The hardware and software required at Bidders end shall be provided by the Bidder. Bidder shall lay the redundant cables up to GPS panel in main control room. d) Fire signal shall be provided from the purchasers FPS control system & the cable for the same shall be terminated by purchaser at the bidders PLC .Bidder shall consider required no of IOs for the Fire Input signal. 8.10 DATA / DRAWINGS TO BE ENCLOSED WITH THE BID a) Deviation list: Deviations, if any, shall be specifically listed under Schedule of Deviations. If no deviation is listed, it will be presumed that the BIDDER has complied with all the clauses in specification. b) Item wise confirmation to each clause c) Deviations in the features of PLC as given in 8.6.19. d) PLC system configuration Diagram e) P&IDs clearly indicating the following: 1. All instruments with tag nos. in line with BIDDERs Instrument Schedule. 2. Actuation levels for all switches Eg:- High, Low etc. 3. Signal destination for each signal Eg:- to control panel, to MCC etc. 4. Functionality for each signal Eg:- To Pump start interlock, to trip pump etc. 8.11 DATA / DRAWINGS TO BE FURNISHED DURING DETAILED ENGINEERING BIDDER shall furnish the following documents for PURCHASER/ CONSULTANTs review and approval during detailed engineering. a) P&I diagrams for all the systems in Bidders scope.
ISSUE R0
SPEC. NO. TCE-5607A-C-811-08

b) Manufacturers data sheets for all field instruments along with catalogues. c) PLC configuration Drawing d) BOM of PLC system e) GA drawing of all PLC panels f) Power distribution and earthing diagrams
g) Signal distribution diagram. h) Factory Acceptance Test Procedure i) Termination details of all signals and power supplies on control panel and junction box terminal details. Instrument/control cable schedule.
j)
k) Interconnection schedule for all cables with individual wire termination details. i. The BIDDER shall incorporate the following information furnished (markedup) by the PURCHASER/ENGINEER on their wiring diagrams: Terminal numbers of the motor control centre and external interlocks and the same shall be used for preparation of inter-connection schedule.
ii.
l)
GA drawing for local control panel, with Bill of Material.
m) Panel internal wiring diagram and wiring diagrams showing interconnection details between control panels & MCC and between control panel & field instruments / junction boxes. n) Local control Panel internal wiring diagram and wiring diagrams showing interconnection details between control panels & MCC and between control panel & field instruments / junction boxes. o) Schedule of Instruments with settings. p) JB schedule indicating terminal details.
ISSUE R0
SPEC. NO. TCE-5607A-C-811-08

8.12 LAYOUT REQUIREMENTS The exact routing of impulse pipes shall be decided at site during erection depending upon the location of tap points. PURCHASER reserves the right to approve the suitable location and grouping of instruments in Junction boxes. 8.13 INSTALLATION REQUIREMENTS The installation shall be done as per the standards. The exact routing of impulse pipes/tubes shall be decided at site during erection by the BIDDER depending upon the location of tap points. 8.14 ERECTION, TESTING & COMMISSIONING Erection, testing and commissioning of all the instruments specified is in BIDDERs scope. 8.15 GUARANTEES All instruments supplied by BIDDER shall be guaranteed for proper functioning within an accuracy called for. i) All binary field devices viz., switches included in the scope of BIDDER shall have two SPDT switches. Both the contacts shall be wired to the JB.
ii) All instruments to be supplied shall be tagged as per PURCHASER/ENGINEERs tagging procedure. The tagging procedure shall be informed to the successful BIDDER. iii) The scale graduations for all instrumentation and control equipment shall be in SI units. iv) The instrument tap point isolating valves (root valves) shall be located such that they are accessible from platforms/walkways. v) All signaling contacts shall be of SPDT type. vi) All local gauges dial size shall be 150 mm. vii) Adequate marshalling facilities shall be provided for each field instrument. Tap point/instrument isolation valves shall be of globe type and drain/vent valves (globe) shall be provided, wherever required. Material and pressure rating of valves, impulse piping and fittings shall be so selected to meet the design requirements. All instruments shall be rigidly supported to provide for vibrationISSUE R0
SPEC. NO. TCE-5607A-C-811-08

free mounting. Impulse piping shall be routed and supported in a manner to provide main line/duct/equipment movements. The tap point isolating valves shall be mounted with stem horizontal length-wise and the impulse line gradient shall be at least 1 : 10. viii) All accessories shall be supplied, on as required basis. ix) Technical features and sub-bidders of I&C equipment are subject to Purchasers approval.
8.16
TERMINAL POINTS
Bidder shall note & confirm the following terminal points:
Sl. No. 1.0
System Bidirectional redundant OPC link to Purchasers DCS GPS master clock signal
Terminal Point Bidder shall terminate the OPC link cables upto purchasers DCS cabinet in main control Room. Bidder shall terminate the redundant cables upto the purchasers GPS master clock panel in main control room with all required necessary hard wire & software.
2.0
2.0 2.1 2.2 3.0
Cables (a) Instrumentation cables All instrumentation Cables shall be in bidders scope. (b) Control cables All Control Cables shall be in bidders scope. Fire signal form main fire Purchaser shall provide the fire signal & alarm panel terminating the cable at bidder panel is in purchasers scope. Bidder shall consider sufficient no of IOs for the same signals.
ISSUE R0
SPEC. NO. TCE-5607A-C-811-08

8.17
SPARES
8.17.1 Essential Spares The Essential Spares shall be supplied as detailed below. a) b) For all field Instruments, a min of one (1) or 20% of the quantity of each type or range, which ever is higher is to be provided. For control / pneumatic valves, a min of one (1) or 20% of the quantity of each type or range of packing and gaskets, actuator diaphragm, pilot relay and Orings.
c) For solenoid valves / moisture traps / any special valves, a min of two (2) or 20% of the quantity of each type or range of coil (each rating and insulation), gaskets and O-rings. d) For PLC system components, minimum 1 no. of each type of module or 20 % whichever is maximum. 8.17.2 Start up Spares Start up spares which are required during erection and commissioning including completion of performance guarantee test shall be included in the Bidders scope, as required basis. 8.17.3 Recommended Spares Recommended spares required for 3 years of plant operation shall be included. This shall not be taken for bid evaluation purpose. 8.17 POWER SUPPLY AND INSTRUMENT AIR SUPPLY In case any instrument/equipment needs any other supply than provided by PURCHASER, the same shall be arranged by the BIdder by providing suitable power pack. PURCHASER shall provide instrument air at one point at a pressure of 5 7 kg/sq.cm(g) and further instrument air distribution is in BIDDERs scope. 8.18 IMPULSE PIPES & FITTINGS Impulse pipes, fittings and signal piping shall be supplied for all the instruments under the scope of this specification.
ISSUE R0
SPEC. NO. TCE-5607A-C-811-08

8.19
INSTRUMENTS FOR PERFORMANCE TESTING All instruments required for performance testing to prove the guaranteed performance of the Instrumentation and Control Equipment as specified in this Section, shall be loaned to the PURCHASER by the BIDDER, at no extra cost, for the duration of the Performance Test. These test instruments shall have test certificates, from reputed test house, valid for the duration of the performance test.
8.20
CODES AND STANDARDS
8.20.1 All equipment and services covered under this specification shall comply with all currently applicable statutes, regulations and safety codes in the locality where the equipment shall be installed. All codes and standards refer to in this specification shall be understood to be the latest version on the date of offer made by Bidder unless otherwise specified. If such standards are not existing for any equipment or system, the same shall comply with the applicable recommendations of the following professional institutes : (a) (b) (c) (d) (e) (f) (g) (f) National Electricity Manufacturers Association (NEMA) The Institute of Electrical and Electronic Engineers (IEEE). Instrumentation, Systems and Automation society (ISA). American National Standards Institute (ANSI). Deutsche Industries Norman (DIN). International Electrochemical Commission (IEC). Verin Deutschar Eisecnhuttenleutte (VDE) Indian Standard Institute (ISI).
8.20.2 Standards not indicated in the specification are acceptable subject to approval by the PURCHASER/Engineer if they are established to be equal or superior to the standards indicated in the specification. 8.20.3 The BIDDER shall furnish English translation of all standards to which equipment and systems offered conform to. 8.20.4 The following specific codes and standards are applicable: Instrumentation Symbols and identification Binary logic diagrams for process operation ISA S 5.1 ISA S 5.2 the
ISSUE R0
SPEC. NO. TCE-5607A-C-811-08

Graphic symbols for inst. logic and comp. System Environmental conditions Bearing Temperature Monitoring Systems Valves Seat Leakage Thermocouples
ISA S 5.3 ISA S 71.04 API 670 ANSI B 16.104 ANSI MC 96.1
Measurement & Control, Electrical sensors, Elec. DIN 19243 Position sensors & Sig. Converters for IS two wire DC systems. Industrial Pt RTD Measurement of Fluid Flow by Meter Run Temperature Measurement Degree of Protection by Enclosure Notes : All other relevant codes, as applicable, are to be used along with the above basic codes and of latest version. The codes and standards specified above are indicative but not exhaustive. 8.21 1. LIST OF SUB-VENDORS FOR INSTRUMENTATION AND CONTROL SYSTEM PLC a) Allen Bradley b) GE-Fanuc c) Schneider Electric d) Siemens 2. LOCAL CONTROL PANELS a) Industrial Controls & Appliances (P) Ltd. b) J & H
ISSUE R0
DIN 43760/ IEC 751 ISO 5167 ANSI MC 96.1 / IEC 751 IEC 529
SPEC. NO. TCE-5607A-C-811-08

c) Pyrotech d) Rittal e) Chemin 3. INSTRUMENT CABLES a) Incab b) Delton c) Fort Globster Industries d) Universal Cables Ltd e) Reliance Cables f) Gems Cab g) Cords Cable Industries h) Polycab 4. CONTROL CABLES a) Delton b) Incab c) Universal Cables ltd d) Reliance Cables e) Gems Cab. f) Cords Cable Industries g) Polycab 5. DIGITAL DISPLAY UNIT a) Laxsons b) Yogokawa Bluestar Ltd. c) Tata Honeywell Ltd.
ISSUE R0
SPEC. NO. TCE-5607A-C-811-08

d) Gossien Metrawatt 6. ILLUMINATED PUSH BUTTONS a) EAO b) H & B c) L & T d) Ronan e) Tata Honeywell f) Siemens 7. LEVEL GAUGES a) Chemtrols Engg. b) Levcon c) Sigma Instruments co. d) Technomatic (India) pvt. ltd. e) Teleflo Instruments co. ltd. 8. LEVEL SWITCHES a) Bells Control Ltd. b) Levcon c) Magnetrol d) Placka 9. POSITION TRANSMITTER a) Endress & Hauser b) Yamatake c) Siemens d) Gulde
ISSUE R0
SPEC. NO. TCE-5607A-C-811-08

10.
PRESSURE INDICATORS a) Bells Controls ltd. b) General Instruments c) A.N. Instruments d) Gauges Bourdon e) Industrial Eqpt. co. f) Waaree Instruments Ltd.
g) Odion
11.
PRESSURE SWITCHES a) Indfoss (India) Ltd. b) Switzer Instruments ltd. c) Varma Trafag d) A.N. Instruments e) Waaree Instruments Ltd
12.
PUSH BUTTONS a) Honeywell b) Larsen & Toubro ltd. c) Siemens ltd. d) Tele Mechanic
13.
RELAYS a) Jyothi b) ABB c) Paramount d) Omron

ISSUE R0
SPEC. NO. TCE-5607A-C-811-08

e) SIEMENS 14. SOLENOID VALVES a) Asco b) Avcon c) Rotex d) Schrader e) Herion-Norgren f) Schovill Duncan Ltd. 15. TEMPERATURE INDICATORS a) G.I.Consortium b) Bells Controls c) Waaree instruments ltd d) Dresser-USA 16. UPS a) Emerson b) DB Power Electronics. 17. TERMINAL BLOCKS a) Phoenix b) Weidmueller c) Wago 18. MINIATURE CIRCUIT BREAKERS a) Siemens b) ABB c) L & T.
ISSUE R0
SPEC. NO. TCE-5607A-C-811-08

NOTES 1. Wherever the make is not specified for any item, the Bidder shall indicate 2 or 3 reputed makes, out of which Purchaser / Consultant shall select any one which is acceptable suggest an acceptable make. This shall have no price implication.
ISSUE R0
SPEC. NO. TCE-5607A-C-811-08

9.0 9.1
TERMINAL POINTS Make up water piping connection for cooling tower, chilled water expansion tank and air washer tank will be made available within 3 metres from the respective equipment by the PURCHASER. All drain piping upto nearest drain points in A/C plant room, AHU rooms, air washer rooms & near cooling towers shall be supplied and erected by A/C and Ventilation VENDOR.
9.2
ISSUE R0
SPEC. NO. TCE-5607A-C-811-08

10.0
EQUIPMENT AND SERVICES BY OTHERS The following equipment and services will be provided by the PURCHASER:
10.1
All civil works such as concrete foundations for all equipment, making good of walls, floor or slab openings etc is by civil Bidder. Any minor modifications to wall & floor openings, if required, shall be by VENDOR. Provision of rooms for A/C plants, AHUs, air washers and air washer rooms, RCC tanks for air washers, catwalk inside the air washer tank. Drain points in the A/C plant room, AHU rooms, air washer rooms and near cooling towers. Water and electricity for construction, testing and commissioning purposes at one suitable point as agreed upon prior to the start of work. Electricity for construction will be on chargeable basis. Provision of adequate quantity of make-up water (service water) for air washers, cooling towers and expansion tank. For water analysis refer sheet 2 of 2 of this section. False ceiling in the air-conditioned areas. Light coloured venetian blinds for the exposed windows of air-conditioned areas. 50 mm thick resin bonded mineral wool or equivalent roof insulation for all roof slabs of air-conditioned areas and AHU rooms as required. Earthing grid.
10.2 10.3 10.4
10.5
10.6 10.7 10.8 10.9
10.10 All power cabling and control cabling other than those covered in this specification.
ISSUE R0
SPEC. NO. TCE-5607A-C-811-08

SERVICE WATER ANALYSIS Sl.No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Constituent Colour & Odour pH Total alkalinity in ppm Total Hardness as Ca CO3 ppm Mg Hardness as Ca CO3 ppm Ca Hardness as Ca CO3 ppm Cl as such ppm SO4 as Ca CO3 ppm TDS as Ca CO3 ppm Conductivity (S/cm) Silica ppm Sodium as such ppm Suspended Solids mg/l Turbidity Analysis Colourless & Odourless 7.5 72 64 22 42 5.6 1.9 108 164 5.6 7.15 20 20 NTU
ISSUE R0
SPEC. NO. TCE-5607A-C-811-08

11.0 11.1
DATA/INFORMATION TO BE FURNISHED WITH THE BID BIDDER shall furnish complete information called for in Data Sheets-A and in all Data Sheets-B and all the schedules in Section-F, failing which the Bid will be considered as incomplete and the PURCHASER reserves the right to reject the Bid. BIDDER shall submit complete cooling load calculations for summer, monsoon and winter for all the air-conditioned areas in support of the equipment capacities offered by him. They should also furnish pressure drop calculations in piping in support of their pump selection for the air conditioning and evaporative cooling systems. Drawings indicating overall dimensions and weights of chilling unit, pumps, cooling towers, supply air fans & exhaust fans, roof extractors and their mounting arrangement. Capacity rating charts for supply fans, exhaust fans, pumps and roof extractors giving air flow, static pressure, speed & power consumptions. Schedule of Submission of Major Drawings by the VENDOR after the award of contract The VENDOR shall submit the following key drawings/data showing engineering information for PURCHASERs approval/information according to the schedule listed below.
11.2
11.3
11.4 11.5
11.5.1
Air-conditioning System a. A/C plant room layout drawings including foundation details b. AHU room layout drawings c. Cooling tower details & layout d. Ducting layout e. Cooling water piping layout f. Duct lining & insulation details
For approval (weeks) from the date of letter of intent : Within 4 weeks : Within 4 weeks : Within 4 weeks : Within 4 weeks : Within 5 weeks : Within 5 weeks : Within 5 weeks
g. Fresh air unit/assembly details
ISSUE R0
SPEC. NO. TCE-5607A-C-811-08

11.5.2
Evaporative cooling system/mechanical Ventilation system: a. Air washer room layout including fan and pump foundation/location details and insert and opening details b. Air washer spray chamber and assembly details c. Air washer circulating water piping layout d. Mounting details of: i. Axial/propeller fans ii. Roof extractors e. Duct layouts for TG building : 8 weeks : 4 weeks : 8 weeks : Within 8 weeks
: Within 4 weeks : Within 6 weeks : Within 8 weeks
11.5.3 Motor / load list (for all motors) 11.5.4 Rating of all exhaust fans & roof extractors 11.5.5 General a. Block interlock diagram for sequential operation and safety interlocks and writeup on control system for complete airconditioning / evaporative cooling/ mechanical ventilation system b. Drawings as called for in Section C8 11.5.6 Operation and maintenance manuals for various equipment/ system offered 11.5.7 Remaining drawings shall be submitted on a Mutually agreed schedule 11.5.8 Performance curve for supply fans, exhaust fans, roof extractors and pump
: 12 weeks : Within 4 weeks : 12 weeks
: Within 4 weeks
ISSUE R0
SPEC. NO. TCE-5607A-C-811-08

12.0
LIST OF DRAWINGS ENCLOSED
SL. NO. 12.1 12.1 12.2 12.3
DRAWING NO.
TITLE
TCE.5607A-100-GA-1001 TCE.5607A-201-GA-1011 TCE.5607A-201-GA-1012 TCE.5607A-201-GA-1013
P5 P0 P0 P0
PLOT PLAN TG BUILDING GROUND FLOOR PLAN AT EL. 0.00 M GENERAL ARRANGEMENT TG BUILDING FLOOR PLAN AT EL. 5.50 M GENERAL ARRANGEMENT TG BUILDING OPERATING FLOOR PLAN AT EL. 11.00 M GENERAL ARRANGEMENT TG BUILDING MISCELLANEOUS FLOOR PLAN GA TG & SG AREA GENERAL ARRANGEMENT - CROSS SECTION P & I DIAGRAM FOR CONDENSER AND CHILLED WATER PIPING FOR AC PLANT CIRCULATING WATER FOR AIR WASHER - FLOW DIAGRAM SINGLE LINE DIAGRA FOR AC AND VENTILATION
12.4 12.5 12.6
TCE.5607A-201-GA-1014 TCE.5607A-201-GA-1015 TCE.5607A-ME-SK-010 (SH 1 OF 2) TCE.5607A-ME-SK-010 (SH 2 OF 2) TCE.5607A-EL-SK-2009
P0 P0 P0
12.7
P0
12.8
P0
ISSUE R0
SPEC.NO. TCE-5607A-C-811-08

SECTION :
C13
SHEET 1 OF 6
13.0 13.1
PAINTING SCOPE This section covers the painting requirements for the power plant equipment, structures, piping etc. and any other surface required to be painted.
13.2
CODES AND STANDARDS Painting of equipment shall be carried out as per the specifications indicated below and shall conform to the relevant IS specification for the material and workmanship. The following Indian Standards may be referred to for carrying out the painting job: IS:5 IS:1303 IS:2379 IS:1477 : : : : Colours for ready mixed paints and enamels Glossary of terms relating to paints Colour code for identification of pipelines Code of practice for painting of ferrous metals in buildings (Parts I & II) IS:2524 : Code of practice for painting of non-ferrous metals in buildings (Parts I & II) IS:2395 : Code of practice for painting of concrete, masonry and plaster surfaces (Parts I & II) IS:2338 : Code of practice for finishing of wood and wood based materials (Parts I & II) IS:6278 : Code of practice for white washing and colour Washing IS:3140 : Code of practice for painting asbestos cement building products
ISSUE R0

SECTION :
C13
SHEET 2 OF 6
IS:158
Ready mixed paint, brushing, bituminous, black, Lead free, acid, alkali, water and heat resisting
IS:2074
Ready mixed paint, air drying, red Oxide Zinc Chrome, priming
IS:104 IS: 2932
: :
Ready mixed paint, brushing, Zinc Chrome, priming Enamel, synthetic, exterior (a) undercoating (b) finishing
13.3
PREPARATION OF SURFACES All surfaces to be painted shall be thoroughly cleaned of all grease, oil, loose mill scale, dust, rust and any other foreign matter. Mechanical cleaning by power tool and scrapping with steel wire brushes or shot / sand blasting shall be adopted to clean the surfaces to SA 2 . Cleaning with solvents shall be resorted to only in such areas where other methods specified above have not achieved the desired results. Cleaning with solvents shall be adopted only after written approval of the PURCHASER / ENGINEER. For bought out items of electrical and instrumentation the surfaces shall be pre treated through chemical cleaning (7 tank process).
13.4
PRIMER PAINT After the surface is prepared, the primer coats for Epoxy paint confirming to IS 14506 shall be applied. Primer shall be applied to ensure a continuous film without holidays
13.5
FINISH PAINT Epoxy paint conforming to IS 14209 shall be used for finish coats. The colour/shade shall be as approved by the PURCHASER. After cleaning the dust on the dried up primer, first coat of Epoxy paint shall be applied. After this first coat dries up hard, the gloss from the entire surface shall be gently removed and surface dusted off. There after, the second finish coat of Epoxy paint shall be applied.
ISSUE R0

SECTION :
C13

13.6 SUGGESTED COLOUR CODES FOR PAINTING
SHEET 3 OF 6
SL. NO.
ITEM/SERVICE
COLOUR
IS-5 Grade
COLOUR (BAND)
IS-5
1.0
Structures, platforms, galleries, ladders and handrails
Dark Admirality Grey
632
2.0
Boiler casing, ESP and ducting
Nut Brown
413
3.0
Crane
3.1
Crane structure
Golden Yellow
356
3.2
Trolley and hook Fans, pumps, motors, compressors
Crimson Light Grey
540 631
4.0
5.0
Tanks (without insulation and cladding)
5.1
Outdoor
Aluminium
5.2
Indoor
Light grey
631
ISSUE R0

SECTION :
C13
SHEET 4 OF 6
SL. NO.
ITEM/SERVICE
COLOUR
IS-5 Grade
COLOUR (BAND)
IS-5
6.0
Vessels & all other proprietary equipment (without insulation & cladding) Switchgear Control & relay panels
Light grey
631
7.0 8.0
Light grey Light grey
631 631/70 78 of IS 1650 356
9.0
Turbine
Golden Yellow Light grey Aluminium Signal red
10.0 11.0 12.0 13.0
Generator & exciter Transformers Machinery guards Piping (without insulation and cladding_) Water System Boiler feed Condensate D M Water Soft water Bearing cooling water Potable & filtered water Service & clarified water Raw water Cooling water
631 537
--
13.1
Sea green Sea green Sea green Sea green Sea green Sea green Sea green Sea green Sea green
217 217 217 217 217 217 217 217 217
Light brown Light orange French blue French blue French blue French blue White French blue
410 557 166 166 166 166 166
ISSUE R0

SECTION :
C13
SHEET 5 OF 6
SL. NO.
ITEM/SERVICE
COLOUR
IS-5 Grade
COLOUR (BAND)
IS-5
13.2
Air System Station air Control air Sky blue Sky blue 101 101 White -
13.3
Oil system Fuel oil Light oil Light brown Light Brown 410 410 French Brilliant green Light grey Light orange 166 221
Lubricating oil Transformer oil 13.4 Gas system Carbon dioxide
Light brown Light brown
410 410
631 557
Canary yellow Fire red Sky blue Light brown Black
309
Light grey
631
13.5 13.6 13.7 13.8
Fire services Vacuum pipes Fuel pipes (pulverised coal) Drainage
536 101 410 -
Black -
Whether the above codes pertain to epoxy painting is to be checked. Notes: 1. This colour code basically refers to IS:2379 modifications. for piping with necessary
2. Where band colour is specified, same shall be provided at 30 metre intervals on long uninterrupted lines and also adjacent to valves and junctions.
ISSUE R0
SPEC. NO. TCE-5607A-C-811-08

SECTION: C14 SHEET 1 OF 3
LIST OF PROPOSED MAKES Chillers : Carrier / Voltas / Blue star / Kirloskar / Trane Beacon Weir / KBL / KSB / M & P / Grundfos / ITT B & G / Armstrong Bluestar / Voltas/ Citizen / Zeco / Caryaire /Suvidha Savier/ ETA / Trane / Carrier/VTS ABB / VOLTAS / BLUESTAR / HPS Patel Airflow / Alstom (GEC) / Flakt / Nadi /Kruger/ Nicotra / Greenheck / Comefri Jaypee / Zeco/ McCann / Edge Tech ABB / Crompton Greaves/ (Marathon) Alstom (GEC) / Siemens /BBL/ KEC John flower / Purogen / spectrum/ Anfilco / Dyan / Aerosol Flamco / Amtrol / Anergy Be limo / Joventa / Siemens / Honeywell /Johnson / Sauter
Back pull out centrifugal pumps
Air handling unit (Double skin : sandwiched type) Air washer / UAF casing and tank Centrifugal fan / Axial fan : :
Cooling coil LT Motor
: :
Air filter
Automatic Air vents
Motorized actuators for dampers : and valves for open / close and Modulating duty Strip heater / Pan Humidifier :
ALCO / Hot set Bankin / Leader /Crawley & Ray/ Kolley/ H.Sarkar Advance / Leader / Intervalve / BDK / L & T Audco Kruger / Alstom (GEC) / Khaitan fans / Patel air flow / Nicotra / Dustven Tata / SAIL/ Bhusan steel/ Jindal / Essar / Nippon Ajanta tube/ Jindal pipe/ Surya roshni/ TISCO / Bansal / SAIL/ Maharashtra
ISSUE R0
C.I Gate / Globe / Check valve (65 : NB to 500NB) Non return valves :
Exhaust fan (propeller type) with : Motor G.I.Sheet :
M.S / G.I Pipe
SPEC. NO. TCE-5607A-C-811-08

Seamless CI / M.S.Y-Strainer Butterfly valve : : Sant / H SARKAR / EMERALD / DS ENGG Advance/ Intervalve / L&T Audco Levcon/ D.K.Instrument
Level gauge/Flow Switch / Level : switch (float type) / Water pressure Switch / water flow switch / Air flow switch Pressure gauge Temperature gauge RH sensor / Temp Sensor Modulating Motor/DP Switch : : / :
A.N.Instruments / H.Guru A.N.Instruments / Guru Honeywell / Johnson control / Siemens / D.K instrument / General Instrument Eureka / Placks / Trac
Flow meter (Rotameter type) / RH : sensor / temp sensor / modulating Motor / DP switch / Humidistat/ safety Thermostat MCC /Control panel :
AREVA / L&T SHNIEDER
/ GE / SIEMENS /
Microprocessor based PLC panel LT Control cable/Power cable
: :
ABB / Allen Braadley / L&T / GE Fanuc Delton cable / Industrial cable / Cords cable / Paramount cable / Universal cable / Polycab cable / Crystal cable Paramount cable / universal cable / Delton cable / NICCO / INCAB / Reliance UP Twiga / Lloyd / Ownes Corning / Kimmco Beardsell / Thermowel / Llyods / Cooline / Quality Thermopack Sevenstar/ Aerovent Blue Star/ Voltas/ Carrier / OGeneral / LG
Inst cable
Thermal insulation
Expanded Polystyrene section & slab) Pre insulated pipes
(Pipe :
Ductable / Non ductable Split / : Window AC
ISSUE R0
SPEC. NO. TCE-5607A-C-811-08

Grills/ Diffuser (AL) / VCD Louvers / : Fire dampers
Ravistar / Dynacraft / Caryaire / Air master / Ruskin / TSC / George Rao & Co / Green Heck Advance / T & A Hydronics / Intervalve / Audco / Flowcon Advance / Intervalve / L & T Audco / TAP / RC / ITAP / RB DK Instruments / Honeywell
Balancing Valves
Ball Valves
Geyser stat / Air stat
ISSUE R0

Section C

Încărcat de

Informații document

Drepturi de autor

Formate disponibile

Partajați acest document

Partajați sau inserați document

Opțiuni de partajare

Vi se pare util acest document?

Este necorespunzător acest conținut?

Drepturi de autor:

Formate disponibile

Section C

Încărcat de

Drepturi de autor:

Formate disponibile

SPEC. NO.

BHUBANESHWAR POWER PRIVATE LIMITED

AIR-CONDITIONING AND VENTILATION SYSTEMS

(ii) (iii) (iv) 1.1.2

WET BULB TEMPERATURE 26.8 C 26.3 0C 16.7 0C

SPEC. NO. TCE-5607A-C-811-08

BHUBANESHWAR POWER PRIVATE LIMITED

AIR-CONDITIONING AND VENTILATION SYSTEMS

SPEC. NO. TCE-5607A-C-811-08

BHUBANESHWAR POWER PRIVATE LIMITED

AIR-CONDITIONING AND VENTILATION SYSTEMS

SPEC. NO. TCE-5607A-C-811-08

BHUBANESHWAR POWER PRIVATE LIMITED

AIR-CONDITIONING AND VENTILATION SYSTEMS

SPEC. NO. TCE-5607A-C-811-08

BHUBANESHWAR POWER PRIVATE LIMITED

AIR-CONDITIONING AND VENTILATION SYSTEMS

Each Screw chilling unit shall comprise of the following :

SPEC. NO. TCE-5607A-C-811-08

BHUBANESHWAR POWER PRIVATE LIMITED

AIR-CONDITIONING AND VENTILATION SYSTEMS

SPEC. NO. TCE-5607A-C-811-08

BHUBANESHWAR POWER PRIVATE LIMITED

AIR-CONDITIONING AND VENTILATION SYSTEMS

SPEC. NO. TCE-5607A-C-811-08

BHUBANESHWAR POWER PRIVATE LIMITED

AIR-CONDITIONING AND VENTILATION SYSTEMS

SPEC. NO. TCE-5607A-C-811-08

BHUBANESHWAR POWER PRIVATE LIMITED

AIR-CONDITIONING AND VENTILATION SYSTEMS

SPEC. NO. TCE-5607A-C-811-08

BHUBANESHWAR POWER PRIVATE LIMITED

AIR-CONDITIONING AND VENTILATION SYSTEMS

Difluoro methane, 31 Pentafluoro ethane

SPEC. NO. TCE-5607A-C-811-08

BHUBANESHWAR POWER PRIVATE LIMITED

AIR-CONDITIONING AND VENTILATION SYSTEMS

SPEC. NO. TCE-5607A-C-811-08

BHUBANESHWAR POWER PRIVATE LIMITED

AIR-CONDITIONING AND VENTILATION SYSTEMS

Thickness (mm) 0.63 0.80 1.00 1.25

SPEC. NO. TCE-5607A-C-811-08

BHUBANESHWAR POWER PRIVATE LIMITED

AIR-CONDITIONING AND VENTILATION SYSTEMS

SPEC. NO. TCE-5607A-C-811-08

BHUBANESHWAR POWER PRIVATE LIMITED

AIR-CONDITIONING AND VENTILATION SYSTEMS

SPEC. NO. TCE-5607A-C-811-08

BHUBANESHWAR POWER PRIVATE LIMITED

AIR-CONDITIONING AND VENTILATION SYSTEMS

SPEC. NO. TCE-5607A-C-811-08

BHUBANESHWAR POWER PRIVATE LIMITED

AIR-CONDITIONING AND VENTILATION SYSTEMS

1.5.2 1.5.3 1.5.4

SPEC. NO. TCE-5607A-C-811-08

BHUBANESHWAR POWER PRIVATE LIMITED

AIR-CONDITIONING AND VENTILATION SYSTEMS

1.5.6 1.5.7 1.5.8 1.5.9 1.5.10 1.6 1.6.1

Shell - condenser Shell cooler End Cover Tube sheets Tubes

Air Handling Unit:

AHU casing Cooling coil Fan casing Fan shaft

Centrifugal Pump Set:

Casing Impeller Shaft

: Cast iron, IS:210 Gr. FG 260 : Bronze IS 318 Gr 2 : EN 8