Sail Bokaro Ts

STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL LIMITED, BOKARO 7.
0 MT/Y EXPANSION
TECHNICAL SPECIFICATION OF
TERTIARY TREATMENT OF THE TREATED EFFLUENT FROM THE NEW EFFLUENT TREATMENT PLANT & BLOW DOWN FROM COOLING TOWERS OF COLD ROLLING MILL III
(PACKAGE 042A)
MECON LIMITED RANCHI 834 002
MEC/S/E24F/11/40/0/00/042A
FEB, 2013
TERTIARY TREATMENT OF THE TREATED EFFLUENT FROM THE NEW EFFLUENT TREATMENT PLANT OF COLD ROLLING MILL III (Package No. 042A)
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CONTENTS SL. NO. 01.00 02.00 DESCRIPTION INSTRUCTIONS TO TENDERERS SCOPE OF WORK AND BATTERY LIMIT TECHNICAL SPECIFICATION AND DESCRIPTION OF 03.00 WORK 04.00 05.00 06.00 07.00 07.00 DESIGN CRITERIA AIR CONDITIONING AND VENTILATION SYSTEMS HOISTING AND HANDLING FACILITY ELECTRICS, INSTRUMENTATION & CONTROL ELECTRICS & CONTROL 93 to 124 66 to 72 73 to 85 86 to 92 30 to 65 PAGE NOS. 1 to 21 22 to 29
07.01 TECHNICAL SPECIFICATION FOR ELECTRICS & AUTOMATION 07.02 ELECTRICS, AUTOMATION & TELECOMMUNICATION 07.03 INSTRUMENTATION & CONTROL 08.00 09.00 10.00 11.00 CIVIL AND ARCHITECTURAL STEEL STRUCTURAL FIRE FIGHTING FACILITIES PROJECT SCHEDULE & PROGRESS MONITORING PERFORMANCE GURANTEES & PRELIMINARY 12.00 ACCEPTANCE TESTS (PAT)/ COMMISSIONING 13.00 TECHNOLOGICAL DOCUMENTATION
125 to 179 180 to 189 190 to 201 202 to 204 205 to 211 212 to 215
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223 to 239
2012 MECON LIMITED ALL RIGHTS RESERVED
TERTIARY TREATMENT PLANT
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01.00
INSTRUCTION TO TENDERER INTRODUCTION Bokaro Steel Plant (BSL) of Steel Authority of India Limited (SAIL) is in the process of enhancement of its production capacity as worked out in its corporate plan-2012. Under this program, a new Tertiary Treatment Plant with inlet capacity of 90m3/hr shall be installed. The proposal envisages addition of a new Tertiary Treatment Plant of capacity 90 m3/hr with necessary pretreatment, zero liquid discharge treatment plant of capacity 26 m3/hr along with auxiliaries. THE NEED & OBJECTIVE The expansion proposal considers installation of one new cold rolling mill complex as well as revamping / modernisation / augmentation of existing facilities to meet the envisaged production and objectives. Further, to achieve zero discharge, a dedicated Tertiary treatment plant for treating of the treated effluent from the Effluent Treatment Plant of CRM III, cooling tower blowdown alongwith ZLD Plant shall be provided. It is envisaged to reuse treated water as make up to cooling tower of the new CRM III of Bokaro Steel Plant / SAIL.
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INTENT OF THE SPECIFICATION The intent of this specification is to cover the design, engineering, manufacture/ fabrication, supply, transportation, unloading, storage, transportation to site, erection, testing and commissioning of Tertiary Treatment Plant along with auxiliaries.
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The intent of this Specification is to make the tenderer appreciate the scope for this package to enable him to submit a detailed comprehensive offer matching the requirement of the augmentation program as specified in this document. The tenderer shall base his offer on the information contained in this specification. The Tenderer shall satisfied himself regarding suitability of the plant and equipment and system, specified in the technical document and take full responsibility for suitability thereof for output, reliable working as well as ease of operation, inspection, and maintenance including replacement with minimum down time.
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All equipment/ systems shall be complete in all respects & any equipment or accessories not covered in the technical specification but essential for proper design and operation shall be deemed to be included in the scope of the Contractor. The Tenderer shall satisfy himself regarding the nature and location of work place, kind of equipment, facilities, services etc. needed during performance of work, general and local conditions as well as all other matters which can, in any way, affect the work covered in this specification. Effort shall be made by the Tenderer to maximize equipment/ supplies from indigenous sources. The successful Tenderer shall be responsible for coordinating the supplies covered in the different parts of this Specification from different sources and execute the contract within agreed time schedule. All the equipment & supplies shall be suitable for the tropical climatic conditions prevailing at Bokaro Steel Plant site. This technical specification shall be read in conjunction with the following documents irrespective of whether attention to the same has been specifically drawn or not: Standard Bidding document (SBD) General Specification (GTS) General Conditions for Contract (GCC)
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01.02 01.02.01
SITE CONDITIONS Location Bokaro steel plant is located 320 km from Kolkata, 1110 km from Delhi, 680 km from Bhilai, 300 km from Rourkela, 160 km from Durgapur, 140 km from Tatanagar and 146 km from Ranchi, It is situated in Bokaro District of Jharkhand State and is located at a Latitude 23 Deg. 40N and Longitude 86 Deg. 7E. The nearest railway station is Bokaro Steel city on S.E. Railways.
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Climatological data and other general information Average elevation 229 m above mean sea level. Barometric pressure Ambient temperature Absolute maximum Absolute minimum Highest of mean monthly Relative humidity (maximum) Climate Ambient air quality Mean wind speed Maximum wind speed Rainfall: Annual average Heaviest in 24 hours Design ambient conditions Season Summer Monsoon Winter Air conditioning DTB Deg C RH% 45 26 34 65 10 Ventilation DTB Deg C RH% 40 40 32 67 980 mb 46.10C 1.80C 43.80C 100% Tropical humid Industrial 7.8 kwph 108 kmph 1197.3 mm 272.0mm
Temperatures inside shop premises to be taken as 50C above ambient, unless otherwise specified. 01.02.03 Railways Bokaro Steel Plant is connected to Indian Railways network viz.
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Bokaro Steel City Station of S.E. Railways. The track gauge of south Eastern Railways as well as of the works railway is standard broad gauge i.e. 1676 mm Any equipment exceeding the standard moving dimensions will be considered as over dimensioned (O.D) consignment. In all such cases, prior approval of the concerned railway authorities should be taken before movement of O.D. consignment is undertaken. In addition bogie well wagons are also available with the Indian Railways for the transportation of special consignments. 01.02.04 Sea Port The site can be served from both Kolkata and Haldia Ports which are approximately 360 Km away from the site by rail. 01.02.05 Roads The plant is well connected with National Highway No. 32 and National Highway No. 33. 01.02.06 Air traffic The nearest air port connected to the national network is Ranchi, which is approximately 146 Km from the plant and the nearest international air port is Calcutta at approximately 320 Km by road from the plant. A small private air strip exists at Bokaro Steel City where facilities for landing light air craft are available. 01.02.07 Communication Facilities for domestic and international communication exist at Bokaro Steel City. 01.03 01.03.01 REGULATIONS AND STANDARDS All equipment shall be designed, assembled, erected and tested in accordance with the standards of National Standards institutions of the country where the equipment will be manufactured and/or latest publication of the relevant Indian, IPSS, and International Stations like, ASTM, BS, DIN, etc. These standards shall also include relevant statutory regulations/ standards like pollution control, electricity rules, safety rules, static and mobile pressure vessel
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rules, boiler regulation act, etc., conforming to Jharkhand state/ Indian and/or international standards. 01.03.02 The latest revisions of the relevant Indian/international standards shall be used by the successful tenderer for materials, design, fabrication, manufacture, inspection, installation and testing of the plant and equipment. All weights and dimensions shall be in metric system. English language shall be used in drawings, documents, manuals reports official correspondence, etc. The list of the standards proposed to be followed by the Tenderer shall be indicated in the offer. Tenderer shall also refer in this regard relevant chapter of General Specification. STANDARDISATION The Tenderer shall ensure that the plant and equipment offered have maximum interchangeability and similarity of equipment & components in order to minimize the inventory of spares parts and ease of their changeability / replacement. The Tenderer shall select the make/ manufacturer of items/ equipment, such as electrical equipment, gear boxes, couplings, bearings, hydraulic equipment, instruments & controls, or other similar items from the list of Preferred makes (of the Purchaser) issued along with this Tender. 01.05 GUARANTEE: Tenderer shall be responsible for trouble free operation and satisfactory performance of all the equipment supplied by them. The material used shall be new and best of its kind available and shall conform to relevant latest Indian standards and international standards. The guarantee shall also cover faulty design or materials or workmanship. The supplier shall do all rectification or replacement under the guarantee free of cost. The Tenderer shall replace the wrong/ defective equipment supplied by them, missing items, (observed during inspection at site
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after receipt of materials) or any damages caused to equipment during transportation free of cost after receipt of information from the Purchaser. In case of any dispute, decision of purchaser shall be final. The supplier shall depute his representative to site for replacement/ rectification work without any extra cost to purchaser. 01.06 IMPLEMENTATION PHILOSOPHY This package shall be executed on Turnkey Basis i.e. successful Tenderer shall be responsible for all activities from design to commissioning. Tenderer may submit their best offer on Turn Key basis for this package as per their resources, ability and subject to fulfillment of the eligibility criteria of this Tender. However, the Purchaser reserves the right to accept/ reject the offers in totality or alter the specified quantity of supply/ services or delete any item/ service from the scope of work without assigning any reason .The Purchaser reserves the right to procure directly some items/ equipment as per Tenderers design & specification at the cost of successful tenderer in the interest of timely completion of the project. 01.07 The Tenderer shall visit the site for assessing prevailing site conditions and satisfy himself fully with the scope and extent of the work involved prior to submission of his offer. Certificate from employer regarding site visit is to be enclosed alongwith the offer. Offer received without this certificate shall be summarily rejected. The Tenderer shall carefully check the enclosed Technical Specifications, General Technical Specification & GCC and shall satisfy himself as to the suitability of the process and equipment as specified in the Technical Specification and shall take full responsibility for the efficient operation and guaranteed performance of the plant and equipment offered. The main basic offer of the Tenderer shall be strictly as per the stipulations of the Technical Specification enclosed herewith. Any offer with deviations in process and/or equipment selection from this Technical Specification shall be considered non-responsive and shall be liable to be rejected summarily. However, the Tenderer may offer deviations from the main offer as separate annexure with corresponding add-on and take-off prices.
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01.10
This specification lays down broad nature of work to be executed. The tenderer shall, however, include all items of work whether specifically mentioned in this document or not, but required to render the individual equipment/ systems complete in all respect for safe and smooth operation achieving specified performance. GENERAL Any contradiction between the provisions called for in the specification and any other documents enclosed with the tender enquiry, shall be a matter of clarification to be sought by Tenderer from the Purchaser. It shall be deemed that Tenderer has clearly understood the contents and meaning of specification, requirements and scope of work and studied the Tender documents. Any representation after the submission of the tender for any revision/ modification of the tender on the ground of non-compliance of the specification shall not be accepted. The Tenderer shall inspect the site and satisfy himself with respect to the nature and extent of the work involved and also to obtain first hand information regarding the site condition. If the Tenderer needs any clarification from the Purchaser, the same shall be sought in writing from the Purchaser/ Consultant, sufficiently in advance so that reply is given & quotation is submitted in time. Tenderer shall list -out in their offer for all equipment along with its component / parts indicating make, type and other details. In respect of components / parts of equipment whose details are not mentioned during tender stage, Purchaser / Consultant reserves the right to specify particular type and make of such items even after award of Contract. Generally, preferred makes shall be as per the relevant chapter of this Specification/ GS. The Tenderer shall clearly bring out in their offer any deviation from the Technical Specification in respect of scope of work, technical specification of different equipment or any other details clearly mentioning the clause and page number of TS. The successful Tenderer shall submit well in advance general arrangement, scheme drawings, welding procedures, material specification, testing method, erection procedures, etc. for various
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components, sub-assemblies and the complete equipment for the approval of Purchaser / Consultant. Only after approval is accorded the successful Tenderer shall start manufacture or erection of the equipment as applicable. However, such approval shall not relieve the successful Tenderer of his responsibilities towards completion of work as defined in the contract and proper functioning of equipment / system as per guaranteed output. During the course of manufacture/ erection, if any additions/ alterations are found necessary by Purchaser / Consultant and intimated to the successful Tenderer in the equipment/ components, the same shall be implemented by the successful tenderer without any extra cost. 01.11.08 All necessary facilities including tools, tackles, testing equipment, instruments, accessories, etc. shall be provided by the successful Tenderer to enable stage-wise inspection of equipment by Purchaser/ Consultant during its manufacture/ fabrication, erection and commissioning. All working parts of the equipment shall be easily accessible and maintainable. All equipment and accessories shall conform to the latest Indian/ International Standards and IPPS (Inter Plant Steel Standard) wherever applicable. The successful Tenderer shall furnish un-priced copies of the orders placed on his sub-vendors for information and monitoring by the Purchaser to ensure that orders are placed well in time and on approved vendors/ sub-contractors only. The successful Tenderer shall ensure deputation of well experienced engineers and technical staff from various disciplines for erection, testing and commissioning of the mechanical, electrical equipment, Instruments, Pipelines, civil work and structural work. STATUTORY REGULATIONS AND STANDARDS The Successful Tenderer shall be solely responsible for obtaining necessary clearances from the various statutory bodies of Govt. of India, State Govt. of Jharkhand and as applicable during the course of design, manufacture/ fabrication, transportation, storage, erection and commissioning of the plant and equipment. All Standards mentioned herein after, and to be followed by successful Tenderer for design, manufacture / fabrication erection,
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testing and commissioning, shall be of latest edition. 01.12.03 All electrical equipment supplied shall be designed, manufactured, tested & erected as per the latest revision of Indian Electricity Rules, Statutory requirements of the Govt. of India, Govt. of West Bengal, Safety codes and Technical Rules/Norms/Guidelines QUALITY SYSTEM, INSPECTION & TESTING Quality System, Inspection & Test of Plant/ Equipment shall be as per the chapter GS-05 of General Technical Specification. 01.14 01.14.01 CAPABILITY OF THE TENDERER The Tenderer shall be capable to design, engineer, procure, supply, manufacture/ fabricate, erect and commission the specified equipment within the specified delivery period indicated in this specification. In this regard the Tenderer shall submit a list of qualified engineers for design and engineering, various manufacturing facilities, man-power availability, testing facilities, erection facilities, etc. to enable the Purchaser / Consultant to assess the capability of the Tenderer. The Tenderer shall also submit along-with his offer a statement of similar job executed by them during the last ten years which shall include brief system detail, name of key persons involved with design and engineering, capacity of the plant, location, date of initial operation/ status, clients name, order value, clients performance certificate etc LANGUAGE AND UNIT All technical details, dimension, weight and quantities shall be in metric units. All drawings, data sheets, name plates of equipment, material test certificates, equipment performance test results, etc., shall be in English language.
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01.16 01.16.01 a)
SAFETY Safety Regulations The Tenderer shall comply with the relevant Safety Rules and Regulations applicable in the state but not limited to the following: b) c) State Factory Rules/Acts Indian Electricity Rules/Acts Indian Explosive Manuals/Acts Carbide of calcium Rules/Acts Static and Mobile Pressure Vessels (Unfired) Rules / Acts Fire protection manual issued by Tariff Advisory Committee (India) Pollution Control Regulations / Acts
Strict attention shall be paid to all statutory regulations and safety rules for prevention of accidents. The safety posters/regulation for prevention of accidents shall be displayed by the Tenderer at appropriate places. Notices and warning signs shall be displayed for all sources of dangers. The Tenderer is not permitted to construct any temporary road crossing on the rail tracks for the sake of their convenience at work site. When the work is carried-out at night or in the obscure day light, adequate arrangements for flood lighting in the working area shall be made by the Tenderer at his own cost and got approved by the Purchaser. All handling / transport and rigging equipment including lifting tools and tackles shall be checked at regular intervals and kept in good and safe working condition. A register is to be maintained regarding the results of periodical tests/checks and other particulars in respect of each and every such equipment. The Tenderer must take sufficient care in moving his construction plant and equipment from one place to another, so that those do not cause any damage to the property of the Purchaser or obstruct construction activities of other Tenderers.
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h)
The successful Tenderer shall depute a full time safety engineer who will exclusively look after all the jobs pertaining to safety at site and keep close liaison with Purchaser / Consultant. He will be responsible for maintaining safe working condition at site, promoting safety consciousness among the workmen and reporting to concerned authorities in case of accident /dangerous occurrences. A protocol shall be prepared in association with the concerned agencies of Purchaser / Consultant before execution of work in hazardous areas like Working at height Storage of inflammable materials Danger of electric shocks Explosion risks Excavations more than 2m deep, etc.
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01.16.02 a)
Safety while working with Explosives Explosives shall not be used on the work site by the successful Tenderer without the written permission of the Purchaser and that too only in the manner and to the extent to which it has been prescribed. Explosives shall be stored in special premises approved by the Purchaser and at the cost of the successful Tenderer who shall be liable for all damages, loss or injury to any person or property and shall be responsible for complying with all statutory obligations in these respects. Safety Appliances The successful Tenderer shall provide the safety appliances conforming to the relevant Indian Standards to all their workmen and supervisors engaged by them as well as by the subcontractors. The Tenderer shall ensure that all the workmen and supervisors, are using the safety appliances regularly during work at site. Any violation in safety provisions or failure to maintain safe working conditions will lead to serious penalty on the Tenderer and finally may lead to termination of the Contract.
b)
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c)
The workmen of the Tenderer deployed for construction and erection in hazardous areas shall be provided with personnel protective safety appliances of special nature suitable for hazardous working conditions. Safety during Construction/ Execution The successful Tenderer shall be responsible for the safety of his workmen and employees. The successful Tenderer shall ensure that safety practices are followed so as to prevent personal injury to his workmen and also to other persons working/passing by in that area. The successful Tenderer shall ensure that in case of any accident, the same are reported without delay to the Purchaser/Statutory Authorities as per Rules. In case of any injury/accident, the Tenderer shall bear all the expenditure for medical treatment and shall pay the compensation in case of permanent disability or death. The Tenderer shall ensure that all personnel employed do not stray into other areas. Any injury caused due to this shall be the sole responsibility of the Tenderer. The Tenderer shall ensure that skilled labours required for specific works have necessary trade certificates and adequate experience of the job. This is likely to be checked by the Purchaser. The concerned operators, mechanics, electricians, fitters, riggers, etc. must be fully conversant with the hazards associated in operation/maintenance of their relevant equipment. Safe Work Platforms The successful Tenderer shall use strong and secured planks and boards of the right sizes. These planks shall be painted at the edges brightly to warn the workers for any misuse (usually zebra paint) Barricades should be put-up to prevent them from falling. The successful Tenderers shall make sure that scaffoldings are erected by trained scaffolders. Supervisors must inspect scaffoldings once every week.
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01.16.06 a) b) c) d) 01.16.07 a) b) c) 01.16.08 a) b) c) 01.16.09 a) b) c) 01.16.10 a)
Falling Objects and Debris No loose materials which can fall down should be kept on the working platforms. Overhead shelters should be provided to minimize damage from falling objects. Strong nets to be provided to catch these objects or debris. Nets must envelop all sides of the building / construction area. Personal Safety Equipment Workers must wear approved safety helmets and shoes. For those working in high places safety belts shall be provided. The safety belts must be attached to strong anchorage points. Operating Construction Machine The successful Tenderers shall make sure that those operating the construction machinery are well trained for their jobs. The keys of such machinery shall be kept with the authorized persons. The keys shall be removed after use of the machine. Safe Electrical Installations The successful Tenderer shall use approved types of electrical sockets and plugs. Proper insulators for all electrical wirings shall be provided. Wiring must not be allowed to lie on the floor or on the ground. Safety in Designing of Equipment All machinery and equipment must be equipped with safety devices. The safety provisions shall conform to the recognized standards, safety codes and statutes.
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b)
All safety measures as required to be adopted as per the statutory regulations and the safety rules of the plant shall be strictly followed by the successful Tenderer during the execution. MATERIAL Materials used for the manufacture/ fabrication of the equipment and its components shall be new & best of its kind and shall be strictly as per the drawings/ data / documents approved by Purchaser / Consultant. All the materials used for manufacture/ fabrication shall conform to latest edition of relevant Indian Standards or in case of nonavailability of Indian Standards the materials shall conform to any International Standards subject to prior approval of the Purchaser / Consultant. All materials used shall be free from surface defects, rusts, cracks and deformation. Only tested materials shall be used for fabrication/ manufacture, painting of equipment and its various components offered. Necessary test certificates shall be submitted to Purchaser / Consultant for various materials including bolts, rivets, electrodes, paints, etc. All these test certificates shall comply with appropriate standards. Construction power & water shall be made available by the Purchaser at a single point. WORKMANSHIP Quality of workmanship shall be in accordance with modern engineering practice. Any defects /deficiencies pointed out by the Purchasers engineers / Consultant during or after commissioning shall be made good as directed without any extra cost to Purchaser. Equipment and its various components shall be generally of welded steel construction unless specified otherwise. The finish of the components shall be first class in all respects. During various stages of manufacture/ fabrication and erection, the Tenderer shall ensure that the various dimensions of the equipment and its components conform to the equipment/ erection drawings approved by Purchaser / Consultant.
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Any fabrication work shall not impair the quality of the material. Wherever applicable mechanized equipments, such as plate bending machine, plate cutting machine, pipe-handling machine, thread milling machine and riveting machines, etc. shall be used. Complete assembly shall be fabricated/ manufactured with minimum number of welded joints and the seams of the weld shall be dispositioned in such a way that no two seams come in one line. All the pipe connections to the equipment shall be truly perpendicular/ exactly to the angle shown in the fabrication drawing. All the flanges shall be welded so as their surfaces are truly perpendicular to the respective pipe axes. SHIPPING PROTECTION All equipment shall be packed properly for prevention of damage during transit and deterioration during storage
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COMPLETENESS Any items of work, supply and services which has not been specifically mentioned but is required for completing the design, engineering, manufacture, supply erection, testing and commissioning of the Tertiary Treatment Plant for tertiary treatment of the treated effluent from the new Effluent Treatment Plant of CRM III shall be under the Tenderers scope for work without any extra cost. The tenderer shall clearly indicate such additional requirement, if any, with adequate justification.
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OFFICE FURNISHING The successful tenderer shall supply fully furnished office for water complex Incharge, other officers, Almirahs and other racks for keeping official documents, spares etc., furniture for operators room, control room, MCC room, different premises, etc. The tenderer shall submit exhaustive list along with the offer. The furnishings shall be of reputed make with latest design.
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DELIVERY SCHEDULE The complete tertiary treatment of the treated effluent from the new Effluent Treatment Plant of CRM III duly erected & tested and
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complete in all respects shall be ready for commissioning within 15 months from the date of LOI. 01.23.02 The Tenderer shall include in his offer a firm time-bound schedule giving duration of various activities viz. design & engineering, equipment manufacture including procurement of brought-outs, delivery, structural erection, equipment erection, testing and commissioning. The above schedule shall be supported by Bar chart. The schedules shall be adhered to strictly and following feed back information shall be furnished within the time as stipulated below: Submission of General arrangement and Basic Engineering drawings shall commence after 4 weeks from the date of signing of contract. Submission of detailed drgs. for approval shall commence after 8 weeks from the date of signing of contract. Penalties, liquidated damages, force majeure and other clauses related to delivery and erection schedule shall be governed by the Standard Bidding Documents (SBD) of SAIL. 01.24 01.24.01 .01 GENERAL INSTRUCTIONS ON DESIGN AND SUPPLY Plan and Equipment General The selection, design and manufacture/ fabrication of plan and equipment shall be suitable for the intended service and duty conditions and ensure maximum interchangeability of components and least maintenance. Each unit shall be complete in all respects. In the interest of Standardization, the Purchaser reserves the right of selecting a particular make of equipment / component and the Contractor shall supply the items according to acceptable make or make approved by the Purchaser. All the equipment, technological structures, pipes, valves, fittings, etc shall be subjected to inspection and testing as per accepted national or international standards and practices. All the components shall be subjected to inspection and testing as per standard practices of the manufacturer prior to offering them for
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inspection by the Purchaser / his authorized representative. All equipment shall be assembled at manufacturers works on a suitable bed. Alignment of all assemblies, levels and centre lines shall be measured and recorded. Any errors of deviations form the approved drawings shall be corrected. All equipment shall be complete with approved safety devices, wherever a potential hazard to personnel and or equipment exists. There shall be adequate provision for safe access of personnel to and around the equipment for operational and maintenance functions. All equipment shall be complete in all respects including all accessories essential for proper installation, operation and maintenance irrespective of whether such items are specifically mentioned in the specifications or not. Machinery and equipment shall be designed to have good maintainability. All working parts shall be arranged for convenience of operation, inspection, lubrication and ease of repair and replacement of parts and sub-assemblies with minimum downtime. Suitable working platform, walkways, ladders, lifting tackles and tools required for the above shall be provided. The fabrication and assembly areas shall be kept clean and free from contamination. During assembly of major components, a polythene covering shall be maintained in position to prevent ingress of dirt, grease, etc from overhead cranes or other equipment. During fabrication, equipment, pipes, etc shall be kept sealed to the extent possible to avoid entry of foreign matter and contamination by dirt. All equipment shall be visually inspected in the presence of an inspector immediately before closure. A system of physical identification and accountability shall be used to account for all tools, test equipment, shipping blanks and other items used during assembly to obviate the possibility of their being left inside vessels or equipment.
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.02
Design Basis Machinery and machinery components shall be compatible with the operating conditions in the plant atmospheric conditions at Bokaro Steel Plant. Standardization and unification shall be carried out to the maximum extent for the various sub-assemblies constituting the machinery. Items shall be designed such that they can be dismantled quickly without disturbing the installation of the neighboring units. Modular construction shall be used, wherever possible. All equipment shall be designed for high productivity, maintainability and reliability of operation. Components shall be designed to meet the specified mechanical properties like hardness, strength, rigidity, wear resistance, heat resistance, resistance to vibrations, etc. Seats for elements of machinery on fabricated frame shall have machined surfaces. Alternatively, suitable machined packing shall be used for obtaining accurate alignment of the mechanism. All loose packing shall be tack welded after alignment. All rotating part shall be properly balanced to avoid run-out, vibration, misalignment and increased load on bearing. Depending upon the requirement, arrangement shall be made for static, dynamic or biplane balancing. Due care shall be taken to avoid stress concentration by properly rounding off sharp comers, providing suitable radii and specifying suitable methods of manufacture. The design of components shall be carried out based on yield strength and adequate factor of safety. The design of mechanical components shall take into consideration the maximum starting torque delivered by motors or the maximum braking torque, whichever is greater.
01.24.02 .01
Manufacturing and Fabrication General All forgings, castings and structural materials shall conform to the relevant BIS international standards.
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Special non-ferrous materials required for manufacturing parts subject to heavy pressure, severe working conditions, and/or requiring high tensile strength, toughness and resistance to corrosion shall be used. .02 Welded Joints While designing welded joints for items subject to dynamic loading and in other high strength joints, attention shall be paid to the following points: Intersection of welds shall be avoided. Edge preparation for butt welding shall be designed with a view of using minimum weld metal so as to minimize lock up stresses. Deep penetration fillet welds shall be used in preference to normal fillet welds. Where welded attachments in heavily stressed zones are unavoidable, the weld profile shall merge smoothly into the parent metal. Intermittent butt welds shall be used to resist wear except in positions subject to dynamic, repetitive and ultimate stresses. Sufficient surface convexity shall be provided by reinforcement to ensure full cross-sectional area at the joint. The dimensions of welded joints shall be such as to permit complete fusion through-out the thickness of the sections being welded. Joint positioning shall foresee easy access for welding. Machinery part made up from plates or structural shapes by welding shall be welded electrically by the most modern practice as described in the BIS handbook of metal arc welding or the welding handbook of the American welding Society. Weldments requiring dimensional stability shall be stress relived prior to machining. All welding shall be shown in drawing according relevant international standards.
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Soldering and brazing for joining non-ferrous metals shall be properly fused and sealed to withstand designed stresses. Correct and accurate machining of all parts shall be carried-out according to desired dimensions and surface finish conforming to ISO/T-468. All sliding parts as per tolerance requirements shall be properly ground to ensure a continuous oil film and minimum friction. High quality surface finish and close tolerance shall be obtained, wherever required, by suitable machining procedures. The selection of tolerance zones shall conform to IS : 2709. The permissible machining variations in dimensions without specified tolerance shall conform to IS:2102 or relevant ISO standards. Bearings All parts subject to reciprocal motion and rubbing against other parts shall be provided with bronze or other suitable liners to minimize wear. The liners shall conform to IS : 318 / International standards capable of being adjusted to compensate for wear. All rotating parts supported on frames shall have proper bearings, depending upon speed, torque, load conditions, etc.
.03
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Machine Frames and Bases All machine bases shall be designed for maximum strength and rigidity consistent with good design. Base plates shall be of welded steel construction. Those shall be designed with sufficient depth and stiffness to ensure rigidity of assembly of motor and reducer. If bases are made of two or more parts to make up height, locating pins shall be provided. Machined bolts shall be used in drilled and reamed holes for connecting the parts. The machine frames shall have suitable I bolt or hook in requisite numbers for lifting purpose during erection and maintenance.
.05
Lubrication The Tenderer shall provide for proper lubrication arrangement for all moving parts of the equipment supplied. The lubrication arrangement can have grease lubrication or oil lubrication as the
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case may be. The selection / design and construction shall be suitable in every way for the service intended and shall be oriented towards maximizing interchangeability of components and minimizing maintenance. 01.24.03 Optimization of Indian Supplies & Services The Contractor shall make all efforts to optimize the supplies and services from Indian sources and shall, however, ensure that the performance of the plant and equipment are achieved as envisaged in the Technical Specifications. 01.25 TRAINING AND SUPERVISION The successful Tenderer shall impart on-site training to the Purchasers personnel in operation and maintenance of the plant / unit during and after commissioning for a period of two month at Bokaro Steel Plant (BSL). Training shall be imparted by experts and shall be in batches. Tenderer shall also arrange plant visits for minimum two plants in India and abroad where the Tenderer has supplied such facility of similar capacity. Schedule and area of training shall be as mutually agreed between Purchaser/ Consultant and Tenderer. The tenderer shall bear all expenses on account of this training and make all arrangements The successful Tenderer shall also supervise the operation and maintenance of the plant / unit during commissioning and after successful commissioning and handing over the plant to buyer for a minimum period of six months.
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02.00
SCOPE OF WORK AND BATTERY LIMIT The scope of work of the Tenderer covers design, engineering, manufacture/ fabrication, shop painting, shop testing, packing, transportation, transit insurance, unloading, storage at site, watch and ward, handling at site, erection, site testing, final painting and commissioning of entire civil work, steel structural work, mechanical equipment, Piping with valves and fittings, handling & hoisting equipment, associated electrics, instrumentation & control, illumination, telecommunication, air conditioning & ventilation etc in accordance with the requirement of the proposed plant complete with interconnecting pipes and cables of the water system for the proposed Tertiary Treatment Plant Complex as per the technical specification outlined hereinafter on turnkey basis and the specifications laid down in various chapters in this document and also as per General Technical Specification (GS-02). The scope of work shall include the following activities:
i)
Supply of all technical literature, drawings & documents, general arrangement drawings, assembly & sub assembly drawings of all the plant & equipment, construction & erection & as-built drawings, operation & maintenance manuals, etc. Submission of all design calculations, data sheets for various equipments, pipeline sizing calculation and calculation for sizing of various sub systems and integrated systems for approval of Purchaser/ Consultant and finalizing the same as per approval of Purchaser/ Consultant. Tertiary Treatment system shall in general comprise of the following facilities:a) Tertiary treatment of the treated effluent from the new Effluent Treatment Plant of CRM III and Cooling Towers blow down from different technological unit of CRM III b) c) d) e) Treatment of RO reject & under flow from HRSCC (Water Supply complex) Chemical dosing facilities Sludge dewatering plant Zero Liquid discharge plant
ii)
iii)
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f) g) h) i) j) k) l) m) n) o) p) q) r) s) t)
BOD Plant RCC Collection sumps for Blow down (from different Cooling Tower) and Common Collection sump, Pumping system at different sumps as indicated elsewhere. Water supply system for air conditioning & ventilation of the tertiary treatment complex. Make-Up Water system Drinking water system Water based fire water system Area drainage /storm water drainage system Fecal sewer disposal from toilets Other miscellaneous water systems. Associated electrics and Instrumentation/Automation Material handling facilities. Civil and structural work Air-conditioning and ventilation system RCC road to connect interconnecting road from Network of Road in the tertiary treatment complex interconnecting different buildings/ units and connection to nearest Road. The approach road for the proposed tertiary treatment plant shall be extended by providing a railway level crossing at one side, approach road to the water supply system shall be extended by providing a railway level crossing at other side and the approach road for the Nitrogen storage tanks also shall be extended up to tertiary treatment plant.
u)
v) w)
Site leveling to terrace level, cutting of trees, bushes etc including any approval required from statutory authorities. Taking tapping steam header located at W-279 and extending the pipe to ZLD plant.
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iv) v)
Supply of commissioning spares & consumables Tenderer shall submit the tentative list of two years spares along with the offer. However they shall submit final list of two years operation and maintenance spares during detailed engineering along with technical specification and catalogues. Supply of special tools, tackles for construction, erection, operation and repair & maintenance of the plant & equipment. All necessary connections for hook up with Purchasers system at battery limits. Supply of erection, testing & commissioning materials. Network flushing fluids, chemicals & consumables. First fill of oils, lubricants, filter media, resins, chemical reagents and other consumables. Participation in design conference with the Purchaser & Consultant as and when called for. Fulfillment of guarantee of all plant & equipment, sub systems & integrated system of water supply facilities covering various cooling water system. Pipeline structural stockades, bridges, R.C.C pedestals for overhead pipelines. Pipeline supports, thrust blocks / anchor blocks, etc. Inspection and performance testing of individual equipment and system as a whole. Tertiary treatment System shall be complete in all respects and any equipment or material not specifically mentioned in this specification, but required for safe, efficient & smooth operation and guaranteed performance of the plant will be deemed to be included under the scope of work of the Tenderer. Tertiary treatment plant building / Sludge dewatering plant/ Zero discharge plant building/ Chemical house comprising pump sets, filters, treatment plant, handling facilities, valves, pipe & fitting, along with associated electrics, instruments, material handling, Air
vi)
vii)
viii) ix) x)
xi)
xii)
xiii)
xiv) xv)
xvi)
02.01
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conditioning/ Ventilation system for each buildings and control room / MCC room. 02.02 Filter house with back wash water tank & waste water tank comprising filters, handling equipment, valves, pipe & fitting along with associated electrics, instruments. Water based fire fighting system as per TAC norms comprising valves, pipe & fitting, along with requisite nos. of Yard hydrants and landing valves, piping network etc. Tentative area layout is shown in the drawing enclosed with this document. The Tenderer shall prepare and submit along with his offer detail layout drawing, P & I diagram and duly dimensioned general arrangement drawings of each unit of water supply complex taking due consideration of maintenance space and approach roads. Tenderer shall furnish comprehensive mechanical engineering, civil engineering, electrical & Instrumentation engineering and structural engineering design drawings for pump houses, sumps & reservoir, over head tanks, filter house, R O based tertiary treatment plant, zero liquid discharge plant, electrical rooms, pipe trestles, area drainage network, sewerage system etc. for approval. Pumps, pressure filters, under slung cranes, chemical dosing system, Filtration plant, R O based tertiary treatment plant, sludge dewatering plant, zero liquid discharge plant, valves, pipes, fittings and accessories along with associated electrics, instrumentations, PLC and other equipment selected for the project shall conform to relevant Indian or other reputed international standards with regard to materials of construction, dimensions, manufacture, testing and acceptance criteria. Materials of construction of various components shall be decided in due consideration of the nature of fluid being handled. Makes of all bought-out items shall be as per the preferred makes indicated elsewhere in this document. Warranty and Guarantee The Contractor shall warrant for satisfactory performance of the equipment and material for a period of 18 months from the date of the last dispatch or 12 months from the date of commissioning of
02.03
02.04
02.05
02.06
02.07
02.08
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equipment whichever is later. The Contractor shall replace/repair within seven days of receiving the notice at his own cost any defective parts in the equipment of his own manufacture or those of his sub-contractors. The Contractor shall guarantee various performance parameters as specified in various chapters of this document. 02.09 BATTERY LIMIT The Tenderer is to collect treated Effluent from new ETP of CRM III, Blow down water from different Cooling Towers (7 nos.) located at different places as indicated in the layout Drawing No. MEC/11/40/E24F/TS/WS/042A/0001 (R0), RO reject from water supply complex of CRM III, underflow from HRSCC (Water Supply Complex), make-up water, drinking water, fire water from the TOPs and treat the water to make it suitable for reuse as makeup water to circulation system and supply the treated water as make-up at the TOP as indicated below: 02.09.01 Treated effluent from the new Effluent Treatment Plant of CRM III Tenderer shall plan to extend Treated effluent from the new Effluent Treatment Plant of CRM III which will be available at @ of 40 m3/h at a pressure of approx. 0.6 Kg/cm at a co-ordinate X+2547.00/Y+8842.00 at 0.3 m above area ground level for further treatment into BOD Plant. The pipe size is DN 80. However, Coordinates indicated are tentative and shall be finalized during engg. Sl. No. 1 2 Flow Qty. (m/hr) Effluent collection 35 sump BOD Treated 35 water sump Unit Description Coordinates Capacity Sump (m) of
X+2547, 70 Y+8842 To be 70 decided during DE
Tenderer shall extend the pipe from TOP with an isolation valve to a collection sump and from there it will be pumped to BOD Plant for necessary BOD treatment. The treated water from the BOD Plant shall be collected into treated water sump. The water from the
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treated water sump will be pumped to Collection sump of capacity 200 m located in the Tertiary Treatment Plant area. (Refer Scheme drawing no. MEC/11/40/E24F/TS/WS/042A/0002 (R 0). The treated water will be pumped to Water complex as makeup and the reject water will be pumped to ZLD Plant. The treated water pipeline shall be extended to sump of the cooling tower / sump located in circulating water complex. Additionally bypass pipeline for discharge of the RO reject shall be kept upto the sand bed located in water complex to meet any eventuality incase of stoppage of ZLD plant . 02.09.02 Blow Down from Cooling Towers of different Technological Unit of CRM III, Tenderer shall plan to collect the Blow down water from the Cooling Towers of different Chiller Plant of Technological unit of CRM III. The minimum Blow Down sump capacity shall be as indicated. Sl. No. 1 2 3 4 5 6 7 Flow Qty. (m/hr) PLTCM & HDGL- 8.5 ECL HRCC 1.5 BAF & SPM ROLL SHOP Tension Leveler CAS Hydrogen generation Plant 3.5 1.5 2.0 4.5 2.0 Unit Description Approx Coordinates X+3068, Y+8651 X+3060, Y+8503 X+3016, Y+8263 X+3018, Y+8101 X+2828, Y+8817 X+2650, Y+8505 Capacity of BD Sump (m) 20 5 10 5 5 10 5
Tenderer shall extend the blowdown pipeline from tapping point with an isolation valve to the RCC blowdown Sumps. The blow down water will be collected in the sump of minimum capacity mentioned above. The collected blow down water will be pumped into a common collection sump of minimum capacity 200 m located in the Tertiary Treatment Plant area. The blow down will be pumped into the common collection sump through a common header of size
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DN150. (Please refer Scheme MEC/11/40/E24F/TS/WS/042A/0002 (R 0)).
drawing
no.
The treated water will be pumped to Water complex to be used as makeup and the reject water will be pumped to ZLD Plant. 02.09.03 RO reject & underflow of HRSCC (Water Supply Complex) Tenderer shall plan to pump the RO reject & underflow of HRSCC from Water Supply Complex of CRM III to the proposed Zero Liquid Discharge plant. The quantity of the reject water / underflow is as indicated below at indicated TOP (approximate coordinates indicated below): Sl. No. 1 2 Flow Qty. (m/hr) RO reject (Water 11 Supply Complex) Underflow from 5 HRSCC (Water Supply Complex) Unit Description Coordinates Capacity Sump (m) X+2510, Y+8726 X+2516, Y+8726 25 10 of
Tenderer shall extend the pipeline from tapping point with an isolation valve to the proposed systems for necessary treatment. The RO reject will be directly pumped into the Zero Liquid Discharge plant with separate network of piping system. The collected underflow from existing HRSCC will be pumped into common collection pump through the common pipe header of size DN150. (Please refer Scheme drawing no. MEC/11/40/E24F/TS/WS/042A/0002 (R 0). 02.09.04 INDUSTRIAL MAKE-UP WATER Tenderer shall plan to extend Industrial quality make-up water for the said plant, if required, from the proposed industrial make-up water network which will be made available to the successful Tenderer at only one point at an approx. co-ordinate i.e. X+2585.259/ Y+8749.467 at an elevation of approx. 8m above area ground level and at a pressure of approx. 1.0 Kg/cm. Coordinates are tentative and shall be finalized during engg.). Tenderer will extend the same from tapping point with an isolation valve to their proposed systems and the Tenderer will indicate the
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quantity of make-up water requirement, pipe size, end connection, MOC of pipeline, etc. from the tapping point. 02.09.05 DRINKING WATER Tenderer shall plan to extend drinking water for the said plant from the proposed drinking water network which will be made available to the successful Tenderer at only one point at an approx. coordinate i.e. X+2585.259/ Y+8749.467 at an elevation of approx. 8m above area ground level and at a pressure of approx. 1.0 Kg/cm. Coordinates are tentative and shall be finalized during engg.). Tenderer will extend the same from tapping point with an isolation valve in a valve pit to their proposed systems for the entire need and the Tenderer will indicate the quantity of drinking water requirement, pipe size, end connection, MOC of pipeline, etc. from the tapping point. Online booster will not be accepted. If pressure of drinking water is felt inadequate, a drinking water sump with pumps and piping, valves, valve pits etc will be provided by the successful Tenderer. The details and specification for drinking water system shall be as per GTS. 02.09.04 FIRE WATER SYSTEM Tenderer shall plan to extend fire fighting water with an isolation valve for the entire area (inside & outside up to peripheral area of the proposed building) from the existing fire water network of the integrated steel plant which will be made available to the successful Tenderer at only one point at an approx. co-ordinate i.e. X+2585.259/ Y+8749.467 at an elevation of approx. 8m above area ground level and at a pressure of approx. 7.0 Kg/cm. (Coordinates shall be finalized during engg.). Tenderer will indicate pipe size, end connection, MOC of pipeline, etc. at the tap-off point. TREATED WATER FOR REUSE AS MAKE-UP TO COOLING TOWER The Tenderer shall supply treated water as make-up for cooling tower of CRM-III. Treated water pipeline shall be laid from the proposed Tertiary treatment plant upto the existing cold water sump of the new CRM-III at an approx. co-ordinate i.e. X+2569.889/ Y+8735.152. TOP of the cold water sump is approx. 4 m above area ground level. Tenderer will indicate pipe size, end connection, MOC of pipeline, etc. at the supply point.
02.09.05
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03.00
TECHNICAL SPECIFICATION AND DESCRIPTION OF WORK It is envisaged to provide a Tertiary treatment plant of to treat the cooling tower blowdown water, treated water from proposed ETP of CRM III, RO reject and underflow of water complex . It comprises of pre-treatment unit, Reverse Osmosis (RO) unit to obtain acceptable quality of make-up water for reuse in the plant with zero discharge concept along with sludge dewatering plant and Zero discharge plant. The RO reject and underflow from HRCC from existing Water Supply Complex of CRM III shall be directly pumped into the Zero discharge plant. Tenderer to provide collection sump for the inlet effluent and a BOD treatment plant of capacity 40 m3/h to treat the effluent received from the existing ETP. The treated water from the BOD plant is to be collected in a sump and pump into the common collection sump located in the Tertiary Treatment plant area. The treated water from BOD plant shall be pumped with separate piping system into the common collection sump located in the Tertiary Treatment Plant area. Tenderer shall also provide individual collection sump to collect blow down from Cooling Towers of different Technological units with separate pumping system to pump the collected water into the common collection sump located in the Tertiary Treatment plant area. Tenderer shall also provide collection sump for the underflow from existing HRSCC (located in Water Supply Complex of CRM III). All the collected water will be pumped to the common collection sump (located in tertiary treatment plant area) with a common pipe header of size DN150. The pipe header will be routed through pipe trestle. The pipe header will be laid underground from the coordinate X+2586/ Y+8750 upto the entry point of common collection at coordinate X+2569/ Y+8878. Please refer the scheme MEC/11/40/E24F/TS/WS/042A/0002 (R 0). drawing no.
Tenderer has to prepare layout for the treatment units based on available space and shall design supply, erect, commission and establish guaranteed performance parameters of the Tertiary treatment plant of new CRM Complex. The following pumping
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system / pumping stations and systems shall be provided as per following as covered in this specification:a) Extension of piping system for Effluent water from the existing Effluent treatment Plant TOP. b) Pumping & piping system for blow down from Cooling Towers of different Technological unit of CRM III. c) BOD Treatment plant for treating the effluent from the existing ETP. d) Individual Collection sump (at respective locations of different units) 10 nos. e) Common Collection sump (1 no.) f) VT pump details to be provided at different collection sumps : Sl. No. Unit Description Pump Capacity approx (m/hr) 10 Head (mWC)
2 3 4 5 6 7 8
PLTCM & HDGLECL BD transfer pump HRCC BD transfer pump BAF & SPM BD transfer pump ROLL SHOP BD transfer pump Tension Leveler BD transfer pump CAS BD transfer pump Hydrogen Generation Plant RO reject transfer pump (Water Supply Complex) Underflow transfer pump from HRSCC (Water
To be decided during DE To be decided during DE To be decided during DE To be decided during DE To be decided during DE To be decided during DE To be decided during DE To be decided during DE To be decided during DE
5 10 5 5 10 5 14
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10 11
Supply Complex) Effluent transfer pump to BOD plant BOD treated water transfer pump
40 40
To be decided during DE To be decided during DE
g) Primary treatment units comprising of: i) ii) iii) iv) v) vi) vii) viii) Equalization tank 1 no. Effluent feed pumps 2 Nos. (1W+1S) Flash Mixer 2 Nos. Solid Contact Clarifier Reactor - 1 No. Clarified water storage tank 1 No, Clarified water pumps 2 Nos. (1W+1S) Ozone Treatment NaOCl Dosing System & Lime, Dolomite, FeCl3, Polymer dosing facilities 1 complete set as reqd. with chemical dosing tank (2 Nos.) and dosing pumps (2 Nos. - 1W+1S) for type of chemicals Sludge dewatering plant (sludge sump, Sludge Sump Blower, sludge transfer pumps, centrifuge, Ploymer Dosing System) 1 set complete
ix)
h) Tertiary treatment units comprising of: i) ii) iii) iv) v) vi) vii) viii) ix) x) xi) xii) xiii) Multigrade filters - 3 Nos. (2W+1S) Filter Air blowers 2 Nos. (1W+1S) Backwash water overhead tank - 1 no. Advanced membrane technology: filtration UF Permeate storage Tank (1No) UF Back Flush pump 2 Nos (1W+1S) Required Chemical cleaning system for UF Cartridge Filter feed Pumps 3 Nos (2W+1S) Cartridge filters 3 Nos. High pressure pumps 3 Nos. (2W+1S) RO modules 2 trains Chemical dosing facilities 1 complete set as reqd. with Chemical dosing tank (2 No.) and dosing pumps (2 Nos. - 1W+1S) for type of chemicals (Acid, SBS & Anti-scalent) Chemical cleaning for RO and flushing facilities 1 set Permeate transfer pumps 2 Nos. (1W+1S)
xiv) xv)
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xvi)
pH correction system with static mixer
i) Zero Liquid discharge Plant comprising of: i) ii) Polymeric Heat Exchanger Type Mechanical Vapor Compressor system 1 complete set Chemical dosing tanks & pumps - 1 complete set as reqd. with Chemical dosing tank (1 No.) and dosing pumps (2 Nos. - 1W+1S) for type of chemicals
j) Pipe Tunnels / Pipe trestles for inter plant pipelines. k) Sanitary sewerage system for toilets / wash basins. l) Area drainage/ storm water drainage for the Tertiary Treatment Plant complex. m) The water supply complex will have roads with approach to each building. n) Supply of treated effluent as make-up to cooling tower upto the battery limit. o) Make-up, drinking, fire water system. p) Area leveling upto terrace level, cutting of trees, shifting of pipe (500T) and scraps within a lead of 8 km inside the plant. q) Dismantling of existing watch tower and provision of new watch tower 03.01 03.01.01 DESIGN CONSIDERATION RO based Tertiary treatment plant is proposed for the treatment of blow down water of various cooling towers , advanced treatment of treated effluent from the existing Effluent Treatment Plant of CRM III of Bokaro Steel Plant / SAIL for further reuse as make up to cooling tower of circulation system of CRM - III. The Tertiary treatment plant shall consist of pre-treatment plant to treat the incoming effluent to the quality as acceptable for the RO plant. The Tenderer shall, in general, give careful attention to pretreatment programme to protect the RO elements and in particular, the compatibility of various processes adopted. The design of the system shall be based on 25 percent degradation in the incoming
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effluent water quality indicated under enclosed Annexure. For details refer to GTS. 03.01.02 To satisfy the performance requirements, it will be imperative to consider both pressure and temperature effects and to size the RO trains accordingly within the limitations of the selected high pressure pump performance. The RO system shall be sized to produce the rated output and quality for the entire system for 15 years life and 3 years of the RO membrane and 5 year for UF Membrane. As such, initial operating pressure at any temperature shall be maintained at a minimum value to keep the membrane compaction rate within the design value. High pressure pumps shall be selected to permit inlet pressure adjustments to be made to compensate for membrane compaction and temperature variations. Tenderer shall also include necessary additional pre-treatment facilities for removal of any other specific constitutes which may be detected during subsequent detailed analyses of Treated effluent from the new Effluent Treatment Plant of CRM III and may cause membrane fouling. Tenderer shall include necessary oxidizing agent, as required and shall also consider addition of polymer for enhancement of settling and filtration and any subsequent treatment for removal of excess oxidants and COD etc. as required. Tenderer shall furnish adequate justification for adequacy of the pre-treatment for the R.O plant being offered by him. PROCESS DESCRIPTION The tertiary treatment plant shall have following stages of treatment scheme for satisfying the norms of treated water quality. Primary Treatment comprising of Equalization tank, Flash Mixer, Solid Contact Clarifier Reactor, sludge dewatering plant Tertiary Treatment comprising of Multi Grade Filter and Advanced membrane technology comprising of Ultra, reverse Osmosis. Zero Liquid discharge Plant Make-up clarified water, drinking water, fire fighting facilities Whereas basic pretreatment required for membrane separation process have been highlighted in this specification, the Tenderer shall, in general, give careful attention to pretreatment programme
03.01.03
03.01.04
03.02
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to protect the RO elements and in particular, the compatibility of various processes adopted. 03.02.01 Treated effluent from the new Effluent Treatment Plant of CRM III shall be collected into Equalization tank having retention time about 2 hours where Sodium Hypochlorite / suitable chemical shall be dosed. One tank in MSRL construction and two dosing pumps shall be provided for dosing Sodium Hypochlorite for pre-chlorination purposes i.e. to take care of BOD & COD present in effluent water. Effluent water from the tank shall be pumped by means of two pumps (one working and one standby) to the pre-treatment units i.e. in HRSCC, from where it will be collected in CWST and will be pumped by means of two pumps (one working and one standby) to Multi-Grade pressure Sand filters to remove the suspended matter from effluent water. Backwashing of the filters shall be done with the help of OHT. The waste back washed Waste water will be collected in waste collection pit and from where it will be pumped to flash mixer. FLASH MIXER The raw effluent from equalization tank shall be pumped to flash mixer unit, where Lime, Dolomite shall be added to increase the PH of effluent, for reduction in silica content of effluent and to enhance the settling of solid particles present in effluent. ACTIVATED CARBON FILTER (ACF): Either Na2So3 shall be dosed in the filtered water or Activated Carbon Filter (ACF) shall be provided for de-chlorination purpose and accordingly either one tank in FRP construction with agitator and two pumps shall be provided for Na2So3 dosing or one ACF along with all piping shall be provided. Back washing of ACF shall be done with the help of OHT and waste back washed water shall be used for dilution of RO reject. HIGH RATE SOLID CONTACT CLARIFIER (HRSCC) After Chemical reaction with the lime and dolomite lime effluent will enter under gravity to Ultra High Rate Solid contact clarifier where FeCl3 and Polyelectrolyte shall be dosed in the effluent. The incoming solids brought in contact with a solid layer near the bottom. The incoming solids rise and come in contact with solids in the sludge layer.
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This layer act as a blanket and the incoming solids agglomerate and remain enmeshed within this blanket. The clarified water rises upward while a distinct interface retains the solids below. The Solid contact clarifier has better hydraulic performance and has minimum retention time for effective solids removal. Clarifier mechanism provided for continuous mechanical removal of settle able solids. The sludge removal mechanism revolves slowly and scraps with settled solids at the bottom and clear effluent overflows into the peripheral launder. The sludge generated from HRSCC will be collected in sludge sump and wil be sent to Centrifuge for dewatering. Polymer dosing system need to be provided with dosing tanks and pumps. Overflow from the clarifier shall be passed through chlorine contact chamber after pH correction by acid in upstream channel before collecting into the Clarified water tank. 03.02.02 TERTIARY TREATMENT MULTI GRADE FILTER (MGF) Clarified water will then pass through the MGF for removing suspended solids, turbidity etc. The arrested solids/ turbidity in the filter shall be removed by back washing. Treated effluent from the new Effluent Treatment Plant of CRM III will be pumped to Multimedia filter for removal of suspended solids. The Multi Grade Filter is made of MSRL vertical vessel. It is fitted with top inlet distributor and Strainer on Plate type of bottom collecting system. Externally this unit is fitted with frontal pipe work and auto control valves. The unit is isolated for backwash, when the pressure drop across the bed increases than specified limit (0.8 Kg/cm) or quality of filtered water deteriorates, whichever is earlier. DEWATERING SYSTEM Dewatering is a physical unit operation used to reduce the moisture
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content of sludge. Sludge generated from clarifier shall be dewatered by Centrifuge. The filtrate from Centrifuge shall be routed back under gravity to the Filter Back wash collection tank from where it will be pump to Flush Mixer. The filtered and sterilized water shall be dosed with hydrochloric acid for lowering pH so as to avoid the possibility of scale formation on membranes. The pH correction of feed water shall be followed by chemical treatment with Sodium Bi-sulphite to remove any free residual chlorine it any and anti-scalant to avoid scaling of membrane. Acid SBS and Anti-scalant dosing systems shall consist of acid day tank and SBA and AS Mix tanks respectively and separate dosing pumps for each system. Further, a bulk acid storage tank and two unloading pumps shall be provided for handling of acid. 03.02.03 ADVANCED MEMBRANE TECHNOLOGY The treatment system for effluent water shall comprise two Two train of UF and Membrane trains of latest technology. The RO system shall be sized to produce the rated output and quality for the entire life of the system 15 years and UF membrane (5 years) and RO Membrane (3years). As such, initial operating pressure at any temperature shall be maintained at a minimum value to keep the membrane compaction rate within the design value. High pressure pumps shall be selected to permit inlet pressure adjustments to be made to compensate for membrane compaction and temperature variations. The pre-treated filtered water will be passed through basket type strainer & then through the filtration skid. For the removal of colloidal suspended solids, colloidal solids that may be present in the water, a skid mounted, automatically operated Filtration system shall be provided. Removing of solids from the water will help in reducing the COD, BOD content in the water. The reject / Waste generated from the Ultra filtration shall be taken back into the Filter back wash collection sump and from where it will be pumped inlet of Flash mixer Tank
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This system will have the facility of automatic valves provided on the backwash & reject line to facilitate on-line backwashing. This function shall be controlled and monitored by PLC operation and hence avoid any manual operation or supervision. ULTRA FILTRATION MEMBRANES Membrane filtration module shall be used for the removal of colloidal matters, suspended solids & pretreatment to reverse osmosis system. It also helps in removing COD, BOD to some extent due to separation of solids. . REVERSE OSMOSIS SYSTEM Pretreated water after adjustment of pH and chemical conditioning shall be pumped by high pressure pumps (Two working pump and two standby pump) into reverse osmosis train. The permeate from pressure tubes of R.O. blocks shall be combined and shall flow to the Permeate water storage tank. Provision shall be made for flushing of the system automatically after each shutdown so as to prevent the precipitation of sparingly soluble materials on the membrane surface during periods of shutdown. PH of the permeate will be corrected by caustic soda. The alkali dosing system shall consist of one alkali preparation tank, one alkali day tank and two alkali metering pump. Alkali preparation tank shall be fitted with agitator for making solution using flakes. Dosing of SBS and anti scalant in the RO Feed is to be done to make sure that the Feed Water free from Chlorine and Scaling tendency on the Membranes in controlled within the limits. The system comprises of Two dosing pump and two solution tank. Micron Cartridge Filter to be provided which shall remove fine colloidal suspended impurities, which have escaped from upstream units. The unit shall reject fine solids upto 5 , which if carried over can clog the RO membrane. The unit shall be fitted with PP wound cartridge, which shall have more dirt holding capacity compared to other standard type of cartridges. The RO system shall comprise of R.O. membranes housed in FRP Pressure Vessels. All interconnecting low-pressure shall be Extra Strong u-PVC and high pressure shall be Stainless Steel SS316.
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Necessary instrumentation to be provided to monitor the operation of the system. Dedicated Chemical Cleaning System comprising of a Chemical preparation tank, a Centrifugal Pump in SS 316 Construction and a cartridge filter unit (CSRL) shall be provided. AUTOMATION PHILOSOPHY: The Cross flow Filtration system will have automatic operation. Necessary tripping facilities shall be provided through PLC for safe operation of the system. When the system trips, there will be visual display in the panel and also annunciation to this effect. The R.O system will be manually operated. Since cleaning to the membrane system requires intermittently, manual operation system provided for cleaning of both filtration as well as RO Systems. EQUIPMENT SPECIFICATION The proposed reverse osmosis plant shall be housed in a building. The building shall house multi-media filters, cartridge filters, highpressure pumps, RO modules, various chemical dosing facilities, Permeate water pumps, chemical cleaning and flushing facilities. The contractor shall plan the permeate tank outside the RO plant building. The building shall be provided suitable material handling and ventilation facilities. Provision for storage of all chemicals for meeting at least one month requirement shall be kept. ULTRA VIOLET STERILIZER Water from multi-media filters, Activated carbon filter shall be passed through ultraviolet sterilizer for disinfection. The ultraviolet radiation of 200-290 nanometers shall be generated by the mercury vapor arc tube. The radiation chamber shall be of 304 SS construction and wetted parts shall be of SS material. A control box shall be provided containing electrical power supply for the UV tube including switch, time totaliser and lamp-on indication. The design shall ensure full rated life of the lamp. Electrical components shall be isolated from the water stream to ensure safety. The lamp temperature shall be maintained thermostatically. Water stream shall not be heated with any appreciable rise in temperature in the process of disinfection through UV radiation.
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Design shall ensure easy accessibility to components for maintenance. The contractor shall indicate nature and frequency of routine maintenance of the UV sterilizer for its continued reliable use. SBS DOSING Two dosing tank in MSRL construction will be provided along with SS316 agitator for dosing of SBS in the feed to the cartridge filter. The diaphragm type dosing pump is a Auto stock adjustment variable discharge pump. The pumps are calibrated to dose a pre-set quantity of the chemical. Anti-Scalant DOSING Two dosing tank in MSRL construction will be provided along with SS 316 agitator for dosing of AS in the feed to the cartridge filter. The diaphragm type dosing pump is a Auto stock adjustment variable discharge pump. The pumps are calibrated to dose a pre-set quantity of the chemical. HIGH PRESSURE PUMPS Pumps will be mounted on the respective RO skid and reserve pump shall be supplied which will also be mounted on RO skid. R.O. TRAINS (BLOCKS) The R.O. train shall be installed having capacity to meet the required through-put. RO train shall be equipped with valves, piping work, flushing and cleaning connections, instrumentation and control console. R.O. train shall be an integrated assembly of high strength fiber glass reinforced epoxy thermally cured pressure tubes housing the R.O. membrane elements, feed, product and concentrate piping, all mounted on a high-strength steel structure. RO train shall receive high pressure feed water through the control valve of Globe type at dischange of each High Pressure pump and in Reject discharge of each RO Skid which will be preset to a specific operating pressure to maintain design permeate flow rate. Necessary protection device shall be provided against potential start-up surge pressures. High pressure alarm system shall be provided to prevent excess pressure on the feed side. In feed and Reject line magnetic type flow indicator transmitter to be provided
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RO MEMBRANE CLEANING SYSTEM The tenderer shall provide membrane cleaning system in the RO plant by chemical recirculation when the pressure drop across the system exceeds the preset value. The cleaning system shall comprise one chemical solution tank, two chemical recirculation pumps and one cartridge filter (CSRL). The chemical solution tank shall be provided with motorized stirrer to prepare chemical solution. AUTO PH CORRECTION FACILITIES Facilities shall be provided to dose either caustic soda into the water followed by a static mixer and pH meter permeate tank for final pH correction to 8 (approx.). These shall be done on automatic basis. Alkali preparation tank in MSRL construction equipped with motor driven agitator. Alkali dosing tank in SS construction Alkali dosing pump in SS construction 03.02.04 001 ZERO LIQUID DISCHARGE PLANT PROCESS DESIGN BASIS The feed to the Zero Liquid discharge Plant shall be the streams from RO reject from RO plant in TTP area and Water Supply Complex of CRM III. The reject streams TDS may not be more than 6000 ppm. This needs to be concentrated to almost 60,000 or more using either a membrane based concentration step or a thermal based brine concentrator for the process to effective and technically feasible. The feed to the Zero Liquid discharge Plant shall be the streams from RO reject from RO plant, RO Reject from Water Complex and underflow of HRCC. 002 PROCESS DESCRIPTION The system shall be based on Polymeric Heat Exchanger Type Mechanical Vapor compression principle. The system shall be fully integrated automated system incorporating a mechanical vapor compression unit with vibrating screen bowl centrifuge. The high
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purity distillate produced in the system shall be used as process makeup water. The evaporation system shall be sized for concentrating R.O. rejects and shall have the required normal water evaporation capacity. The reject from the waste streams shall be collected in separate wastewater tanks. The wastewater shall then be pumped at constant rate for preheating by exchanging heat with the outgoing distillate. The most cost-effective plate and frame exchanger for this service shall be provided. The preheated reject shall flow into the flash tank. The Slurry shall discharge continuously from the flash tank to the centrifuge. This slurry is fed to the centrifuge which shall separate out the salt crystals as a cake. The evaporated vapor shall flow through the mist eliminator in flash Tank to the suction of the Mechanical Vapor Compressor. The compressed vapor shall flow to the heating side of the evaporator. As it condenses, it shall transfer the latent heat of vaporization back to the liquid film on the tube side. Condensed water vapor shall be pumped out of the system as distillate after transferring heat in the forced Circulation Heat Exchanger. ZLD Plant Treatment Steps: Following treatment steps are envisaged in the Evaporation Plant: 1) 2) 3) 4) Preheating of the Feed Evaporation of the water and concentrating the feed in MVR Evaporator using polymeric heat exchanger. Super saturation of the concentrate in MEE (Falling Film / Forced Circulation) Separation of salt and mother liquor.
Process Description of Falling Film & Forced Circulation / MVR Evaporator: The reject of 5% to 6 % solids from RO plant, RO Reject from Water Complex and underflow of HRCC shall be fed in to the Evaporator plant. Evaporation takes place under vacuum when it reaches its boiling point when heated with steam initially. The vapour generated flows into a fan, which adds energy by increasing the pressure and temperature of the vapour. After compression the vapour releases its latent heat and condenses by transferring the heat through the polymeric heat exchangers causing the solution on the exterior surface to release more vapour. The concentration of
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the liquor increases as the evaporation progresses and concentrate is discharged to the MEE (Combination of falling Film and Forced Circulation) Process Description of Falling & Forced Circulation Evaporator: The reject of about 15% total solids from MVRE process is preheated in pre-heaters. The preheated feed is then pumped through the calandria of the evaporation plant to be concentrated by vaporizing the water using dry saturated steam from the Boiler. The evaporation takes place under vacuum. The concentration of the liquor increases as the evaporation progresses and achieves a maximum possible saturation of major salt. The final concentrate is super-saturated in salt recovery system comprising evaporative crystallizer and centrifuged to separate the dry salt from mother liquor. The evaporated water is then condensed using a condenser and pumped to the condensate tank for storage. 003 INDICATIVE LIST OF EQUIPMENT SL. NO. 1. 2. 3. 4. EQUIPMENT Waste Collection Tank Waste Feed Pump Reject Heat Exchanger Mechanical Vapor Compressor polymeric heat exchanger SPECIFICATION / M.O.C RCC tank Duplex SS Titanium Plates Casing Cast Iron Impellers Ductile Iron Shaft Alloy Steel With 17 -4 PH SS cap screws SS 316 SS 316 Shell SS Tubes Gr. 2 Titanium Duplex SS CS Rubber lined CS Rubber lined CS Rubber lined Duplex SS HDPE SS 316 HDPE SS 316 QTY. 1 4 2 2
5. 6. 7. 8. 9. 10. 11 12. 13. 14. 15. 16. 17.

Distillate Pump Distillate Tank Forced Circulation Heat Exchanger Recirculation Pump Flash Tank Foam Separator Filtrate Tank Filtrate Pump Centrifuge Antifoam Dosing Tank Antifoam Dosing Pump Caustic Dosing Tank Caustic Dosing Pump
2 2 2 2 2 2 1 4 2 1 4 1 4
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03.03
Treated effluent from the new Effluent Treatment Plant of CRM III Design Inlet Effluent Analysis for Tertiary treatment: Sl. No. 1 2 3 4 5 6 7 8 Parameters pH Suspended solids Oil & Grease BOD ( 3 days 27 deg C) COD Iron (as Fe) Zinc (as Zn) Total dissolved solids Units mg/l mg/l mg/l mg/l mg/l mg/l mg/l Values 7.0 -8.5 < 50 <5 < 30 < 250 <3 <5 5180
Tenderer shall extend the pipeline with an isolation valve of DN 80 to the collection sump to be provided by the bidder and pump the collected water to BOD plant for necessary treatment. The treated water from BOD plant shall be collected in separate collection sump with the provision of pumping the treated water to the main collection sump of 200 m. The treated water quality from the BOD plant shall be as follows:
Sl. No. 1 2 3 4 5 6 7 Parameters pH Suspended Solids Oil & Grease BOD (3 days 27 deg C) COD Iron (as Fe) Zinc (as Zn) Units mg/l mg/l mg/l mg/l mg/l mg/l Values 7.0 8.5 5 Negligible < 2.7 <5 < 0.3 0.007
Online booster will not be accepted. If pressure of Effluent water is felt inadequate, an Effluent water Equalisation tank with pumps and piping, valves, etc will be provided by the successful tenderer at the tapping point itself. The details and specification shall be in line with GTS. Tentative Blow Down Analysis from Cooling Towers to be treated in Tertiary treatment: Sl. No. 1. 2.
Parameter pH Turbidity
Unit JTU
Values 8 8.5 --Page 44 of 277
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Sl. No. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
Parameter Dissolved Oxygen p Alkalinity Total Alkalinity Acidity Total Hardness Non-Carbonate Hardness Carbonate Hardness Calcium as Ca Magnesium as Mg Iron as Fe Sulphate as SO4 Chloride as Cl Total Solids Total Dissolved Solids Suspended Solids Oil & Grease Temperature Silica as SiO2
Unit mg/l -do-do-do-do-do-do-do-do-do-do-do-do-do-do-do0 C mg/l
Values 7.8 < 8.0 < 203 Nil < 255 < 60 < 195 < 60 < 19.5 < 0.9 --< 45 < 750 < 675 < 75 Nil 35 60
The final treated water quality from the Tertiary Treatment Plant to be used as makeup to the cooling tower shall be as follows: Sl. No. Parameter Unit Values 1. pH 8 8.5 2. Turbidity JTU --3. Dissolved Oxygen mg/l 7.8 4. p Alkalinity -do< 8.0 5. Total Alkalinity -do< 65 6. Acidity -doNil 7. Total Hardness -do< 85 8. Non-Carbonate Hardness -do< 20 9. Carbonate Hardness -do< 65 10. Calcium as Ca -do< 20 11. Magnesium as Mg -do< 6.5 12. Iron as Fe -do< 0.3 13. Sulphate as SO4 -do--14. Chloride as Cl -do< 15 15. Total Solids -do< 254 16. Total Dissolved Solids -do< 225 17. Suspended Solids -do< 25 18. Oil & Grease -doNil 0 19. Temperature C 35 20. Silica as SiO2 mg/l 2
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03.04
INDUSTRIAL MAKE-UP WATER Tenderer shall plan to extend Industrial quality make-up water (qualities as indicated below) for the said plant, if required, from the proposed industrial make-up water network which will be made available at the battery limit. Sl. No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. Parameter pH Turbidity Dissolved Oxygen p Alkalinity Total Alkalinity Acidity Total Hardness Non-Carbonate Hardness Carbonate Hardness Calcium as Ca Magnesium as Mg Iron as Fe Sulphate as SO4 Chloride as Cl Total Solids Total Dissolved Solids Suspended Solids Oil & Grease Temperature Silica as SiO2 Unit JTU mg/l -do-do-do-do-do-do-do-do-do-do-do-do-do-do-do0 C mg/l Values 8 8.5 --7.8 < 8.0 < 65 Nil < 85 < 20 < 65 < 20 < 6.5 < 0.3 --< 15 < 250 < 225 < 25 Nil 35 2
Tenderer shall extend the pipeline from tapping point with an isolation valve in a valve pit to their proposed systems for the entire need and the Tenderer shall indicate the quantity of make-up water requirement, pipe size, end connection, MOC of pipeline, etc. from the tapping point. Online booster will not be accepted. If pressure of industrial make up water is felt inadequate, a makeup water sump with pumps and piping, valves, valve pits etc will be provided by the successful tenderer. The details and specification for make-up water system shall comply GTS. 03.05 DRINKING WATER Tenderer shall plan to extend drinking water for the said plant from
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the proposed drinking water network which will be made available at the battery limit. Drinking Water analysis shall be as per IS: 10500-1992 Tenderer will extend the same from tapping point with an isolation valve in a valve pit to their proposed systems for the entire need and the Tenderer will indicate the quantity of drinking water requirement, pipe size, end connection, MOC of pipeline, etc. from the tapping point. Online booster will not be accepted. If pressure of drinking water is felt inadequate, a drinking water sump with pumps and piping, valves, valve pits etc will be provided by the successful tenderer. The details and specification for drinking water system shall comply GTS. 03.06 FIRE WATER SYSTEM To cater to the needs of water based fire-fighting system, an independent pressurized fire water piping network comprising internal/ external hydrants, hoses, hose reel, hose box, valves, nozzles, couplings and all other equipment will be provided by the successful Tenderer. Tenderer shall plan to extend fire fighting water with an isolation valve for the entire area (inside & outside up to peripheral area of the proposed building) from the existing fire water network of the integrated plant. Tenderer shall indicate pipe size, end connection, MOC of pipeline, etc. at the tap-off point. 03.07 TREATED WATER FOR REUSE AS MAKE-UP TO COOLING TOWER The tenderer shall supply treated water as make-up for cooling tower of CRM-III. Treated water pipeline shall be laid from the proposed Tertiary treatment plant upto the existing cold water sump of the new CRM-III at an approx. co-ordinate i.e. X+2569.889/ Y+8735.152. Top of the cold water sump is approx. 3m above area ground level. Tenderer will indicate pipe size, end connection, MOC of pipeline, etc. at the supply point.
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03.08 (1)
WATER SUPPLY VENTILATION
SYSTEM
FOR
AIR
CONDITIONING
&
The entire piping network for water supply for dust suppression, airconditioning and ventilation and other Systems/ Sub-systems is in the scope of the Tenderer. It shall consist of pumps, valves, pipes, fitting, pipe supports and associated civil, structural, electrical, instrumentation, material handling, air-conditioning & ventilation etc. The details and specification of pumps, valves, pipes, fitting, pipe supports and associated civil, structural, electrical, instrumentation, material handling, air-conditioning & ventilation etc. as specified for cooling water system is applicable for this system also. PUMP HOUSE
(2)
(3)
03.09 1)
The pump house shall be provided with valves, internal piping, control room, material handling facility, air conditioning & ventilation facilities, illumination & instrumentation, etc. Operation of all the pumps, motorized valves, etc. shall be centrally controlled from RO Plant building PLC, located near in the Electrical Control Room. The pump house shall be made of RCC framed structure with brickwork filling. RCC roof shall have parapet wall on the roof. The pump house shall be provided with electrically operated under slung crane with long travel and cross travel movement. Ventilation system along with air washer unit shall be provided. One office room and toilet shall be provided in the pump house for Executives and workers/ operators. Where ever required, the pump house shall be provided with drainage pumps. Other aspects of pump house shall be as per General Technical Specification (GS-02).
2)
3) 4) 5) 6) 7) 8)
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03.10 1)
PUMP SETS All the pumps shall be of horizontal centrifugal split casing side suction side delivery type along with their auxiliary equipment suitable for the required duty conditions and shall be designed and manufactured for continuous duty at full load. Drainage pumps shall be vertical centrifugal type. Supply of pumps shall be complete with electric motor, flexible coupling, coupling guard, common base plate, matching flanges, nuts, bolts, gaskets for suction & delivery, foundation bolts, nuts, washers etc.; complete in all respects. The pump selection shall be with delivery valve in fully open condition The main pumps, drainage pumps shall be operated with PLC on auto mode. For other requirement, reference may be made to GS-02. VALVES 1) Adequate number of isolation valves with stainless steel internals should be provided in the pipeline network for isolation of pipe sections and equipment, control of pressure, flow & level of fluids, venting, draining, pressure relief etc. (working pressure = 16 kg/cm2) Cast Steel Valves shall be provided suitable for service conditions in all respects and located suitably for ease of operation and maintenance. In general, unless otherwise specified, all valves up to DN250 shall be manually operated, from DN300 to DN400 gear operated and DN450 & above electrically operated. All the valves on delivery side of main pumps shall be motorized for automatic operation except fire fighting water pump house. Valves on make up water line for filling of sumps and valves for filling of over head tanks will be electrically operated. All control valves shall be provided with hand wheel. For other requirement, reference may be made to GS-02.
2)
3) 4) 5) 03.11
2)
3)
4) 5)
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03.12 1)
PIPES, FITTINGS & PIPE SUPPORTS The pipe work shall be designed, manufactured, assembled and tested as per the latest standards, codes and recommendations of the Bureau of Indian Standards / ANSI/ ASTM/ AWWA/ any international standards. Pipe work shall be complete in all respects including all accessories essential for proper installation, operation and maintenance, even though such items are not specifically mentioned in the specification. The Tenderer shall supply all the pipes, valves, fittings, pipe supports, flanges, gaskets etc. Each header in the pump house shall be provided with suitable number of valves for isolating and maintenance purpose. Dismantling joints near the pumps on both suction and delivery lines on the main header shall be provided at suitable places. MS/GI pipes as per IS: 1239 (part-I)-2004 heavy class shall be used up to size DN 150 mm and all GI fittings up to size 150mm as per IS:1239 (part-II)-1992 shall be used. Pipes above DN 150 mm shall be as per IS 3589. The fittings shall be fabricated from higher thickness pipeline. Minimum thickness of pipeline shall be as follows Minimum thickness of Pipeline DN200 to DN350 9.52 mm DN400& above 12.0.mm 7) 8) MS fittings shall be fabricated ones above DN 150. MS pipes/fittings shall have welded joints. The pipe laying and erection work shall be carried out according to the standard engineering practice and the drawings and specifications etc. duly approved by the Purchaser/ Consultant. The Tenderer shall take care of positioning, leveling, plumbing and alignment of all the pipelines, valves and equipment as well as supporting structures within required accuracy and tolerance limits. For other requirement, reference may be made to various clauses of GS-02.
2) 3) 4) 5)
6)
9)
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03.13 03.13.01 .01
ERECTION, TESTING AND COMMISSIONING Erection & Commissioning of Plant & Equipment Scope of Work for Erection The intent of the specification is to define the scope of the Contractor with regard to erection, testing and commissioning of equipment / unit / system. The Contractor, amongst other things, shall be responsible for erection of steel structure, plant and equipment, electrics, auxiliaries, etc. as per the scope of supply within the design limit as given in the Technical Specification. The Contractor shall take delivery of the equipment and transport the same to erection site, maintain his own stores for the storage of equipment and all related documents and records and finally transport the equipment to site for erection. He will take an erectioncum-storage insurance policy covering all the risks including third party liabilities for equipment as well as human life. All security arrangements also shall be made by the Contractor. The Contractor shall unpack the cases and do visual checking against physical damages of equipment and do cleaning of the equipment before start of erection. The Contractor shall be responsible for proper and neat storage and also undertake conservation of all consignments including damaged boxes. During storage of equipment, the Contractor shall take into account deterioration and carry out the reconservation of the complete equipment / parts / suppliers as may be necessary as per the Storage Instructions of the Manufacturer of equipment / components. The Contractor shall also supply the consumables required for such reconservation work and repair / replace parts required thereof for the proper functioning of the equipment after erection and commissioning. Damage / shortage of the equipment / component during transit / transfer / storage, shall be made good by the Contractor without loss of time so as not to upset the agreed erection and commissioning schedule and at extra cost to the Purchaser. Delay on account of settlement of insurance claims by the Contractor shall not be taken into cognizance by the Purchaser.
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The Contractor shall be liable to make good any damage to existing equipment and / or facilities caused by the Contractors personnel. In case any existing equipment of facility is required to be dismantled for erection of the new equipment, the same shall be restored at no extra cost to the Purchaser. The Contractor shall lay and maintain properly all the temporary supply lines at the erection site for temporary power, water, and air connections required for erection purpose, from the points earmarked by the Purchaser for this purpose. The Contractor shall provide all necessary construction tools and tackles (other than special tools & tackles) compressors, small hand tools, instruments, all commissioning instruments, welding equipment, service bolts, nuts, jigs and fixtures, winches, alignment tools, precision levels etc. and other equipment which may be required for carrying out the erection work efficiency within the time schedule. Unless otherwise specified, the above construction materials shall be the property of the Contractor after the erection work is over. Special tools & tackles obtained by the Purchaser with the equipment will, however, be the property of the Purchaser. The Contractor shall provide erection consumables like oxygen and acetylene gas, welding rods, solder lugs, oil, grease, kerosene, cotton waste, etc. required for erection of plant and equipment. The Contractor shall erect and maintain his own site offices, main stores and site temporary stores as required for the work and arrange for maintaining in neat manner the area placed at his disposal. The Contractor shall provide sufficient fencing, notice boards and lights to protect and warn others as may be considered necessary by the Purchaser. All materials used for providing these facilities shall be properties of the Contractor. On placement of order, the Contractor shall provide his scheme for mobilization with bar chart indicating clearly the resources of erection machinery manpower and machinery proposed to be deployed to ensure timely completion of work and quality of workmanship. On request, the Purchaser may help the Contractor by providing any special handling / construction equipment needed in the interest of work subject to availability and on payment of hire charges, and other conditions prevailing in the Purchasers plant. However, such requirement must be mentioned in the tender /
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quotation of the Contractor. The plant and equipment will be erected as per the instructions of the manufacturers / suppliers and under the supervision of the supervisory personnel, to the deputed by the Contractor at site. The Contractor shall also undertake rectification work on account of manufacturing defects, required for proper erection and assembly, which can be done at site only according to site condition. The Contractor shall align, level, couple and securely fix all equipment and accessories in accordance with drawings and / or instructions. All precision survey instruments including leveling instruments shall be arranged by the Contractor. The Contractor shall supply materials and carry out flushing and first filling of oil and lubricants, grease, chemicals and as required till successful commissioning. Laying and termination of cables, bus bars, bus ducts, lighting and earthing shall be done by the Contractor. The contractor shall be responsible for protection and / or diversion of all underground services, electrical / telecommunication cables etc., wherever required, including supply of materials / cables etc. for such protection / diversion work, if asked for by the Purchaser. The Contractor shall check electrical connections to individual items. The Contractor shall be responsible for checking the correctness of erection of mechanical equipment, electrical equipment etc. as per the specification and relevant drawings. The Contractor shall arrange all facilities at site to undertake radiographic testing and stress relieving of but welded joints, as required. The Contractor shall be responsible for the management of erection work with proper and adequate supervision for ensuring progress of erection work and quality of workmanship. The Contractor shall deploy required number of supervisory, skilled, unskilled and auxiliary labour as required, for the erection work and
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comply with such reasonable instructions of the Purchaser in the interest of satisfactory progress and completion of the work according to the schedule. The Contractor shall be responsible for total commissioning of the plant including cold trail run and demonstration of Performance Guarantee Test. The Purchasers supervisory and skilled operating personnel shall, however, be available to work under the guidance and supervision of the Contractor during the commissioning period and performance guarantee test. The Contractor shall organize the work in a manner that other work at site is not impeded and the workmen therein not endangered. He shall arrange temporary access at site, if required, for the erection work. The Contractor shall intimate the Purchaser / concerned plant authorities in writing well in advance about the requirement of shut down of any of the existing units / facilities for inter-connection / incorporation of additional facilities. The shut down period shall be mutually discussed and finalized. The work to be undertaken during the shutdown period shall be planned meticulously by the Contractor to reduce the shut down period to the minimum. The Contractor shall return to the Purchaser all crates, packing cases and packing materials and all returnable supplies belonging to the Purchaser at a place designated by the Purchaser at the erection site in the conditions these exist during and after erection work is completed. The tests / checks to be conducted during erection by the Contractor shall be as per the manufacturers instructions. The Contractor shall attend to the rectification of erection defects, if any, expeditiously. The Contractor shall arrange all testing instruments for such testing at site. The Contractor shall carryout final painting including supply of paint of the plant & equipment erected as per the instructions of the Purchaser. The Contractor shall indicate to the Purchaser well in advance the requirement of services such as electrical power, water, compressed air, etc. required during construction / erection period. All safety, health and pollution control measure, as required to be
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adopted as per the statutory regulations and the Safety Codes for projects issued along with the tender documents otherwise required or implied by statutory regulations or practices, shall be strictly followed by the Contractor during the execution of the Contract. The Contractor shall set up a suitable safety organization of his own at site in this regard. The Contractor shall comply with all Statutory Rules & Regulations with respect to the employment of labour at site including payment of minimum wages, deduction of employees contribution to Provident Funds, depositing the same along with Contractors contribution to the Provident Fund Commissioner, Employees State Insurance and other statutory deductions / obligations. At the end of the work the Contractor shall remove all such temporary structures put up by him and hand over the site to the Purchaser in neat and tidy manner. .02 Supervision of Erection, Testing, Performance Guarantee Tests Commissioning and
03.14.01
The Contractor shall depute at site engineer / specialists from various disciplines for the supervision of erection, testing trial run, commissioning and performance guarantee tests of the plant and equipment under his scope of supply including the foreign engineers / specialists from various discipline. The above mentioned Indian and foreign engineers / specialists shall supervise the erection, testing, commissioning and conducting of performance guarantee tests of the plant and equipment with their auxiliaries so as to establish to the Purchaser that the guarantees as stipulated by the Purchaser and agreed by the Contractor are fully met. Bio-data of the experts / specialists / engineers shall be furnished to the Purchaser for approval sufficiently in advance before their deputation at site. The Purchaser may place his engineers of respective disciplines to witness successive steps adopted in successful erection, testing, commissioning and performance guarantee tests.
03.14.02
The erection of all plant and equipment shall be carried out according to the latest engineering practices and according to the drawings, specifications, Instructions etc. duly approved by the Purchaser. The contractor shall carryout the work in the presence of and / or as per the instructions of site engineer /supervisory personnel deputed by the Purchaser. Highly skilled workmen shall
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carry out the erection. The successful Tenderer shall select and adopt methods and procedures for equipment erection to suit the nature of equipment and erection work involved according to the best modern practice and his own experience in such work. The successful Tenderer shall be solely responsible to provide competent and adequate supervision to ensure that assembly, erection, testing and commissioning are in compliance with the drawings approved by Purchaser / Consultant. The successful Tenderer shall not make any alteration to equipment to facilitate assembly or erection work, without prior approval of Purchaser / Consultant. 03.14.03 The Tenderer shall supply all required manpower, tools and related equipment, all hoisting equipment, all necessary scaffoldings, all necessary transporting equipment, consumables. Construction and erection materials, petrol, diesel oil, Kerosene, solvents, sealing compound, tapes, brazing and soldering materials, welding and brazing gases, erection bolts, nuts and packing sheets/compounds, temporary supports, wooden blocks, spacers, templates, jute and cotton wastes, sand/emery paper etc. as required for the satisfactory completion of work. The Tenderer shall make his own arrangement for handling the equipment and pipelines at the stores and transporting it to the site for installation. All assembly and erection procedures adopted by the successful Tenderer shall be open for inspection and approval by Purchaser / Consultant. Acceptance of assembly or erection procedures shall not in any way relieve the successful Tenderer of his responsibility for proper erection of the equipment. After erection, all equipment having moving part, subject to pressures or voltages shall be given trial operation. The trial operation shall consist of 24 hours of continuous operation. All modifications and rectifications required during the trial operation or required for proper operation shall be done at his own cost by the Tenderer as accepted by the Purchaser. Provision of special tools and tackles and necessary man power for construction, erection, operation and repair/maintenance of the plant and equipment. The successful Tenderer shall check centerlines, levels, etc.
03.14.04
03.14.05
03.14.06
03.14.07
03.14.08
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including checking lines, levels, positions and plumbs of all equipment bolts and pockets of all equipment/ trestle foundations on which the equipment / trestles shall be installed. Any defect observed in the equipment foundations shall be immediately brought to the notice of Purchaser / Consultant. The successful Tenderer shall fully satisfy himself regarding the correctness of equipment foundations before installing the equipment on the foundations. 03.14.09 A non-corrodible name plate giving major characteristics for the mechanical as well as electrical and instrumentation equipment shall be provided on each equipment. Cutting /drilling holes if required in floors/walls and making good of the same shall be done by the successful Tenderer with prior approval of Purchaser / Consultant. The successful Tenderer shall ensure complete assembly and erection of all equipment, pipe work, ductwork, cables and conduits, bus bars, earthing, structural steelwork in pipe supports, civil foundations of trestles and equipment, cable trays, etc. including aligning, lining, leveling, coupling and grouting of anchor bolts and base plates, curing, welding of supports and connecting-up electric power supply, water and utility connections from the terminal points to make the equipment ready for commissioning. The successful Tenderer shall provide required safety apparel for erection personnel; keep the place clean and hand over in tidy condition after completion of work. The successful Tenderer shall obtain approval from statutory authorities and concerned departments as may be required for the installation and carrying-out any changes called for by the said authorities at no extra cost to Purchaser. The successful Tenderer shall include supply of all required consumables and erection materials but not limited to shim stocks and bed plates, cover plates, tags, jointing compounds, Prussian blue, petrol, diesel, kerosene, solvents, sealing compounds, taper, connectors, brazing and soldering materials, welding and brazing gases and rods, electrodes and wires, grouting materials, erection cleats, bolts, nuts and rivets, rawl plugs, piano wires, packing materials, temporary supports, wood tonnage and blocks, spacers, templates, jute and cotton waste cloth, sand and emery paper, etc. as required for the completion of the work according to the contract.
03.14.10
03.14.11
03.14.12
03.14.13
03.14.14
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Additional embedment, if any, required for mounting of control stands, etc. shall be provided by the successful Tenderer. All materials used in connection with erection work shall comply with the appropriate Indian Standards. 03.14.15 Throughout the performance of the work, the successful Tenderer shall keep equipment, structures and materials adequately braced by guys, struts or other approved means which shall be supplied and installed by the successful Tenderer as required till the erection work is satisfactorily completed. Such guys, shoring, bracing, strutting, planking, supports, etc. shall not interfere with the work of other agencies and shall not damage or cause distortion to other works executed by other agencies. Prior permission shall be obtained by successful Tenderer from Purchaser / Consultant before welding any temporary supporting member to the permanent structures of building. The successful Tenderer shall schedule his work to meet the targets as may be specified by Purchaser / Consultant from time to time and ensure that drawings, materials, equipment and services required from others are requisitioned well in advance of the requirement at site, so as to meet the demands of the erection schedule. Delays which may affect the progress of work shall be brought immediately to the notice of Purchaser / Consultant in writing. The successful Tenderer shall reschedule the work and/or perform overtime work at his own cost with the approval of Purchaser / Consultant as may be necessary to meet the required erection program. The top of the concrete foundations shall be thoroughly cleaned with air or air and water jet by the successful Tenderer prior to placing of bed plates, cover plates, sole or sub-sole plates on foundations. Concrete surface shall be roughed-up by chipping 5 to 10 mm deep uniformly and the surface shall be washed clean with jet of water to remove fine dust. The successful Tenderer shall place bed plates, cover plates, sole or sub-sole plates on the foundations and shim-up with the machined steel wedges until the equipment is in level as checked with precision machinists levels. Required machined steel wedges and shim stocks shall be furnished by the successful Tenderer and used in sufficient numbers to avoid unsupported spans with any perceptible deflection. The successful Tenderer shall not use thinner plates to make-up thicker packing.
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03.14.19
The successful Tenderer shall furnish in his offer a complete list of equipment, tools, tackles, instruments, etc. which he shall bring to the site for erection, start-up, testing and commissioning of equipment. Adequate segmentation and interconnections shall be provided in the distribution networks to afford maximum flexibility of operation and maintenance. Rotating equipment shall be checked for proper direction of rotation and shaft alignment. Equipment subject to pressures shall be carefully examined for leakage. All equipment, such as pressure taps, temperature measurement connections, flow measurement devices etc. shall be provided by the Tenderer. On completion of the work, the Tenderer shall remove and dispose off all rubbish and other unsightly materials caused by his working to a distance of five kilometer from shop area or as directed by the Purchaser and thereby leaving the premises in good, clean, safe and operable condition. All the equipment shall be subject to stage inspection by the successful Tenderers own inspecting authority. However, Purchasers Inspector may visit the works from time to time that shall have free access to all the places of the manufacturing premises where any part/parts are under manufacturer. The successful Tenderers inspecting authority shall keep a close surveillance in respect of the job for the design, dimensions, tolerances, surface finish etc. Before giving call for final inspection, all the documents shall be furnished to the Purchaser. The record of manufacturing details, inspection and tests carried out by the successful Tenderer shall be made available to the final Inspecting Authority. However, approval and final inspection at the manufacturing works shall not relieve the successful Tenderer of responsibility of replacing at his cost any defective part/material which may be detected by the purchaser during erection and commissioning or guarantee period. Inspection of the item will be carried out in line with the approved QAP of the Purchase Order. All materials required for fabrication, construction, testing and inspection shall be supplied by the Tenderer. No material shall be
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free issue to the Tenderer. 03.14.28 The test shall be conducted at shop for various sub-assemblies/ assemblies of equipment as per common industrial practices, unless otherwise specified. Extent of testing shall be finalized during formulation of detailed QAP. All inspection shall be carried out at the manufacturers shop/works. No equipment or part item shall be dispatched without final inspection and issuance of inspection certificate. All equipment, assemblies, sub-assemblies shall be shop tested as per relevant standards and the test certificates shall be submitted by the supplier. All the tests on the fabricated/ manufactured equipment shall be carried out generally as per the relevant Indian Standards or equivalent International Standards. Requisite number of copies of test certificates, as agreed between the successful Tenderer and Purchaser / Consultant shall be furnished for all the equipment and its components offered. Erection, testing & commissioning of various equipments and piping etc shall be done also inline with details given in various chapters of GS-02. Obtain necessary clearances from statutory authorities / state govt. / central govt. as required on behalf of the purchaser. WELDING Welding procedures shall be prepared in line with IS: 7307 (Part-I) and tests shall be carried-out to quality procedures. Number of procedures will depend on variables like positions of welding, thickness range, etc. Once a welding procedure is qualified, strict adherence to it shall be made during actual welding. Welders employed shall be qualified as per IS: 7310 (Part-I) after passing necessary tests to be witnessed by Purchaser / Consultant. Welding consumables shall be of approved type. Such consumables are, however, subject to qualifying initial check tests as per IS: 814.
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The successful Tenderer shall strictly follow approved welding procedures during actual welding. Inspection shall be carried out by Contractor during the various stages of welding. The following documents shall be maintained by the successful Tenderer and produced as and when asked for by the Purchaser / Consultant. a) Documents on approved deviations, if any. b) Documents (certificates, etc.) confirming the quality of electrodes and accessories used in welding. c) List of certificates on qualification of welders who carried out welding and also their identification stamps on welding done by them. 03.16 WRAPPING/ COATING OF UNDER GROUND PIPELINES Underground mild steel pipes shall be wrapped with coal tar based tape as per IS 13357 or wrapped and coated generally as per IS: 10221 1982 (Reaffirmed in 1991) (Code of practice for coating and wrapping of underground mild steel pipelines) and as per the following procedure. a) b) c) Before applying the tapes, the pipes should be hydro-tested. The pipe surface shall be cleaned by wire brushing for removal of loose scale, rust, dirt, foreign debris etc. A single coat of coal tar & solvent based primer having a density 0.9 to 0.95 gm/cm3 shall be applied by brush to give a thin continuous coating over the area to be protected. Application of factory made wrapping tape of minimum 3 mm thickness shall be provided for pipe sizes upto DN 150. For sizes DN 200 and above, 4mm thick tapes shall be provided. The tapes shall be wound spirally using thermo fusion over the surface of pipe with a minimum overlap of 25 mm. It shall be ensured that the tape is in contact with the underlying surface and no wrinkles of air pockets are formed. Pipes wrapped with tapes shall be holiday tested before lowering into trenches.
d)
e)
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f)
For other requirement, reference may be made to various clauses of GS-02. TESTING OF PIPELINES
03.17 a)
Preliminary acceptance test for erected pipelines shall be carried out as follows: Checking of pipelines as per manufacturers certificate / approved drawings. Visual examination of welds. Dimensional checks as per the approved erection drawings. Checking of welded joints by chalk and kerosene test.
b)
Hydraulic test & procedure: Pipelines for liquid services after erection shall be hydraulically tested by water at 1.5 times maximum system pressure as per stipulation of drawings. For carrying out hydraulic tests, the erection Contractor shall arrange testing equipment like tanks, pumps, temporary pipes, valves at his cost. Pipelines shall be kept pressurized until the entire section under test has been examined for leakage. However, minimum duration for keeping pipes under hydrostatic pressure shall not be less than 2 hours. Defects revealed by the tests shall be repaired or defective parts replaced and the system shall be retested. Welded joints shall be subjected to hand hammer test while under test pressure. The pipeline or section thereof under testing shall be slowly filled and the test pressure measured at the lowest point of elevation, shall be applied by means of pump. The duration of each pressure test shall be not less than two hours, and shall be as per the relevant standards. During the test period there shall be no drop in pressure in case of hydraulic tests and maximum of 1 per cent pressure drop in case of pneumatic tests for air lines and gas lines after temperature corrections. While a line is under pressure all visible leaks shall be prevented by tightening wherever possible. Other type of defective joints shall be cut and replaced. Any cracked or defective pipe, fitting, valve etc.
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shall be removed and replaced by contractor with sound material and the test shall be repeated until the results are satisfactory. Defective welds shall be repaired by removing the defective piece of pipe which caused the leak and re-welding. No weld leaks shall be repaired by mechanical caulking. The contractor shall arrange pumps, barrels, tanks bulkheads, blanks, connections, test gauges and all other equipment necessary for pressure testing. Compressed air shall be arranged by the contractor through portable air compressors. The contractor shall furnish, install and dismantle all temporary lines to the system under test. The contractor shall conduct all tests and keep proper records of all tests, duly certified by the Engineer. Values of line pressure and temperature as well as ambient conditions shall be taken at each reading. The intervals between the successive readings shall be 30 minutes unless otherwise directed by the site engineers of the purchasers representative. Tested pressure gauges, temperature indicators etc. shall be used in duplicate for tests. The contractor shall arrange water for testing of equipment and water piping system before installation. For other requirement, reference may be made to various clauses of GS-02. 03.18 FLUSHING OF PIPELINES Pipelines for water systems shall be flushed with water to remove all debris, dirt, rust particles, etc. Initial Flushing The following shall be planned and done before initial flushing: i) Various types of control valves, cocks, orifice plates, filters etc. shall be removed and fitted with distance pieces. The above fittings will be flushed and cleaned manually. All heat exchangers, water pumps strainers etc. shall be isolated during flushing and cleaning operation. All the pumps and equipment in the cleaning circuit shall be isolated by blanking and by passing through temporary connections on the pipeline. If filters and strainers are kept in the main circuit during
ii)
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flushing operation, these will be removed, cleaned and refitted after flushing is completed. iii) iv) The pipes not coming in direct circulation shall be dismantle and flushed separately by making suitable closed ring. For other requirement, reference may be made to various clauses of GS-02. PASSIVATION OF PIPELINES Prior to commissioning the network, pre-treatment passivation of the cooling water system is required to ensure maximum service life of equipment to be cooled. Pre-treatment is a two-phase programme consisting of pre-cleaning and pre-filming. Pre-cleaning Pre-cleaning shall aim at removing left over foreign material after flushing of the pipe lines. This shall provide a clean surface for promotion of conform protective corrosion inhibitor film. A power polymeric anti-foulant shall be used for a period of 3-4 days followed by heavy blow down. Pre-filming / passivation Pre-filming or passivation shall be done to promote rapid formation of corrosion inhibitor film on the metal surface. Chemicals required for passivation shall be supplied by contractor. However passivation shall be carried out by the contractor as per the instructions / manual of supplier. For other requirement, reference may be made to various clauses of GS-02. PAINTING All Plant, equipment, valves, piping etc. shall be painted as per the specification given in general requirements of painting and as per requirement and approval of Purchaser. General Specification GS09 may be referred for this purpose.
03.19
03.20
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03.21
INSPECTION All Plant, equipment, piping etc. shall be inspected as per the specification given in general requirements of inspection and as per requirement and approval of Purchaser. General Specification GS05 may be referred for this purpose.
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04.00 04.01
DESIGN CRITERIA Design criteria for the following units / equipment have been covered in GS-02. Pump house Pipe work Pumps Blowers Filtration Plant Fire fighting system Valves Rubber expansion joints Sluice gates Chemical dosing system Degasser tower and degassed water storage tank Spares & consumables Preliminary acceptance test
04.02
Design criteria for the following units/ equipment have been covered in this Technical Specification. Overhead tanks The staging height for back wash water tank shall be 15 - 20m depending on requirement of filters. Overhead tanks will be provided with level measurement, overflow, drain and air vent connections.
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04.02.02
Cartridge filter No. of units Design flow capacity Filtration capacity : : : 2 for feed water and 1 for cleaning of RO blocks. 75 m3/h for each unit. 10 micron
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Material of construction
Carbon steel, internally lined with hyplon. Removable polypropylene material element. Frontal piping with control valves, instruments etc.
Filter cartridge
Fittings
04.02.03 001
High Pressure pumps High pressure pump selection shall be made based on the most optimum pump curve with the highest possible efficiency. The throttling of the high pressure pump pressure at the RO inlet shall be minimized to avoid loss of energy and the operating pressures shall be selected in such a fashion that consumption of power is kept at the minimum while an optimum balance is maintained between the power and membrane replacement costs. Specification of pumps No. of pump sets Design capacity Design head : : : 2 (1 working and 1 standby) 80 m3/h Sufficient to maintain design output at 25 deg.C upto 15 years life cycle of R.O. element. Multistage Horizontal centrifugal, (preferably of ring section casing, diffuser type)
002
Type
Preferred material of construction: Suction casing Discharge casing Intermediate casing Impeller Diffuser Main shaft Shaft sleeve : : : : : : : CF8M CF8M CF8M CF8M CF8M SS 316 SS 316
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04.02.04 001
RO Trains (Blocks) A total of two R.O. trains shall be installed with capacity to meet together, the required through-put even after 15 years of operation. Each train shall be equipped with its own semi automatic, automatic valves, piping work, flushing and cleaning Connections, instrumentation and control console. Each R.O. train shall be an integrated assembly of high strength fibre glass reinforced epoxy thermally cured pressure tubes housing the R.O. membrane elements, feed, product and concentrate piping, all mounted on a high-strength steel structure. Pressure tubes shall be arranged in a series/ parallel array to achieve the desired water recovery. The membrane elements in the plant shall be spiral wound composite polyamide membrane elements. Design of the system shall entail careful balancing of RO membrane distribution in various banks to simultaneously achieve both the quality as well as quantity for each train. Product water tube shall be fibre glass reinforced epoxy pipe. The following applications data of the membrane shall be furnished with the offer: a) b) c) d) e) f) g) Maximum applied pressure Maximum feed flow to element Maximum operating temperature Feed water pH range Maximum feed water turbidity Maximum feed water silting index Maximum concentrates flow
002
003
004
In addition, the Tenderer shall furnish alongwith the offer the following membrane graphs showing (a) (b) Relationship between feed pressure and productivity and salt passage correction factor. Relationship between feed concentration productivity and salt correction factor.
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(c) (d) (e) (f) (g) (h) 005
Relationship between feed temperature and productivity Relationship between feed temperature and salt passage correction factor. Relationship between recovery and productivity and salt passage correction factor. Relationship between operating time and productivity and salt passage correction factor. Relationship between flow and pressure drop across the element. Element initial capacity under standard rated conditions.
Each RO train shall receive high pressure feed water through a pressure control valve which will be preset to a specific operating pressure to maintain design permeate flow rate. Necessary protection device shall be provided against potential start-up surge pressures. High pressure alarm system shall be provided to prevent excess pressure on the feed side.
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04.02.05
Degasifier tower & degasified water (permeate) tank
001
Degasifier tower No. of unit Material of construction : : 1 (One) MSRL
002
Degasifier Blower No. of blower Type : : 2 (1 Working and 1 Standby) Rotary, twin lobe type
003
Degasified Permeate tank Storage capacity Material of construction pH correction facilities : : : hr. storage capacity MSRL Facilities shall be provided to dose either caustic soda or soda ash into the degasified permeate tank for final pH correction to 7.2 (approx.)
004
Degasified Permeate pump No. of pump sets : 2 (1 Working and 1 Standby) : Wetted part of SS316 construction
Preferred material of construction
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04.03
DATA SHEETS Data sheets for the equipment have been covered in GS-02. In addition, the Tenderer shall furnish the following along with the offer: Catridge Filter Sl. No. 1 2 Parameters Quantity Vessel dimension - Dia, mm - Height, mm Design flow (each filter), m3/h Material of construction - Body - Catridge Particle removal size To be furnished by Tenderer
3 4
RO Block Sl. No. 1 2 3 4 a b c d e f g h i 5 a B C Parameters No. of RO Blocks No. of tubes per block and array Manufacturers name Pressure tube Material Nominal pressure rating Minimum no. of membrane element per tube End closure type End cap type Feed and concentrate piping material Product connection Support system Vessel hold down clamp Membrane element Membrane Material & type Outer wrap Application data - Max. applied pressure
To be furnished by Tenderer
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Sl. No.
Parameters - Max. feed flow to element - Max. operating temperature - Feed water pH range - Max. feed water turbidity - Max. feed water silting index - Max. concentrate flow Whether membrane graphs as per TS submitted (YES/ NO)
To be furnished by Tenderer
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05.00 05.01
AIR-CONDITIONING & VENTILATION SYSTEM Scope of work The scope of work of the Tenderer pertaining to air-conditioning and ventilation systems for tertiary treatment of the treated effluent from the new effluent treatment plant of CRM-III to meet the technological requirement as per technical specification shall include the design, manufacture / procurement, inspection, shop painting and supply for site / Contractors site-stores, transportation of materials to erection site, storage, testing, erection, commissioning and performance guarantee of air conditioning and ventilation systems. Air conditioning system shall be provided for control rooms, PLC rooms, computer room, instrumentation rooms, laboratory rooms, senior officers rooms, conference room, control rooms of chemical house, RO plant building and Zero liquid discharge plant building etc. Air washer system for Pumphouse, MCC room and water cooled package AC (1W+1S) with condenser cooling pumps (1W+1S) and cooling tower for Control Room shall be provided. Exhaust ventilation shall be provided for chemical house, RO plant building and Zero liquid discharge plant building, transformer room, battery room, store room, toilet and other areas not catered by air conditioning system & plenum ventilation systems.
05.02 i.
Design Criteria for Air Conditioning and Ventilation Systems The following design data shall be considered for selecting and sizing various equipment for chilled water plant, air conditioning and ventilation systems: SEASON SUMMER MONSOON WINTER TEMPERATURE (DBT) 0C 45 33 10 RELATIVE HUMIDITY (%) 26 70 -
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The different air conditioned rooms shall be maintained at 23+2 0C and 55+5 % RH. ii. The temperature of the premises (plenum ventilation by air washer system) shall be maintained at < 38 0C. The supply air quantity shall be minimum 15 air change/ hour (for MCC room, cable basement & other electrical premises) & and for dry system 20 air change/ hour. Water eliminator in air washer shall be of PVC. If cooling load calculation requires more supply air quantity, then the same shall be provided. 2-3 mm WC pressurization shall be maintained. All glasses in air-conditioner served premises shall be double glass type with airtight double door entry. The temperature of the areas being exhaust ventilated shall not exceed 3 0C above the ambient. For improved water quality in refrigeration system chemically treated water shall be considered for corrosion protection. Alternatively soft water plant shall be installed for make-up water supply. Preferably Exhaust fan rpm shall not exceed 900. AC & ventilation plant room shall be provided adjacent to the served premises. All fasteners shall be hot dip galvanized unless stated otherwise. Noise level of equipment shall be limited to 85 dB (A) at 1 m distance from the equipment unless stated otherwise elsewhere. Noise level inside the air conditioned & ventilated served premises shall be limited to 65 dB (A). Motor rating shall be minimum 20% more than the BKW Fire damper (fusible link type) interlocked with fire detection system shall be provided for all served electrical premises, cable basement, cable tunnel premises & susceptible fire hazard premises. Cooling load calculations (as per Carrier Handbook Guidelines) and system capacity & configuration shall be submitted by successful tenderer before submitting any detailed engineering drawing Due to space constraint water cooled packaged A/c unit is suggested instead of centralized DX based system.
iii.
iv. v. vi.
vii. viii. ix. x. xi. xii. xiii.
xiv.
xv.
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05.03
Applicable Standards and Norms All equipment, systems and practices shall conform to those contained in the following publications, norms/guidelines, standards, acts and rules. Publications of Bureau of Indian standards (BIS) American Conference of Governmental Industrial Hygienists (ACGIH) publication USA. Interplant standard specifications (IPSS) for steel plants. Publications of International standards organization (ISO). VDI stipulation of vibration level. ARI Standard 550-92. ASHRAE handbook Handbook of Air Conditioning System Design by Carrier Air Conditioning Company Indian electricity rules The list furnished for standards and norms may not cover certain aspects or products. In such cases where norms/standards/guidelines other than those listed above are followed, the Tenderer shall furnish a copy of such documents in support for the Purchasers perusal and acceptance of this project. Whenever a contradiction is found between the different documents, the decision of the Purchasers shall be final and binding.
05.04 05.04.01 i.
System Description Air Conditioning Facilities Type of air conditioning system to be provided as per the following general guidelines: Type of Air Conditioning System Split air conditioner/ ductable split air conditioner Water cooled package air conditioners Premises Premises with cooling load less than 5 TR. Premises with cooling load between 5 TR to 15 TR.
ii.
The air conditioning system shall include refrigeration m/c with starter panel (starting control), microprocessor based control panel (safety & operating controls) and sensors. The air conditioning
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system shall include condenser water pump, induced draft FRP cooling tower, condenser water piping, make up water tank for cooling tower (storage capacity of minimum 8 hours operation), G.I. ducting, fine filter, air supply grills/ diffusers, thermal insulation of ducts ( for ducts passing through the non air conditioned area & tail end of ducts in air conditioned area), acoustic insulation of ducts (up to 6 m length) at the outlet duct of package air conditioner & AHU, under deck insulation of all exposed roofs in air conditioned premises, MCC/ starter panels, necessary electrics, instrumentation etc. Cooling tower shall be installed at the highest point of water circuit. Make up water tank shall be provided at higher elevation than the cooling tower basin. iii. Pressure gauge & temperature gauge shall be provided at inlet & outlet water line of cooler, condenser, package AC. Pressure gauge at pump inlet & outlet shall be provided. In general 100% standby shall be provided for air conditioning system. Refrigerant compressor shall be either semi- hermetic or sealed type. R-22 refrigerant shall be used. Condenser shall be shell and tube type, with water in the finned copper tubes and sized for full refrigerant pump down capacity. The condenser shall have removable heads on both sides for tube cleaning and servicing. A sub cooler shall be provided as an integral part of the condenser. The condenser shall be designed, constructed and inspected to comply with ASME code for unfired pressure vessels. Design working pressure shall be 150 psig on the water side and 350 psig on the refrigerant side. The condenser shall be leak tested at working pressure and include relief valve and purge valve. Heat transfer surface shall be selected for a fouling factor of 0.001 hr- ft2- 0 F / Btu. Water pressure drop at design condition shall not exceed 7 mWC. Refrigerant compressor rpm shall not exceed 1450. Motor shall be TEFC & IP 55 protection (in case of open type compressor). Compressor shall have oil injected lubrication system and have integral or separate oil separation system, oil sump & oil filter. An electric crankcase oil heater shall be provided to maintain the proper oil temperature when the system is not in operation. Automatic pump down shall be provided. Refrigerant compressor shall have automatic capacity control arrangement.
iv.
v.
vi.
vii.
viii. ix.
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x.
Refrigerant pipe line shall be constructed of hard grade copper tubes. Ventilation Facilities The air washer system shall comprise dry panel air filter, air washer, centrifugal fan, pumps (with 100% standby), piping & ducting network, air supply grills, gravity damper, electrics & instrumentation etc. Exhaust fan rpm shall not exceed 900, suitable for 3 phase power supply, motor with class F insulation & IP 55 protection, dynamically balanced. Non-return louver shutter shall be provided at fan discharge side. Exhaust fan casing shall be made of heavy gauge MS sheet & impeller shall be made of die cast aluminium. Exhaust fan for battery room shall be of acid proof construction and flame proof construction (Class II B). Motor shall not come in contact with the air stream. Equipment Specification Pump Mono block pump shall be provided for capacity 10 m3/hr & less. Pump shall conform to IS: 9079-1989. Pump casing will be of C.I & impeller will be of bronze & shall have stuffing box arrangement for gland packing. IP-55 protection motor shall be provided. Horizontal back pull out pump shall be provided for capacity more than 10 m3/hr. Pump shall conform to IS: 1520. Pump casing shall be vertically split type. Impeller rpm shall not exceed 1450. Pump shall be coupled to motor with flexible coupling. Spacer type coupling shall be provided. Pumps shall be fitted with mechanical seal in the gland. Pump shall be fitted with double wearing rings, one is fitted in the front of the impeller on the casing and the other is fitted in the back of the impeller on the impeller itself. Impeller shall be dynamically balanced. The magnitude of peak to peak vibration shall be limited to 75 micron. Pump impeller shall preferably be of non overloading type.
05.04.02 i.
ii.
iii.
05.05
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Material of construction MOC shall be as per GS-02. Common base plate for pump & motor shall be in one piece & made of welded steel construction. Adequate space shall be provided between pump drain connection and base plate for installation of minimum 15 mm drain piping. Pumps shall be supplied with suitable drain pans or drain rim type base plates with tapped drain connections. Critical speed of the shaft shall be at least 30 percent above the operating speed. Water Piping and Fittings Water piping up to 150 mm NB size shall be GI, ERW, heavy class and conforming to IS-1239 Part- 1. The pipes above 150 NB shall be GI, conforming to IS: 3589. For thickness refer to technological chapter. Pipe ends shall be beveled. Pipe fittings be as per IS 1239, Part -2. Plate type pipe flanges (as per IS 6392) shall be provided. Pipes shall be of welded joints. Welding (manual metal arc welding) shall be as per relevant IS code and only certified welders shall be employed. All piping systems shall be hydro tested at 1.5 times the design pressure. Auto air venting valves shall be provided at highest point of the pipe lines & drain valves shall be provided at lowest points of the pipelines in different segments. Valve Butterfly Valves shall be provided in water line of size 65 NB and above and ball valve be provided for pipe size below 65 NB Butterfly valve Type Body
: :
Wafer design, flange less SG iron with nitrile rubber/ EPDM lining
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Disc Stem
: :
SG Iron with teflon (PTFE) coating High tensile stainless steel
The valves shall be provided with integrally moulded & bonded body liner to provide perfect seating and complete isolation of body material from fluid. The body liner shall provide the seating to valve disc, primary seal to the stem & gasket joint with matching pipe flanges. Valves shall be provided with self locking lever operation from open to fully closed position with intermediate positions marked on the indicator plate mounted on the top flange. The valves shall conform to BS: 5155 / IS: 13095. Extended valve shaft shall be provided so that the lever can be operated without any obstruction on the insulated pipes. Gear operated valves shall be provided for sizes more than 250 NB. Ball Valve Body : Body liner : Ball : 3 piece design Socket welded type Cast steel Nitrile rubber/ EPDM ASTM A351 Gr CF8
Ball valves shall be with 200 mm length welded joint pipes from manufacturer works. Check valve Type : Dual plate check valve with two springs hinged on a central hinge rod SG iron Nitrile rubber/ EPDM ASTM A351 Gr CF8
Body : Body liner : Disc : Wafer design
Pre- Filter before Package A/C Unit & Ventilation System Filtering media shall be of 5 ply HDPE mesh, stitched and pleated to provide maximum filtration area. Filter media shall be supported on either side by galvanised wire mesh. Suitable aluminium spacer shall be provided to segregate the folds to ensure uniform distribution of air flow through the filter. Filter frame shall be fabricated from 18 G GI sheet. Filter frame shall be provided with suitable handles. Filter frame shall be provided with neoprene sponge rubber .Filters shall be capable of being cleaned by
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compressed air/ water flushing. Face velocity of air through filter shall be limited to 2.5 m/s. Efficiency of filter shall not be less than 90% for dust sizes down to 10 micron. Fine Filter (Microvee Filter) Filters shall be constructed by pleating a continuous sheet of filter medium into closely spaced plates separated by heavy corrugated aluminium spacers. They shall be individually tested and certified. A neoprene sponge rubber sealing shall be provided on either face of the filter frame. The filter frame shall be fabricated from aluminium alloy 16 gauge thick (minimum), conforming to IS: 1737. The filter shall be capable of being used up to its final pressure drop. Suitable frame for supporting the filters shall be provided. Differential pressure gauge shall be provided across filter. This filter shall be capable of being cleaned of their accumulated dust either by compressed air or water flushing. GI Ducting The following codes & standard shall be followed: IS: 226 IS: 655 IS: 277, 2003 SMACNA Specification for structural steel (standard quality) Specification for metal air duct. Specification for galvanised steel sheets (Grade-275) Sheet Metal and Air Conditioning Contractors National Association
The air distribution system shall be sized to have a constant frictional drop along its length. The maximum air velocity shall be restricted to 7.5 m/sec for air conditioning and 10 m/s for ventilation ducts. Fine filter shall be provided at outlet duct from package AC unit. Differential pressure gauge shall be provided across filter. Ducts shall be supported by minimum 10 mm MS Rods and 40x40x3 MS angles. The duct supports shall be at a distance of not more than 2500 mm. The MS rods shall be hung by dash fasteners fixed to the ceiling slab. Flexible connection of at least 150 mm width shall be provided
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where the duct connects to the package AC, AHU, fan etc. Flexible connection shall be closely woven, rubber impregnated double layer canvas or neoprene coated fiber glass. Diffusers and Grills Diffusers/grills shall be of extruded aluminium powder coated. All supply air diffusers/grills shall be complete with volume control dampers. Supply air grills/diffuser shall be double deflection type. Air volume control damper shall be operated by a key from the front of grills/diffusers. Thickness of grills, diffuser, and damper shall be as follows: Frame 16 gauge Louvers 18 gauge Suitable vanes shall be provided in duct collar to have uniform/proper air distribution. Bank of baffles wherever required shall also be provided. Air velocity through diffusers & grills shall not exceed 2 m/sec (for A/C system) and 4 m/sec (for ventilation system). Insulation The surface to be insulated both thermally and acoustically shall be thoroughly cleaned. Pressure/Hydrostatic tests shall be carried out before application of insulation. Two coats of primer paint shall be applied on the clean surface and then CPRX Compound (Shalimar Tar products or equivalent) shall be uniformly applied @ 1.5 kg/sq m on the surface to be insulated. Thereafter insulation shall be fixed. Vapour barrier shall be applied over the insulation followed by 24 G Al cladding or sand cement plaster in 2 layers, totaling 12.5 mm Insulation Material Specification Resin bonded glass wool : PUF : PUF pipe support block : Density 48 Kg/m3, IS: 8183 Density 35 + 3 Kg/m3, IS: 12436 Density 120 Kg/m3, IS: 12436
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Type of Insulation Sl. No. (i) Surface Material Refrigerant piping Package AC condensate Insulation material Closed cell foamed plastic Closed cell foamed plastic Insulation -Thickness (mm) 30 Finish Al cladding Al cladding
(ii)
--
30
Air Washer The Air Washer type ventilation system shall have following component & feature: Centrifugal SISW fan with drive motor and accessories such as flexible connections made of EPDM quality canvas, inlet cone for smooth flow of air, VIV at fan inlet, slide rail for motor, common channel base frame etc. Fan shall be coupled to motor with V belts. Fan rpm shall not exceed 1000. Fan shall be dynamically balanced at least grade 6.3 according to ISO 1940. Impeller critical speed minimum 25% above operating speed. The fan shall have following minimum thickness of materials for different parts The fan shall have following minimum thickness of materials for different parts: Capacity Casing Back plate Impeller blade Upto 20, 000 3.15 mm 4 mm 2.5 mm 20,000 - 50,000 4.0 m 6.0 m 3.15 m Above 50,000 5.0 m 6.0 m 5.0 m
However, for 1,00,000 m3/h capacity material of construction shall be changed.
Air washer with GI spray sets, brass nozzles, GI air distributor, PVC water eliminator (5 row deep), tank, casing, water tight inspection door. Air washer casing minimum 3.15 mm thick & water tank 5 mm thick and inner surface spray galvanised. Intermediate chambers (800 mm length) before & after spray
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chamber with inspection door & drilled flange at both ends. Transition piece with drilled flanges at both ends to connect the intermediate chamber with fan inlet through flexible connection. Circulating water pumps with drives (with standby). Circulating water pipeline, quick fill line, make-up water pipe line with float valve (float made of Cu ball) & back up isolation valve, overflow line, drain pipe line (minimum 40 NB size) with pipe fittings, valves, instruments etc. Water spray 1 m3/ hr per 1000 m3/ hr of air quantity. Y-strainer at pump inlet. Ducting network with damper, supply air grill/ diffuser. Dry panel filters (pre- filter) with fixing frame. Gravity damper. Saturation efficiency of air washer shall not be less than 90%. The face velocity of air through air washer shall not be more than 2.5 m/sec. Low level switch at water tank of air washer and this shall be interlocked with pump. Temperature gauges & pressure gauges at pump outlet pipe line. Temperature gauge before & after spray chamber of air washer. The water proof lights inside the air washer chamber. Air distributors and water eliminators shall be of PVC only. The plate thickness for air washer tank shall be 6 mm and for the body of the air washer casing shall be 5 mm. The internal of air washer shall be galvanised/ zinc spray coated. Nozzles shall be provided for air washer unit.
Cooling Tower Type : Induced draft counter flow Casing/ Basin : FRP Frame Work : MS hot dip galvanized Fills : PVC Nozzles : Brass Bolts, nuts, miscellaneous hardware : MS electro galvanized Fan hub & blades : Cast Aluminium Fan type : Axial flow, direct drive Fan speed : 720 rpm Degree of protection of motor : IP 55 (temperature rise limited to
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Ladder Eliminators
: :
class B) Galvanised steel ladder with safety cage & hand railing up to the top of tower. Inclined to 300 to the vertical. No. of deflector to be arranged to reduce drift loss <0.2% of water circulation.
Cooling Tower Accessories i. ii. iii. iv. v. vi. vii. Level switch at cooling tower basin (to be interlocked with pump). Make up connection with float valve (float made of copper) & back up ball valve. Quick fill connection with ball valve. Overflow connection. Drain connection with ball valve. GI wire mesh 18 gauge strainer. Equalizing line of cooling towers with isolation valves
Pressure Gauge Manufacturing Standard Range Range (at pump suction) Dial Diameter Accuracy Degree of protection Sensing element Bourdon tube material Connection Connection size Mounting Case Bezel (screwed) : : : : : : : : : : : : : IS 3624 06 Kg/ cm2 or 0-10 Kg/ cm2 (-)2 to (+) 2 Kg/ cm2 100 mm + 1% of FSD IP 65 Bourdon tube AISI SS316 Screwed BSP (M) Direct with bottom entry Die cast Al stove enamelled black finish Die cast Al stove enamelled black finish Shatter proof glass Al anodised black Al white with black letters AISI 304SS AISI 3166SS : Yes
Dial window : Pointer : Dial : Movement assembly : Shank : Adjustable pulsation damper
Pressure gauges shall be provided with isolation valves (ball valves).

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Temperature Gauge Type : Bi-Metal thermometer Rigid Stem + 1% of FSD AISI 316SS To suit pipe size Cast Al stove enamelled black with weather proof as per IP65 100 mm Bi-Metal strip 8 mm BSP (m) Vertical Bottom 0-60 0C To be provided
Accuracy : Stem of connection metals : Immersion length : Enclosure : Dial Size Sensor Stem dia Connection Mounting Entry Range Thermo well Make Up Water Tank : : : : : : : :
Tanks shall be MS (5 mm thick) & inner surface spray galvanised. Make up water line with float valve & backup ball valve, quick fill line with ball valve, drain line with ball valve, overflow & vent line, level gauge (with isolation valves) shall be provided. Low level switch shall be provided at tank & interlocked with pump.
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06.00 06.01
HOISTING AND HANDLING FACILITY General The scope of work of the Tenderer pertaining to material handling system shall include the design, manufacture / procurement, inspection, shop painting and supply F.O.R. at site / Contractors site-stores, transportation of materials to erection site, storage, testing, erection, commissioning and performance guarantee of material handling system. This section of TS deals with the following sub- system: a). One no. 2T capacity (indoor) Electric Wire Rope hoist in RO Plant Building. b). One no. 2T capacity (indoor) Electric Wire Rope hoist in Chemical House. c). One no. 2T Manual hoist in chemical house. d). Suitable capacity of electric hoist shall be provided as per design requirement in Zero liquid discharge plant building as well as for dewatering plant.
06.02
Scope of Work The scope of work of the Tenderer includes design, engineering, manufacturers, assembly, shop test, painting at manufacturers shop as well as at site after erection, supply including dismantling for transportation, packing, loading and transportation, receipt, unloading, storage and re-conservations at site, erection, testing and commissioning of indicative list of handling and hoisting facilities as indicated in the table below. However the capacity shall be in line with technological requirement to be finalized during engg. Stage. Sl. No. 1. 2. 3. Description 2.0T capacity x 6m lift Electric Hoist. 2.0T capacity x 6m lift Electric Hoist. 2.0T Capacity x 12m lift Manual Hoist Qty 1 1 1 Location RO Plant Bldg. Chemical House Chemical House Remarks
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Sl. No. 4.
Description
Qty
Location Zero liquid discharge plant bldg Dewatering plant
Remarks Capacity will be decided during detail engineering. Capacity will be decided during detail engineering.
Electric Hoist
5.
Electric Hoist
06.03
Design Standard and General Details i. The Electric hoist shall conform to class-1 duty as per IS: 39382005. The structure of Elec. Hoist shall conform to class-2 duty as per IS: 807-2000. The crane/electric hoist shall also conform to various safety codes. The crane/electric hoist shall also (MEC/S/E24F/11/38/0/00/00/F1874/R0). follow GTS
ii.
iii.
iv.
Supply of under slung /over head travelling crane/electric hoist shall be designed as per specific requirement. The crane shall be designed as per IS: 3177-1999/4137-1985. The chain pulley block used shall conform to IS: 3832-2005. The supply includes necessary attachments as required.
v. vi. vii.
viii. Ball & roller anti-friction bearings only shall be used. ix. Swiveling type standard shank hook mounted on grease lubricated anti-friction thrust bearing shall be used and conform to IS: 15560-2005.
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x.
Load chain & operating chain shall be as per relevant IS & the same shall be of calibrated type. The maximum operating effort for hoisting and travel shall be 25 kg & 20 kg respectively. Pulley used for the operating mechanism shall have suitable guards to prevent the operating chain from coming out.
xi.
xii.
xiii. All the open gearings shall have suitable cover. xiv. No-load testing shall be done at works after full assembly in presence of Purchaser. The crane/electric hoist shall be load tested at site after erection. xv. No wooden parts or cast iron parts shall be used on the crane/electric hoist.
xvi. Maximum deflection of the bridge girder with safe working load on the travelling hoist shall not exceed 1/900 of the crane span with travelling hoist stationed at mid-span & excluding deflection due to dead load. xvii. All butt welds on structural members subjected to tensile stress shall be X-rayed. xviii. Travelling speed, tractive efforts & bill of materials shall be indicated by the party during approval of drawing and shall be subject to Purchasers approval. xix. The crane/electric hoist shall be inspected at works by Purchaser or by his representative prior to despatch of the equipments as per mutually agreed procedure (which will be finalised after placement of order).
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06.04
Documentation i. Drawings/ Documents To Be Submitted With The Tender Tender shall be accompanied with General Arrangement drawing/catalogue of crane/electric hoist/chain pulley block showing height of lift, overall dimension, capacity, nos. off, weight, head room of hook, bill of materials etc of the indicated handling & hoisting equipments. ii. Drawings/ Documents To Be Submitted for Approval a. GA Drawing of crane/electric hoist showing all details. b. GA of chain Pulley Block along with Travelling Trolley. c. Structured design, calculation. iii. Final Drawings/Documents To Be Furnished Alongwith The Equipment. a. GA Drawing of crane/electric hoists showing all details. b. GA of chain Pulley Block along with Travelling Trolley. c. Structured design, calculation. d. Material Test Report. e. Inspection Report
06.05
Questionnaire .01 Electric Hoists: a. General i. DPR/TPR/Electric Hoist No. ii. No. off iii. Type iv. Suppliers/Make v. Capacity vi. Span vii. Over hang on either sides
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viii. Duty class ix. Height of Lift Above floor level Below floor level x. Bottom level of track beam b. Hoist i. Speed Type of construction Size Number of falls Rope grade Factor of safety iii. Rope drum Materials Diameter iv. Drives Type & material of gear box Gear & pinion Material & hardness v. Motors Type & number Kw rating Synchronous speed Class of insulation Pull out torque Frame size vi. Brakes Type Size Torque rating ii. Wire ropes
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vii. Hook Type Material viii. Type & Details of limit switches ix. Type of couplings x. Type of bearings c. Trolley i. Speed Numbers Diameter Materials & hardness Max. wheel load Wheel base iii. Drive Type & material of gear box Gear & pinions Material & hardness iv. Motors Type & number Kw rating Synchronous speed Class of insulation Pull out torque Frame size v. Brakes Type Size Torque rating vi. Type & Details of limit switches vii. Type of couplings viii. Type of bearing ix. Type & details of control
ii. Wheels
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x. Wheel load /pair of wheel d. Type & lubrication provided e. Type & size of cables f. Location & control details of hoist Block power feeding arrangement g. Total weight of Electric Hoist .02 Manual Hoist: a. DPR/TPR/Manual Hoist No. b. Capacity c. Quantity d. Height of lift e. Duty class f. Make g. Minm radius of curvature h. Maxm Tractive effort Hoist Travel Movement in m corresponding to Operating chain movement of 30m Hoist Travel
i.
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07.00 07.01 07.01.00
ELECTRICS & CONTROL TECHNICAL AUTOMATION SPECIFICATION FOR ELECTRICS &
GENERAL The scope of work of this specification shall cover design, engg. (including cable & erection engineering & system design), fabrication, manufacture, assembly, testing, inspection, painting, delivery to site including packing & forwarding, transportation, unloading at site, storage under safe custody, erection, site loading / unloading, transportation, testing, start-up, commissioning and demonstration of performance guarantees for electrics, and automation for Tertiary treatment plant equipment as part of new CRM. Power Distribution and Electrics This part of the specification pertains to power distribution system and electrics of proposed Tertiary treatment plant equipment including its automation. All work covered under this part shall meet the requirements specified in the General Technical Specification.
07.01.01
07.01.02
HT/LT Power Supply System & Battery Limit A) Power supply feeders for the Tertiary treatment plant equipment shall be made available from Employers LT Substation at Welfare Building 2 nos, 1250A LT ACB feeder for supply to Tenderers one no double ended Main PDB (with buscoupler) shall be made available from Employers LT switchboards. Tenderer to indicate if clients 6.6KV feeders from MSDS-IX are required for direct supply to required HT motor. B) 32A TPN existing available power supply feeder for each of the following additional unit of Blowdown collection sump/pumps at various locations in CRM complex area (namely at BAF/SPM, HRCC, PLTCM /HDGL/ECL, ROLL SHOP, TLIL and CAS) as stated below , shall be made available to contractor for tapping 415V power supply using tenderers incoming cable and feeding to tenderers Starter / Electrical control panel for each set of 2 nos Blowdown transfer VT pumps with associated sensor. In all cases , the existing feeders as available in the existing plant or near existing plant shall be provided to the tenderer for tapping power supply and same shall suit site conditions.
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C) Feeders required for Blowdown collection sump/pumps at Effluent treatment plant , at Ext water system & at TTP shall be taken from new tenderers PDB panels at TTP for which minimum MCCB rating to be considered shall be 63A for External water system area and 100A for Effluent Treatment Plant. D) Motor feeder shall be considered for Blowdown collection sump/pumps at TTP with its necessary Local control stations. E) Approx. minimum incoming cable distance to be considered for supply by tenderer for each Starter / Electrical control panel shall be 300m. Details of pumps is as follows: of Sr. Location of each Blowdown TPN Feeder rating No. transfer VT pumps available near pumps existing plant for contractors use (*) a. BAF & SPM 32A 2 ( 1W + 1S) b. HRCC 32A 2 ( 1W + 1S) c. PLTCM & HDGL/ECL 32A 2 ( 1W + 1S) d. ROLL SHOP 32A 2 ( 1W + 1S) e. TLIL 32A 2 ( 1W + 1S) f. Compressed Air Station (CAS) 32A 2 ( 1W + 1S) g. Hydrogen generation Plant 32A 2 ( 1W + 1S) h. External water system area Feeder from new 2 ( 1W + 1S) (HRSCC Sludge transfer pump) panel at TTP by tenderer / at ext. water system i. External water system area Feeder from new 2 ( 1W + 1S) (RO Reject transfer pump) panel at TTP by tenderer / at ext. water system j. Effluent Treatment Plant Feeder from new 2 ( 1W + 1S) (Effluent transfer pump) panel at TTP by tenderer k. Effluent Treatment Plant Feeder from new 2 ( 1W + 1S) (treated water transfer pump panel at TTP by from BOD plant) tenderer l. TTP Feeder from new 2 ( 1W + 1S) panel by tenderer (*) Location of feeder shall be decided as per site conditions.
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All further downstream equipment beyond Employers HT/LT switchboard is in the scope of Tenderer that shall include required HT/LT motors, other items like AC motors (HT & LT) , 415V/415V dry type Isolation convertor transformer before VFD panel if required (VFD incomer tapped using LT supply thro Employers LT sub-station) , Electrics for any handling facility with associated ACB/MCCB box used as isolator near handling area/facility, MCC, PDB , LDB , Emergency PDB, Emergency LDB, Illumination equipment with 240VAC and 24VAC sockets for any required technological premises of the Tenderer, FDA system, PLC and automation system with its all required special cables , RIO panels, UPS system, field devices & sensors, cables (including all HT / LT power and control and special cables including all Ethernet / remote I/ communication cable) , All required cable tray & supporting structure from Employers HT/LT board onward ,erection and earthing materials and all other accessories as required are in Tenderers scope. Power supply to HT motors if required from 6.6KV (depending upon the motor rating more than 200KW) shall be provided from Employers 6.6kv switchboard under separate package from HT sub-station building. Supply and laying of HT power and control cables including required cable tray with cable termination (at both ends) shall also be in the scope of work of the Tenderer. The Tenderer shall indicate the requirement of feeders at 6.6KV / 415V along with emergency power for Tertiary treatment plant equipment in the offer to facilitate the planning and designing of Employers Power Distribution Package. The details of connected load (in kW), and 15 minute maximum demand (in kVA) for each feeder / unit shall also be furnished by the Tenderer. Battery Limits The Tenderers battery limit shall start from the outgoings of Employers 6.6 kV switch boards at MSDS-IX HT sub-station room for any HT motor and Employers 415V LT switch boards at PURCHASERS WELFARE BUILDING SUB-STATION. All down stream equipment with cables , erection / earthing materials etc as required is in scope of Tenderer . 07.01.03 Applicable Standards The plant & equipment will meet this TS, General Technical Specification(GTS), relevant Indian Standards, IPSS, and in case
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Indian Standards are not available for any equipment / system, it will meet the international standards & norms such as IEC, IEEE, VDE, DIN, EN. of technical specification in following pages will override in case of any anomaly. Other than IEC, IS/IPSS/IEEE/ EN and other state/central electricity rules and acts will be applicable, which ever is more stringent. The equipment will also conform to the latest Indian Electricity Rules and State Electricity Rules, as regards safety, earthing and other essential provisions specified therein for installation and operation of electrical plants. Equipments in explosion prone area will conform to statutory requirement of explosive area as defined / certified by national bodies (Such as CMRS-Dhanbad, CCENagpur). Fire detection / fighting systems will similarly meet the requirements of NFPA & will be UL/FM /TAC approved. All items of the equipment shall comply with the latest regulations and stipulations of statutory bodies of Government of India & Government of JHARKHAND. The successful Tenderer will have to obtain necessary approvals from statutory authority / authorities and other concerned agencies. All costs on this account shall be borne by the successful Tenderer. However, Tenderer shall be extended assistance by the Employer in this regard. Wherever specification is not clear or information not existent, approval will be given by Employer in the form of comments on information / drawings / data submitted by Tenderer . 07.01.04 Interface Signals Provision of following shall be taken care by Tenderer : Interface (Both hardware and software) with external system, like Employers MV power Distribution system, level-3 system , Employers LV power Distribution system, etc. Interface (Both hardware and software) as required as per detail engineering requirements between starter/ Electrical control panel / RIO as required near each location of Blowdown transfer VT pump in CRM complex area to TTP PLC / MCC system
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07.01.05
Makes of equipment Name of main electrical supplier (OEM for main eqpt) for Tertiary treatment plant equipment / aux. system equipment system Furnish Name Name of Main electrical supplier who shall be responsible for Design , Engineering and supply of scope covered under this part of specification and shall be responsible for integration with all electrics Furnish Name Type of PLC offered will be of same type. PLC and AC drives shall be sourced from Furnish Name Make list shall be as per TS & General Technical Specification(GTS).
07.01.06
Spares All commissioning spares shall be as per GCC. List of minimum commissioning spares shall be as enclosed herewith this TS. However, any additional commissioning spares required during commissioning, if any, shall be supplied by the Tenderer free of charge without affecting the overall time schedule of the project. List of 2 years operation spares/ insurance spares shall be as per GCC Insurance spares shall be as per GCC
07.01.07
Training of Employers Personnel Tenderer to furnish details of training for following category in his offer: a) b) c) d) Providing training to Purchasers personnel on electrics & automation system supplied by the Tenderer at different equipment Manufacturers works Training / hands on training in similar working plants Training at site during commissioning. Involvement of Purchasers personnel in software development shall also be included.
Both theoretical & hands on training shall be involved.
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07.01.08
Painting Shall be as per General Technical Specification(GTS)
07.01.09
Scope of Work Scope shall include :
1.
2. 3. 4.
5. 6. 7. 8. 9. 10. 11. 12.
13.
14.
Main Electrics & automation for Tertiary Treatment Plant to include all required power distribution equipment, all fixed drives , any variable frequency drives if required for Tertiary Treatment Plant, L1 automation including PLCs including automation of water level control , HMI for sequencing / interlocking & monitoring , operator control desk/ posts as required. Standby pumps with automatic start in case of tripping of working pumps or due to working pumps failure to start. Any Distribution / convertor transformer as required. Motor & panel Ventilation as required. Illumination of Tertiary treatment plant including ECR, transformer Room , pump house , any settling tank & filter house , any cooling tower and other installation equipment area / premises, street and area lighting nearby, all blowdown transfer VT pump area in CRM complex area including at EXT. water system area / Effluent treatment plant area / compressed air system area. Air-conditioning & ventilation of ECR and associated premises Provision of LT feeders for Purchasers use. Emergency boards and its distribution as required for Tertiary treatment plant Required Closed circuit video monitoring (CCVM) for Tertiary treatment plant. Required Fire Detection and Alarm system for the plant Basic data & engineering for Telephone network, Loud speaking intercom system, VHF communication. LT AC drive motors complete with necessary accessories and mounted electrics as per the technological requirements. One no double ended Power distribution board, PDB with 1000A incomer and outgoing ACB and MCCBs as required. PDB incomer connected to 1250A incomer panel source at Clients Welfare building sub-station. 415V, LT Electrical control panel / Motor Control Centre (MCC) housing starters for all motors, PDB with all necessary power supply feeders, feeders for illumination, maintenance hoists etc. and as required for the other associated systems. Emergency LDB
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15.
16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32.
33.
Starter / Electrical control panel in IP55 construction and with canopy for each set of Blowdown transfer VT pump area in CRM complex area with necessary RIO panel/ components / for remote interface and with outgoing feeders for pumps/ Dry run protection sensor / local lighting DB as required etc . All the pumps will be provided with dry run protection thro technological group. Control scheme shall be such that standby pumps shall start automatically in case of tripping of working pumps or if working pump fails to start. Any other interface / functional interlocks if required during detail engineering shall be provided. Motor control panel if required for rating greater than 110KW, 415V/415V dry type Isolation transformer (with insulation of class-F and temperature rise limited to class-B) before each feed of Double ended MLDB. Required Local control stations (LCS) and control desk Any Remote I/O panel as required All pump shall be stopped automatically in case of low water level in the sump tank (Dry running protection). Level controller along with probes to be mounted in the electrical control panel. PLCs, HMIs, L1 & L2 automation system , UPS system for Tenderers scope of work , Sensors , Local Control Stations (LCS/ OS) with pedestal support/cover , Control Desks (CD) , Emergency stop PB station with mushroom head PB an indication lamp for each AC motor All required furniture (like table , operator chair , 2 nos almirahs for each automation room , shoe rack) for control room as required Power junction box for LTAC motor greater than 75 KW (Cables from power junction box to motor terminal box shall be copper power cable laid in GI pipe) Junction Boxes (JB) / Pull boxes including water proof stainless steel (for use in water zone area ) junction box as required, IP based closed Circuit TV /CCVM system /monitors/recorder with special cables (Tenderer to specify quantity of CCVM, monitor and recorder offered). Power supply from UPS system included All field mounted devices, measuring instruments, solenoid valves, material sensors & load switches as required to achieve desired functions/ performance as included in new technological package. All required 100A Welding sockets , 15/5A 240VAC sockets , 24VAC sockets. 15/5A 240V Plugs & Sockets for Hand tools/Lamps shall be provided in all technological premises as required All required 11 kV/6.6kv cables , 1.1kV power & control cables and
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35.
36. 37.
38.
interconnecting cables between all equipment, including special cables for electrical / automation system emergency power supply cable from. This shall include all required Screened & all special cables ,data cables , co axial cables, fire resistant / fire proof cables, high temperature cables , Video Optical Fiber cables as required for forging line equipment and other equipments in scope and interconnecting cables between all equipment, including special cables for electrical / automation system emergency power supply cable from. Supply and installation of erection material and accessories including exposed conduits, cable trays (Perforated and ladder) , supports, brackets, cable termination items such as lugs, sockets, glands etc, junction boxes, canopies, GI pipe for earth pits, earthing strips etc.cable joints, cable glands (Double compression brass glands) , Junction boxes, Pull boxes, foundation and fixing bolts/nuts/washers , HT / LT / Control cable termination kits , Earth electrodes and earth pit materials including measurement of soil resistivity at site, cable trench materials with checker plate and any other material required to complete the installation. All required Rigid and flexible conduits , complete with its couplers , bends etc , embedded conduit (where an embedded conduit / floor opening / wall cutout is required at site due to mistake / incomplete information by Tenderer in their civil assignment ) and all required exposed GI pipe and earth strip is included in Tenderers scope Supply and installation of complete equipment Grid earthing system (minimum 3m deep) for TTP equipment and earthing of all electrical equipment under the Tenderer scope & connection of this secondary earthing system made by Tenderer up to Tenderers Primary Grid earthing ring /pits / strip of the plant all around area. Tenderers scope shall include all necessary electronic earthing mats for their equipments with connection by copper cable in GI pipe. Earth mats and earth pits shall be located in the earth mass 1m below ground level . Total primary Earth resistance must be less than one ohm. Earthing of Blowdown transfer VT pump motor / its starter etc in two connections shall be to the nearest available plant earth grid/ strip. Supply of all foundation bolts and special embodiments as required for installation of all equipment covered under this specification. For electronic earthing of PLC and automation system at TTP area , the scope shall also include earth pits / electrodes / copper plate / copper cable.This shall include 12x6m earth mat using buried 50x6m earth strip ( at a cross section of every 300mm x300mm for the whole mat area of 12x6m) at approx. 800mm or below the ground level and then connected to minimum 2 nos earth pits Supply of all electrical equipment as per the preferred make of
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49. 50.
51.
52. 53. 54. 55. 56. 57.
equipment (GS-13). Special tools and tackles as per enclosed list. Commissioning spares as per enclosed list.. Demonstration of integrated performance during guarantee period. Obtaining statutory approval from Central and State govt. authorities for the installation are also included in the scope of work of the Tenderer Complete engineering consisting of submission of all engineering drawings/ documents necessary for proper procurement / installation / commissioning Preparation of cable schedules, electrical connection diagrams. Control schemes to be designed by successful Tenderer shall incorporate all technological control features & interlocking considered necessary for trouble free operation of the package. Supply of all erection accessories, cables and consumables. Safety items like hand gloves, shock treatment charts, rubber mats, danger/caution boards , Discharge rods in front of all panels and in all other required areas. Civil assignment for provision of inserts / cutouts/ conduits/ openings as required for Installation of their entire range of electrical equipment / switchgear room equipment /any transformer/ other equipment and for provision of purchasers cable racks in ECR. Excavation, back filling, and leveling of cable trenches if required. Any additional items/equipment, which are necessary for achieving specified performance and completeness of the equipment shall be provided by the Tenderer without any extra cost and within the time schedule unless it has been excluded from the scope of the Tenderer. Supply and installation of GI pipes in concrete block by Tenderer for protection of cables at road crossings and other places in bay area where cables may be subjected to mechanical stress and damage. Measurement of soil resistivity at site. Provision of surge protection for lightening and switching surges for electrical & electronic equipment shall be by the Tenderer covering all electrical equipments and panels. All foundation mounted motor shall be provided with base frame / sole plates and foundation and fixing bolts/nuts/washers. Provision of FRP (Fibre reinforced plastic) or light alloy material JBs with IP65 protection for use in wet areas. All necessary mounting structure for sensor, piping up the sensor / motor heat exchangers, valves, drying units, filters etc as shall be required shall form part of Tenderers scope. Any additional items/ equipment / work which is necessary for
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60. 61. 62. 63.
successful commissioning and achieving specified performance and completeness of the equipment shall be provided by the Tenderer without any extra cost and within the time schedule unless it has been excluded from the scope of the Tenderer. Illumination load / Utility power supply loads shall be completely separate and shall not be mixed with material handling loads. Equipment shall be supplied as per as per TS and as per General Technical Specifications (GTS). Make of all other electrical equipment shall be inline with "Preferred makes of equipment and supplies of GTS or as specified in TS. All other equipment not covered, specific approval shall be taken by the Tenderer from the Employer. Only one make shall be adopted for each type of equipment considering plant standardization. Provision of cable trenches/ conduit arrangement, drainage pits with its pumps / motors and its controls for cable trench water drainage , minor civil works such as chipping, provision of inserts, opening etc. Any other electrical equipment / accessories as required for the integrated operation of construction water system facilities to meet the technological requirements. 2 years operation and maintenance spare (only list with PU rates for ordering by purchaser later) This specification forms a part of the tender documents and shall be read in conjunction with GTS (GS-03 & other GS) and General Conditions of Contract (standard bidding document) and Instruction to the Tenderer for supply, erection and commissioning of the plant and equipment. In case of any difference between this TS & GTS, the provisions of this TS shall apply.
07.01.10
Following points are to be taken care during engineering and Erection Power feed to the fixed speed DOL start 6.6kV motors if required for KW rating greater than 200KW rating. This shall include all required 6.6kV Cables from Employers HT panel to Tenderer s 6.6kV motors including LT interface/ control cables; Cable laying & termination at both ends including termination kits and required cable trays & supporting structure ) On/Off trip status and actual current display & HMI screens provided at PLC system of technological facility. Tenderer shall specify required numbers of 6.6KV feeders (Feeders to be provided by Employer) indicating their respective maximum demands / connected loads.
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All valve stands shall be supplied as pre-wired with 2.5 sqmm copper cable to junction box (mounted on valve stand structure) The detailed specification and schedule of quantities shall be worked out based on the detailed engineering to be carried out by the contractor, for complete and proper execution of the specified tasks. The quantities of equipment, cables, cable terminations, straight through joints, cable supporting structures, earthing/lightning and erection materials, shall be as per actual requirement in accordance with the approved detail engineering drawings. No claim for any extra payment shall be considered. Equipment will be supplied as per the Technical Specification (TS), General Specifications (GTS) and its subsequent addendum (if any). TS / MOM will prevail over GS in case of any contradiction. Wherever specification is not clear or information not existent, approval will be given by Purchaser in the form of comments on information / drawings / data submitted by Tenderer or as specific approval issued by client. The minimum size of 6.6KV grade cable shall be 3c x240 sq mm XLPE U/E grade & Max. LT power cable size shall be 3.5C x 240 sqmm Tenderer to include all power supply requirement of sensors (especially 24VDC and 240VAC) along with its contact signal as supply part of all PLCs and all RIO panel. Minimum One row of control cable tray racks shall be provided by tenderer in each multiple tray row in ECR-1 and also in entire field RCC trench area to provide adequate space for various conduits required for Fibre optic cabling and for special PLC RIO communication cabling in field area. All cable trays / racks as required in ECR / FIELD cable trench area shall be in bidders scope. Use of rigid GI pipe of size 40 mm dia. for each special comm. Cable/ for Ethernet cable / for profibus cable / for RIO communication cable in control cable tray to prevent any other problem of its vicinity with other power cable / passage blockade due to side support. All control cable trays shall be considered as perforated type. Location panel of TBs for termination of FO cable/ RIO special cable inside VFD panel / MCC RIO and other panels should be sufficient to bring the FO cable/ RIO special cable at a safe distance (approx. 300mm minimum) from power cables outside the panel.
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BD, BE for Relay setting calculation is to be submitted by technologist / Tenderer for use by Employer /LCSS supplier part of basic specification for approval. Power junction box (PJB) in field area as required for power supply to motors for rating greater than 75KW shall be provided by main pump/motor equipment/ technological supplier and same should have following necessary components such as 1. Electrolytic grade shrouded tinned copper bus bar 2. Non-hygroscopic Epoxy moulded insulator 3. FRP barrier 4. Besides , should have Danger board , bottom base channel and support frame for installation , front Double door, rear bolted door , lifting arrangement , Bi-metal strip for termination of aluminium cable at copper bus bar, Bottom gland plates for cable termination with PJB located near motor/pump frame side end. Top gland plate shall be provided if necessary to suit the layout. These boxes shall have gasket and shall be in IP55 protection enclosure. Size of the box shall take care of number of incoming and outgoing aluminium / copper cables including earthing cables. The IP class certificate should be possible for submission by supplier thro proper tests at CPRI. Necessary Cables for Power junction box for LTAC motor terminal box for motor rating greater than 75 KW from power junction box to motor terminal box shall be single core un-armoured copper power cable laid in trifoil on tray / in GI pipe) and same shall be laid in GI pipe / its bend and terminated, All the cadmium coated nut bolts shall be provided for all cable terminations at the bus bars. a. The PJB may be located & installed near the motor to suit site condition with due approval by client/ consultant. b. MJB's shall be made with 2.0mm thick CRCA galvanised sheet with necessary flange & gasket with IP55 degree of protection. c. Apart from side supports, bus bars to be supported from top angles through suitable no. of insulators, intermediate support arms to be provided accordingly. d. Proper arrangement will be provided for mounting of busbar. e. Front & Back are with bolted removable covers. f. Detachable lifting arrangement of PJB shall be provided.
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g. Busbar shall be shrouded and the front door will have danger board. h. PJBs shall have continuous ISA50 on all edges and as intermediate stiffners apart from using as insulator and bus bar supports, this angles shall be fabricated to form the overall junction box and the sheet steel cover shall be welded on this structure frame. i. Short circuit withstand capacity of the busbar arrangement will be 50KA for 1 sec. j. All the busbars will be clearly identified with colour coded heat shrinkable pvc sleeves. k. Non-hygroscopic epoxy insulators will be provided as bus bar support. l. Tinned copper bus bar for phase & for earth shall be provided.size shall suit the current rating required with client/consultant approval. m. 3mm thick cable gland plate in 2 parts (aluminium) shall be provided. n. 75mm height base channel black epoxy painted shall be provided. o. Gaskets shall be used in the grooves of all removable covers and other places as required. p. Bimetallic strip where ever required will be provided at site. q. Bus bar hole dia shall be as required. r. Each line copper bus bar size in sqmm shall be minimum twice the motor rated line current rating in amps. s. Each Earth copper bus bar size in sqmm shall be minimum same as motor rated line current rating in amps. t. The IP class certificate for PJB enclosure in IP55 construction and Copper bus bar temperature rise test certificate should be submitted by supplier thro proper tests at CPRI. Provision of Rigid conduit with threads / bends with threads / coupler/ flexible conduit (with proper size specified) / nipple etc which is required to take a cable from nearest embedded conduit up to the terminal cover/box or from cable trench to motor TB. Installation of vertical conduit from a cable trench to motor TB should preferably by using a saddle with clamps/nut/bolt arrangement instead of welding of vertical conduit at the trench sideways. All these provisions should be specifically detailed out by Tenderer (for each equipment category /type of conduiting / termination) for submission in the form of various erection drawings and formal clearance (cleared for information ) received
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from Employer / consultant. Proper conduit fixing arrangement (to carry fibre optic cable / profibus cable/ RIO communication cable ) in the control cable tray should be followed as cleared for information by Employer / consultant and this provision of fixing typical arrangement should be detailed out in the form of various erection drawings for submission and approval/formal clearance from Employer / consultant . It may be noted that no welding of conduit fixing arrangement is allowed while using a special cable laying.Also, associated proper control junction box (for conduit entry and exit) of 1.6/2mm sheet steel thickness provisions and size (dimension and number of TBs) of various required control JBs should be detailed out for submission / clearance. Various field area installation items such as RIO panels, Junction boxes, Local control box etc require bottom floor mounted structure / wall support structure as part of Tenderers scope. All these provisions should be properly engineered and detailed out for submission and cleared for information from Employer / consultant with regard to location and installation arrangement. These locations shall be specified by tenderer as part of their offer. Each plan drawing of Cable tray arrangement in ECR / cable tunnel shall be cleared for information by Employer / consultant with duly mentioned information by electrical supplier / erectors scope of supply w.r.t. bill of quantity of total cable tray length (for each size of ladder type tray and perforated type tray ) and of supporting structures length / sizes. This detail is helpful for site supervision w.r.t. supply / availability of tray material at site as per site erection priorities. All cable schedules must be submitted by supplier with approx cable length known based on approved equipment location / layout drawings. The approx. total cable length requirement for each cable size / type should be specified by technologist / Tenderer supplier in cable schedule to check / ascertain the availability of total number of cable drums/ cable length as required at site. No clearance shall be given by Employer/ consultant for unapproved cable sizes. If supplied, then the supplier shall be responsible to supply new cables as needed and Employer / consultant shall not be responsible for the same. Tenderer shall mention outer diameter of cable used as part of cable schedule.
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Tenderer to ensure that while finalizing the number of power cable trays in basement or cable tunnel or cable trench, necessary gap between power cables is considered and maintained. Various salient important points of GTS GS-03 which affect operational clearances from Employer / consultant shall be taken care by Tenderer to enable proper care by electrical supplier while preparing drawings. Necessary paint marking of various equipment name / reference number of various tray number marking, Junction box number marking and other required items paint marking as required at site is included in scope of Tenderer/erection contractor. Layout detail of storage equipments by electrical supplier for formal clearance by Employer / consultant with access from two sides / entrances shall be submitted by Tenderer. All cable termination nut / bolts and washers inside all the supplied panels must be supplied as part of Tenderers panel suppliers scope. Various Field area Remote I/O panel shall be supplied by Tenderer/RIO panel supplier with a bottom base frame for installation at plant floor area approx. 500mm above floor area and with a small pedestal for a person to walk up and operate / maintain. All plant floor area Local control station (LCS) shall be supplied with its floor mounting base (with aesthatic look) by Tenderer/LCS supplier. Necessary requirements of control junction box enclosure (IP66/67 class) for location in required water zone (specification / area of water zone to be defined by technologist) of the plant / field area should be specifically mentioned by Tenderer. Quantity / location of water zone Control JB should be specified by technologist. A proper location / layout drawing of connection to Tenderers Grid earthing pit and Tenderers electronic earthing pit (outside ECR building) and its connection shall be approved / cleared by Employer/ consultant. Use of size 65x8 or 75x10 size earth strip for HT cable tray in cable tunnel / other areas is to done by Tenderer. All dry type transformers shall be separately enclosed in a separate room with ventilation system Necessary office buildings with utilities and Foremans room shall be considered as part of assignment and same shall be marked
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on layout as per ECR-1 layout requirements. Supply and installation of GI pipes in concrete block for protection of any cable at road crossings and other places in the bay area where cables may be subjected to mechanical stress and damage. The Tenderer shall submit preliminary Quality Assurance Plan indicating list of Type test & Routine test along with the offer for major items. However, final QAP shall be approved during engineering. All tests shall be done as per relevant standards. All standard diagnostic packages and development tools/ software used during commissioning shall be Employers property. Motor list shall be submitted by Tenderer during engineering & shall cover all equipment in the line including all sensors , solenoids, each application-wise automation provision, Ventilation and air-conditioning system , compressor system, cranes, all bought out items, all items requiring feeders , all other utilities / auxiliary items as required . Cable conduits shall not be buried directly in the earth and shall be embedded inside the concrete. Very long runs and complicated bends shall be avoided. 20% spare conduits shall be provided for future use. Tenderer shall furnish approx. dimensions of ECR with details of provision of cable floors, basement floors, motor house basement etc. Inverter technical data such as Supply voltage, DC link voltage, Output voltage, supply & output frequency, power factor (fundamental & total), efficiency, line side converter & inverter rating shall be furnished. The Tenderer shall submit Quality Assurance Plan for all items to be supplied for approval Quantity and rating as mentioned in the offer for various items shall be considered to be indicative only. Final quantity shall be as per detail engineering requirements. Approach ladders and platforms as required for maintenance access to instruments to be provided. Location of electronics equipment in hot & dusty areas shall be avoided as far as possible. However, if necessary necessary cooling & protection shall be in the scope of the Tenderer Approval of Statutory Authorities: It will be the responsibility of
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the Tenderer to obtain necessary approval of statutory authority as per rules of Govt. of JHARKHAND and Central Electricity Authority for the work under his scope, before energizing/charging the equipment. However, Tenderer shall be extended assistance by the Employer in this regard. The Tenderers scope shall also include engineering for service tunnel / tressel for power supply up to Tenderers Electrical Switch Houses. 07.01.11 Construction Power Supply Tenderer to specify the 415V construction power / Ampere Feeder rating requirement for provision by Employer. All further distribution arrangement, provision of temporary lighting etc. to be provided by Tenderer. Tenderer scope shall include supply , erection and commissioning of all required incoming cables (from an approx. distance of source of 500m) , PCC , PDB and Distribution cables along with o/c, s/c and earth fault protection in incoming ( with KWHr consumption meter in each incomer) and outgoings. Tenderer shall do distribution as per their requirement. ELCB/RCCB shall be provided in outgoing feeders. Minimum 8 runs of 3.5CX 240 sq. mm AYRY cables shall be considered from welfare building TS to each incomer of double ended main PDB at TTP. 07.01.12 Design Criteria a. The equipment offered should be suitable for smooth, efficient and trouble free service in the tropical humid climate prevailing at plant site and under the ambient temperature conditions indicated above for the different areas. Location of electronics equipment in hot & dusty areas shall be avoided as far as possible. However, if necessary, cooling & protection shall be in the scope of the Tenderer. All equipment and accessories located outdoors will be duly protected against weather. b. The electrical equipment shall be of latest state of art design. Older generation equipment shall not be offered. c. For smaller ratings below 630 KVA, AN transformers shall be located in transformer pen or in ECR or in a separate room as per detail engineering requirement. Dry transformer of Very small ratings may be located in a ventilated panel. d. For illumination MLDB, an isolation 415/415V dry type transformer (having spare 50% capacity with insulation of class-F and
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e. f. g. h.
i. j.
k. l.
m.
temperature rise limited to class-B) shall be provided in each LT incomer of the double ended MLDB - main lighting distribution board. E-LDB shall be provided using a feed from any of the Bidders E-PDB. Transformer panel shall have exhaust fans (approx. 4 nos) and a temperature scanner for each phase winding (thro selection) digital display of transformer winding temperature. Crane & illumination loads shall not be mixed. All required MCC shall be single ended. PMCC is not acceptable. All required LDBs/ SLDBs shall be single ended . Dedicated PDB (for motor loads equal to & greater than 132KW) and Double ended MLDB shall be connected to normal power supply. For catering to emergency loads , necessary power supply feeder from clients emergency sub-station PDB . MV motor if required shall be as per TS & GTS GS-03. 12 nos RTDs plus one no. spare shall be used for winding temperature alarm & trip and two nos RTDs plus one no. spare for DE and NDE bearing temperature shall be provided in each MV motor. 6 nos RTDs ( 1 working and one standby for each phase shall be used for winding temperature alarm & trip shall be provided in each LT motor (greater than equal to 110KW) . RTD scanner shall be provided for all MV motors, LT motors (greater than equal to 110KW) and all transformers and shall be located in ECR. Minimum Four nos vibration monitoring probes shall be provided for each MV motor. Vibration sensor shall be covered as part of mechanical / technological system scope of supply. AC motors of ratings in excess of 200 KW (up to 2000KW) shall be connected to the 6.6KV power supply system for DOL starting. Motor rating upto 110kw may be fed from MCC, provided the Short circuit level requirement and permissible voltage drop is met. Motor with rating from and above 125 / 132 kW shall be provided with independent Motor control Panel (MCP) which shall be fed directly from a double ended PDB fed from LCSS/PCC. Power devices like MCCB, Contactors, Microprocessor based motor protection relay, control transformer etc for these drives shall be located in the MCP. Each MCP shall be located in ECR. All these motor control panel / starter box (for which power supply is fed from Employers LCSS/PDB) shall be provided with one number control transformer. Energy efficient motors shall be used as per IS:12615-2011 for large blowers / fans. For energy efficient operation, Fan Motors up to 250 kW shall be fed through LT VFDs. Tenderer to indicate list of such drives in the offer.
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n. Emergency MCC, shall be double ended with buscoupler and having auto changeover arrangement. In case Second incomer is fed from Emergency bus, then 4 pole ACB to be used. o. Rating of MCC incomer shall be restricted to maximum 1000A and care shall be taken to distribute the load as per Technological / locational grouping of load. p. Maximum load on a MCC may be restricted to around 400KW. q. Continuous current rating of the incomer shall be corresponding to MD of the MCC. Main bus bar rating of MCC shall be equal to incomer rating. r. Calculation of the maximum demand of MCC / MCP shall be as per GTS GS-03. s. Necessary derating shall be carried out for ambient temperature, etc. t. All panels in a room shall be preferably of same height and colour so as to form a panel line up which will have good aesthetic appearance. u. All panels to be supplied with base frame & gland plate. v. All bought-out systems shall be supplied in pre-wired condition. All valve stands shall be supplied as per-wired with copper cable having junction box (mounted on valve stand structure) for external cable termination. w. The Employer has the option of selecting the manufacturers of electrical equipment, instruments and controls and any other specialized items in the interest of standardization and the Tenderer shall have to supply equipment of the particular make, if so required. x. RIO panel shall be in IP- 65 construction. y. LED indication shall be provided for all I/Os and for all TBs in PLC and automation / RIO panels. z. All plant aux. motors of rating greater than 5.5 KW and all technological & process related motors shall be hooked up with PLC system for actual current feedback, on/off/trip status & shall have HMI screens. aa. Cable selection shall be based on Indian catalogues as far as possible. bb. For all MV cables, an extra loop of minimum 5m cable length shall be provided. Necessary MV cable diversion on the side of the cable route either in ECR or by the side of ECR. cc. No conduit / cable shall run buried in the soil. Inter shop cable routing shall be either through cable tunnels or through
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dd.
ee.
ff.
gg.
RCC cable trench with slab cover or thorough in RCC block using GI pipes with cable pits (with slab cover ) on each end. Type of Automation equipment, drive controllers and other equipment shall generally be limited to same type for the entire package. Standard Parameters/ Guidelines for surge protection devices in Electrical & Control System applications AND Wiring/ Connection Diagram The assignment drawings submitted shall be commented (if required) by Employer or as required due to any engineering changes for necessary incorporations and issue of revised assignment drawings by Tenderer. Detailed engineering services shall include : preparation of all conduit layout drawings marking all levels / size , furnishing electrical insert requirement in all premises Issue of all assignments for heat load data in all electrical premise , false ceiling / False floor assignments of all ECRs/ Automation room, cable trench layout , cable tunnel layout , civil openings / cutout , cable shafts , as required with details of all Doors sizes/ type, cable tray and support arrangement cum layout drawings , Drain pits assignments for all electrical premises like cable tunnels / ECR basements . This shall include all required engineering like entire cable engineering (preparation of cable schedule, cable routing, Cable / external termination plans & termination instructions, etc). The assignment drawings submitted shall be commented (if required) by Employer for necessary incorporations for issue of revised assignment. Separate Level # 1 automation room shall be established with facility for monitoring / modifying / storing of software and making multiple copies. Provision includes Full voltage sleeves completely wrapped up along the bus bars and removable type insulation covers at the bus bar joints at all switchboards, MCCs etc Motor starting and permissible voltage dips :
hh.
ii.
jj.
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It shall be ensured that when all the loads are in operation and the largest motor is started, the voltage drop at the motor terminals shall not be more than 15% of the nominal voltage at motor terminals. Maximum allowable voltage drop in any feeder under steady state condition shall be maintained as follows :Total voltage drop during running : 6% LTSS to motor : 6% LTSS to MCC/PDB/MLDB if in same building : 2% MCC to motor for above case : 4% LTSS to MCC/PDB/MLDB if in different building: 3% MCC to motor for above case : 3%
Voltage drop at the terminal of other equipment shall be as per the minimum voltage required for proper functioning of the equipment recommended by their manufacturers. 07.01.13 Lightening protection requirement 1) At the Input side of LT Panels (415 VAC) The device used in this application shall be based single spark gap, stage I/ Class B type with rated voltage shall be 320 VAC or above. The surge current handling capacity of device shall be 50 KA of 10/350 uS waveform (between L-N) with a protection level of 0.9 KV. It shall confirm to the latest IEC-61312, IEC-61643-12 guidelines. 2) At the Input Power Supply line of UPS, PLC Cabinets, VFD Panels etc The device used in this application shall be of stage II/ Class C type. The surge current handling capacity of device shall be 20 KA of 8/20 uS waveform with rated voltage above 320 VAC. The device shall be pluggable, Testable and shall have diagnostic functions like overload Indication and remote outputs. It shall confirm to the latest IEC 61643-12 guidelines. 3) Surge Protection Devices for Profibus, Modbus or RS-485 Lines The device (for the required 2-wire or 4-wire Interface) shall have the surge handling capacity of 10 KA (Core-Core) & 20 KA (between Core-Ground). The Device shall be pluggable & on-site testable. It shall confirm to the latest IEC 61643-21 guidelines.
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4) Surge Protection Device for Ethernet Networks The devices for Ethernet networks (alongwith RJ45 connectors) shall be able to protect all 8 signal paths. The discharge surge current handling capacity of device shall be 350 A/ 2.5KA (between Core-Core / Core- Ground) of 8/20 uS waveform. The protection adaptor shall fulfill the performance requirement and transmission quality in acc with Class D (Cat. 5e) The device shall confirm the test standards in acc with IEC 61643-21. 07.01.14 Installation Instructions The surge over-voltage protection devices are to be installed as follows: The point of connection is immediately after the incoming MCB/MCCB of the panel. The connection is made in parallel by using connecting cables between each phase of the device and the neutral to the device as per TT configuration of wiring. The earth point connecting cable is to be kept as short as possible by connecting the cable to the nearest earth point in the panel. Separate junction box can be used if there is a space constraint inside the existing panel. Spares Philosophy The spare philosophy for various equipment shall be as follows: MCC, PDB and MLDB shall be provided with 20% spare feeders or one of each type & rating whichever is higher. DC MCB DB shall be provided with 8 nos. of spare feeders. ACDB of UPS shall be provided with 40% spare feeders. 20% spare terminals shall be provided in each module of MCC, MCP, local control panels / local starters, junction boxes, etc. Control desk and local control box shall be provided with 30% spare terminals. PLC shall be provided with 30% spare terminals. Relay panels / relay modules shall have 20% spare relays of each type fully wired up to the terminal blocks. 20% spare interposing relays fully wired up to the terminal blocks shall be provided in PLC panels. 20% spare Trays & spare conduits and cores in control cable shall be provided for customers future use. 20% of used cable
07.01.15
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tray in a tray section shall be marked as spare tray in cable tray arrangement drawing. For Spare I/O philosophy for PLC , kindly refer Automation Clause.
07.01.16
Following considerations shall be taken care while preparing electrical equipment layout : Minimum panel back side clearance from nearest RCC/wall /column surface shall be 800mm. Minimum front to front clearance between 2 rows of panels shall be 2500mm. This shall be minimum 3000mm in front of MV panel. Minimum front to back clearance between 2 rows of panels shall be 2000mm. For every (3 nos. or less than 3 nos.) embeded GI pipes , one number GI pipes of maximum OD used shall be provided as spare. Same be marked as civil drawings as spare. 50 , 80 and 100 embeded GI pipes shall be used for all application. Embeded GI pipes shall have GI wire to pull cables in future as required. Accordingly, all embedded GI pipes shall be plugged with conduit cover on both end. Transformer room floor shall be 1100mm above ground level. ECR floor level shall suit accordingly. All panels (with base ) shall be installed over plate inserts provided around panel cut out , floor cut outs for cabling shall suit to panel gland plate dimensions. Cable trench width shall be minimum 1200mm for single tray lane and 2200mm for double tray lane . Height of the cable trench shall be with 300mm gap between 2 trays/ with floor level and with additional space for one no. tray for clients use on each side of trench. Drain pits shall be provided for all RCC trenches in open area , for ECR cable cellars / substation basement at suitable intervals , rising above ground floor level with RCC slab cover to enable access / removal of water from ground level. Necessary provision shall be taken care during layout engineering. Necessary slope in RCC trench / cable tunnel / ECR cable cellar shall be provided so that water gets collected from RCC cable trench / cable tunnel / cable cellar to drain pits (located by the side of cable trench / cable tunnel / cable cellar). Each drain pit size shall be minimum 1200(W)x1500(L)x2000(deep below the floor level of cable trench /
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cable tunnel / cable cellar ) mm . Necessary drain pump (1W + 1SB) with its motors shall be installed in drain pits for drainage of water. The submersible drainage pump motor which shall have automatic start / stop facility from MCC shall also have local start facility for which starters / Local box (in IP55 construction) shall be located close-by at a suitable nearest location (duly protected from rains for open area installation) . RCC Cable trench provided shall be behind the panel and not above the panel. Cable trench width shall be width of tray plus 500mm. RCC Cable trench depth shall be such that 300mm gap shall be provided between 2 trays. All RCC cable trenches inside the premises shall have chequered plate cover . All RCC cable trenches in open area shall have RCC slab cover such that water does not enter from top and sides. All necessary plate inserts shall be provided on side walls and ceiling of cable tunnel & ECR basement for support of trays / structure / fittings etc. and in cable trench. No HILTI inserts shall be used in ECR basement and cable tunnel. Embedded conduits (in RCC block) shall be provided from RCC trenches/tunnel up to equipment location for all areas of the plant. Exposed conduits (with proper couplers/ bends etc) shall be provided from end of embedded conduits up to equipment location / level. All GI exposed or embedded pipes shall be of 2mm thickness and shall be used for all cabling installation as per IS-1239 Part-I . Minimum size of GI pipe used shall be of 50mm diameter. All GI pipes shall have GI wire with plugs on both ends for future use. Minimum ratio of GI pipe OD / cable OD shall be 1.7 for straight pipes and 2.0 for bend pipes. Transformer room side wall thickness shall be 375mm minimum. Width of the cable trench shall be 600mm plus width of tray to be installed. Minimum Gap between two consecutive trays shall be o 300 mm for MV to MV & MV to LT. o 250 to 300 mm for all other trays. Type of tray from bottom to top shall have MV power-LT powerLT control-screened. MV power cables tray shall be at the bottom & screen cables shall be on top.
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Electrical panel rooms shall have a minimum clear height of 4.5m. Transformer room shall have a minimum clear height of 5m or more. Cable basement clear height for main ECR shall be minimum 4.5m. For all other ECRs, Cable basement shall have a minimum clear height of 4m or higher if required. ECR-1 premises shall be provided with cable basement. Complete control room automation room housing MCC / computer room / PLC/ PCs shall be provided with False ceiling (at a height of 3m above floor level). All pulpits if required shall have a false floor and also a false ceiling (at a height of 3m above floor level). All MCC / PDB / VFD operator room shall have false ceiling at 3m height above floor level. All premises shall have minimum two doors for entry / exit. For ECR, minimum Door height shall be 2500mm. Width of single door shall be minimum 1000mm and for Double door shall be 1500mm to 2000mm. Necessary stair case shall be provided for each pulpit if required from two sides / faces. ECR basement shall have two entry, connected by two sets of stair cases. Pulpit (if required) floor level shall be approximately 4000mm above the floor and shall be to suit detail engineering requirement. Necessary electrical store room, electronic store room, shift room, tool room, office, managers room shall be air conditioned by Tenderer and marked in layout by Tenderer. All cabling shall be in cable tunnel or in RCC cable trench (with slab cober) in specified area or in RCC block with GI pipe. For long lengths of embedded GI pipe, Necessary intermediate RCC cable pits (with slab cover) shall be provided. Networking FO cable shall be laid in GI pipe (either exposed or in RCC block) all over the plant. 07.01.17 Drawings/Documents to be furnished by Successful Tenderer Basic engineering drawing / documents for approval 1. List of drawings. 2. Overall plant electrical layout showing plant bays / open areas with disposition of all ECR, PLC and automation room, operator room, Cable tunnel, L2 automation room, computer room, UPS room , Battery room, Basement for ECR , Cable basement /
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cellar, MCC / PDB room, Electronic store room etc. 3. Overall Single line diagrams indicating 6.6KV feeders / LT feeders indicating VFDs if reqd , LTMCC, MCPs , PDBs , Main Lighting Distribution Board (MLDB), UPS and emergency feed, along with maximum demand, short circuit levels, ratings, protection and metering devices, etc mentioning connected loads category / facility & its Motor list reference number. 4. Overall Automation configuration (Area wise) showing Basic interconnection & configuration scheme, networking layout and all broad associated equipment/ components / hardware and software descriptions (with equipment location) & basic specification and quantity / location of equipment , PCs, Servers , Printers, network switch , hub , RIOs, PLCs , servers , PLC room , L2 room etc 5. BE with proposed Overall Layout of LSIS , LSTB , VHF and telephone system (Area wise) showing Basic interconnection & configuration scheme, networking layout and all broad associated equipment/ components (with equipment location and cable route ) & basic specification of equipment 6. Overall Layout of FDA system equipment (Area wise) showing Basic interconnection & configuration scheme, networking layout and all broad associated equipment / components (with equipment location and cable route ) & basic specification of equipment 7. Overall Layout of Material handling system electrics (Area wise) showing PDB for power supply distribution and location of various crane isolators / MCCB boxes in entire area 8. Overall Layout of CCVM system with monitors (Area wise) showing Basic interconnection & configuration scheme , networking layout and all broad associated equipment / components (with equipment location and cable route ) & basic specification of equipment 9. List of premises of the entire plant with approx. dimensions (Length, width and Height) for basic approval for Illumination system design and other requirement. 10. Overall Layout of premises Illumination system (Area wise) showing Basic interconnection & configuration scheme and all broad associated equipment / components (with equipment location and cable route ) & basic specification of equipment 11. Calculations for selection of equipment such as MCC, bus bars, cables , Voltage drop calculation , batteries etc. . 12. BE for proposed Overall layout of PF compensation equipment
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Detailed engineering drawings / documents for approval : 1. Overall cable layout (Area wise) with cable route numbers and running level covering all cable cellars, cable trench, cellars, Pump house, all equipment above ground floor and open area equipment. The layout will also show the FO cable route of the plant (Area wise) along with redundant cable route. Overall plant earthing drawing showing Primary earthing drawings indicating embedded earth mats with location, size of strips, level & earth pits with earthing calculation and soil resistivity figures of site as measured. Overall premise Lightening protection and associated earthing layout drawing showing dedicated earth pits, exposed / embedded earth strip and covering all other premises of the plant. Quality assurance plan for various equipment. SLD of Individual panels like LTMCC, MCP, PDB, VFD, MLDB, Automation panels, UPS , etc with maximum demand, short circuit levels, ratings, protection and metering devices, etc mentioning connected loads category / facility & its Motor list reference number. ECR layout showing all ECR panels with dimensions , PLC room, L2 room , AHU room , false floor and ceiling , cable shaft, section details Cable tray layout & section details Equipment and panel list covering all items (Area wise) for reference Overall Single line diagrams for Power Distribution with rating of all switchboards, cable sizes & details of protection and metering. Single line diagrams with type & ratings of components, cable sizes for individual panels like MCC, MCP, PDB, VFD, MLDB, Automation panels, UPS ,Hoist electrics etc. General arrangement drawings with dimensions for different panels / motors / all others electrical items / equipments indicating front, rear, bottom, top view & front view. Schematic drawing of MCC , PDB , VFD , MCP , UPS system, Hoist electrics, PLC system, Server system , FDA system , DE for Tele communication system, Illumination system, Emergency power supply system and other electrical equipments Automation Configuration diagrams with Hardware & software
2.
3.
4. 5.
6.
7. 8. 9.
10.
11.
12.
13.
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details showing entire connectivity for all areas. 14. Layout drawings for all premises for premise Illumination etc 15. Technical data sheets. Drawings / documents for reference / records. 1. Functional description of drives & interlocks as per technological and process requirement 2. Relay setting chart with calculations for total network to ensure proper co-ordination. 3. Earthing calculations and earthing layout (both primary & secondary)/ earthing pit layout including special electronics earthing, if any. 4. Lightening protection drawings. 5. Power & regulation schemes of individual panels like MCC, VFD, PLC, AC drives , UPS , RIO panel , servers etc. with internal wiring/terminal plans & Bill of Quantity. 6. Motors & field devices : Various characteristics & performances Speed-torque, current vs. time, thermal withstands characteristics for Motors, acceleration time calculations, voltage dip calculations etc. 7. List of interfaces between Tenderers equipment and Employers equipment. 8. Cable specification, cable & conduit schedules. 9. Cable Interconnection diagrams. 10. Cable Tray & supporting structures. 11. Civil drawings for embedded inserts including embedded conduits with coordinates and laying route, cable openings and cut outs with dimensions as required for complete electrics under scope of supply shall be submitted for necessary comments under reference category. Tenderer shall furnish the embedded conduit layout as part of civil drawing showing start level, end level, running level, location co-ordinate of start point & end point of conduits and conduit diameter for each conduit as required to be embedded. 12. Layout & scheme for Fire Detection & Alarm. 13. Layout & scheme for BD, BE for Intercom equipment 14. Layout of Air conditioning and ventilation equipment 15. Equipment layout 16. Overall general arrangement, SLD, scheme for the plant 17. Illumination drawing with calculation
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18. Erection drawings including volume of work and Bill of Quantity for erection 19. Erection & commissioning schedules. 20. Drawings/documents for inspection of equipment: : - Type test certificate for identical equipment. - Sub-suppliers/vendors catalogue/technical literature. - Test reports for internal inspection - Test certificate of components. - Technical specification & data sheets of equipment. - All Approved drgs/ Commented drgs as applicable. - Calibration procedure and setting procedure. Automation systems - List and details of automation hardware. - Software including media and documentation. - Description of all components of the user system with functional description, overview flow diagram, interface listing and fault message lists, operator commands, simulation facilities, etc. - Source code of the user system except for mathematical model. - Object code of the user system. - I/O listing - Ladder/block diagrams, etc. - Transformer sizing calculation, flux density calculation, thermal and short circuit force withstand capability calculation - Busbar sizing calculation for LT board, MCC/PDB and busbars - Cable sizing calculation and selection - cable schedule - Guaranteed technical particular (datasheet) of all electrical equipment - External connection diagram - Cable tray and Cable tray support layout with BOQ - Cable laying layout drawing - Lightning protection drawing with calculations Other Drawings/documents : - Operation & maintenance manual.
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Catalogues and manuals. All As-built drawings & as built source codes(except mathematical model) for all softwares . Technical details/ literature/ catalogues of electrical equipments e.g. Transformer/ LTAC board, LT duct, MCCs /PDB , VVVF panel, PLC, UPS , Control desk, LCS, sensors/ transducers, camera & monitors for CCTV, etc. Soft copies of all drawings. Technical specification/data sheet of equipment. Instructions for storage/erection/testing/commissioning Commissioning report.
The successful Tenderer shall submit drawings and documents in hard copies as well as in soft copies as per GCC. Delivery schedule of drawings/ documents to be inline with the overall project schedule. 07.01.18 Battery Limits Power Supply: For normal supply, Tenderer will tap from 2 nos. 1250 A feeders provided at Purchasers 415 V LT double ended s/s of welfare (Admin) building LCSS of new CRM III located near welfare building ( approx 350 m cable route distance). Cable & Cable engineering: Supply, laying & termination of required number of LT cables from Purchasers LT switchboards in Welfare Building s/s and up to Tenderers equipment in Tertiary treatment plant area shall be in Tenderers scope. All required cable tray work with all necessary embedded conduit work in RCC block in normal area, with all necessary all embedded conduit work below existing railway track and connected to RCC cable pits with 75mm thick trench slab cover with cable route connecting Welfare Building s/s and the Tertiary treatment plant electric control room (ECR) in new CRM-3 complex shall be part of Tenderers scope.
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Max. LT power cable size will be 3.5C x 240 sq. mm and will be PVC insulated Aluminum conductor, Armoured / Unarmoured. Road crossing / Rail crossing of cables will be done in RCC conduit block. All Cables shall have flame retardant (FRLS) property as per IS10810 (part-62)-93. Power cables shall be selected from core sizes of 6, 10, 16, 25, 50, 70, 120, 150, 185, 240 sq.mm (Aluminium conductor) Power cables / EPR Flexible Power cables shall be selected from core sizes of 2.5, 4, 6, 10, 16, 25, 50, 70, 120, 150, 185, 240 sq.mm (Copper conductor) 07.01.19 Layout / SLD & Plant Configuration The layout and equipment described in this specification are of representative nature. The Tenderer shall study the specification and satisfy himself thoroughly regarding the workability of the equipment and shall take full responsibility for the guaranteed operation of the equipment as regards output, performance, quality and smooth reliable operation. If the Tenderer feels that any dimension and/or design data for the equipment described hereinafter in his opinion are unsuitable, he shall indicate this specifically and submit an alternative proposal on the basis of the design data he considers suitable and capable of meeting the required operating and duty requirements. Any equipment not included here but is necessary for proper functioning of the Tertiary treatment plant shall form part of Tenderers scope. LT Feeders for Purchasers use: Following ACB/MCCB feeders shall be provided by the Tenderer in their 415 V LT switch board for Purchasers use: 4x 100 A MCCB
07.01.20
Approved makes The equipment offered shall be from the approved list of makes enclosed with GTS / GCC/SBD for Indian sourced items. However for imported items, separate make list shall be furnished by bidders,
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for approval by Purchaser. 07.01.21 Deviations / exclusions No deviation / exclusion of scope from GTS / TS is acceptable. However in case Tenderer is unable to comply with any provision of these specification, he shall clearly bring it out in a separate chapter of his tender giving clause wise deviation / exclusion with reasons. In case such deviations / exclusions are not listed, all clauses of TS/ GTS shall be deemed to be acceptable & complied with. Deviation so listed by Tenderer shall not be considered accepted until the same is discussed and agreement if any is recorded. 07.01.22 Performance Guarantee / PG test / LD Performance guarantees figures, PG test procedures, liquidity damages are specified in GCC/ SBD/ Technological Specification. 07.01.23 Spares, special tools, instruments All commissioning spares as needed for successful commissioning of the units shall be included in the scope of Tenderer including electronic card at least one of each type shall be included as part of commissioning spares. Tenderer shall include a list of such spares in his offer. List of 2 years maintenance spares/ insurance spares shall also be submitted as per SBD/ GCC. Special tools, instruments for commissioning & maintenance shall be in vendors scope and a list shall be included.
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07.02. 07.02.01
ELECTRICS, AUTOMATION & TELECOMMUNICATION Electrics for Tertiary treatment plant, Auxiliary and Services The electrical equipment shall be of latest state of art design.
07.02.02
Scope of work & design basis Scope and scope division shall be as listed at 07.01 above. The scope of work of the Tenderer shall include basic data, basic & detailed design, inspection, supply, erection, commissioning, PG test of all electrical equipments starting from the battery limits onwards such as, LTACB panels for feeding power supplies to various Tertiary treatment plant equipment, Motor Control Centers (MCC), Power Distribution Boards ((PDB), Main Lighting Distribution Board, Lighting control panel, PLCs, HMIs, L1 automation system (with HMI & link with L3) , UPS system, Pulpits (if required) , Sensors , Local Control Stations (LCS/ OS), Control Desks (CD) , Material handling equipments for Tenderers equipments, feeders for shop lighting, Junction Boxes (JB), Welding sockets , solenoids, Illumination system equipment, IP based Closed Ckt Video Monitoring system, FDA system, motor, panel and premise ventilation / air conditioning complete with all power, control, screened, communication, video, optical fiber and special cables , erection and earthing materials, erection and supervision of erection, Testing and commissioning as required for Tertiary treatment plant equipment and its electrical system in the new 1.2 MT CRM-3 Complex for Bokaro Steel Plant of SAIL. The scope of work shall also include basic engineering (excluding supply) for loud speaking communication system, VHF communication system, telephone network and engineering services required for all electrics. The scope includes all supplies associated with required Illumination engineering, electrics for AC ventilation, passive fire protection, standard manual fire protection, MCC, distribution, control, automation etc. Engineering work shall include preparation of equipment layout, conduit layout drawings marking all levels / size, cable / conduit schedule (with size, type, route & end locations), termination plans, civil insert requirement location in all premises , heat load data in all electrical premise, false ceiling / False floor requirements, cable trench layout , cable tunnel layout, pulpit layout, civil assignment drawings for electrical premises.
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Preparation of earthing drawings / lighting layout drawings & lighting SLDs, cable tray and support arrangement cum layout drawings, Drain pits assignments for all electrical premises like cable tunnels / ECR basements, Necessary emergency power requirement for the Tertiary treatment plant equipment shall be specified by Tenderer (giving break up of the emergency loads considered including operating / working loads) and the power supply requirement so that the required feeders can be arranged by Purchaser from their power plant / emergency sources. All emergency loads (such as for emergency wate emergency field power, lighting, etc. as required) shall be considered. Tenderer shall tap emergency LT power provided at ETP LDB. 07.02.03 Design Ambient conditions Following ambient temperature shall be considered in different areas for equipment design. Though the ambient in certain area shall be controlled the equipment shall be derated / designed to meet the following conditions: Sl.No A Area Tertiary treatment plant area / transformer room Direct under sun Electrical Rooms ECR Cable basements / tunnels + 45 Deg. C + 45 Deg. C bay Data + 50 Deg. C
B. C. 1 2. 07.02.04
+55 Deg C
Ambient Condition with AC / Ventilation The electrical control rooms, automation rooms, transformer rooms, cable tunnels, battery rooms, pulpits etc shall be ventilated / air conditioned to meet the requirement of temperature & relative humidity as per GTS. The following ambient conditions will be maintained in various premises:
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Rooms for 11Kv/ 6.6 kV Switchgears, HV: 32 C, RH - 70% (max) MCC, AN transformers & Pressurisation 2 to 3 mm WC LCSS, 415V switchboards, 415V PDBs, MCCs, Battery charger and ACDB / DCDB etc.
Level-1 & 2 automation and Networking, UPS: 24 C, RH 50 to 60% And Pulpit : Pressurisation 2-3 mm WC Office and electronic stores: Electrical Stores: Battery Room/ ONAN Trafo rooms : 25 C, RH 50-60 % : 32 C, RH - 70% (max) : Dry Ventilation
Cable Cellar, Cable Vault, Cable tunnels (max 30 m section): 400C These temperatures shall be maintained and shall over rule any other temperature mentioned elsewhere.
07.02.05
Power supply details & standard voltage levels The following standard voltage levels shall be adopted. Sl. No 1 Description LTAC Data 415V + 10%, -15%, 3 Phase, 50 Hz, +/- 6% 4 wire, solidly earthed, Solidly earthed. Short Circuit level= 50 KA for 1 sec. 2 3 4 5 6 AC control signaling voltage Electro-magnetic brakes Solenoid valves and 230V, +10% obtained using suitable control transformer. 220V, DC, rectifiers obtained through individual
24V,DC, unearthed
Sockets for Welding 415V, 63/100A, 3 pin plus earth with plug purposes interlocked switch Sockets for hand tools 240V, 15A, 2 pin plus earth with plug interlocked switch
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Sl. No 6 7 8 9 07.02.06 1.
Description Sockets for hand tools Illumination system
Data 24V, 5A, 2 pin with plug interlocked switch 230V AC, 50HZ.
PLC incoming power 230 AC, 50 Hz, obtained through UPS supply PLC I/O 24V, DC using separate power supply units.
Equipment Specification / Salient Features Detailed equipment specifications For detailed equipment specification of electrics & automation please refer General Technical Specifications (GTS) - GS-03. Following specification shall apply to electrical equipment for Tertiary treatment plant of 1.2 MT CRM-3 complex of Bokaro Steel Plant (SAIL).
2.
The motors and controls The motors & Controls shall be provided to suit the main & auxiliary mechanical equipment for Tertiary treatment plant. Drives which require speed control, positioning and co-ordinated operation shall be provided with AC motors fed from adjustable speed drive system. All other drives, where speed control is not required, such as pumps, blowers etc may be provided with constant speed AC motors and controlled from motor control centres.
A)
Medium Voltage Motors (if required)
Constructional Features: Stator Frame Stator Core Motor Feet Shaft Degree of Protection Cooling
Fabricated Steel / Cast Iron Laminated sheet of Hi Grade, Lo Loss Silicon Steel Cast feet integral with motor frame Forged Steel IP-55 CACA or CACW cooling, complete with Temperature,
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Pressure and Cooling water Leakage Monitoring Devices Mounting Shaft extension Bearing IM-1001 Cylindrical. Anti-Friction type with Re-greasing facility & Grease Controller for motor up to 1000 KW Rating. Pedestal Type with forced oil Lubrication for motor above 1000 KW Rating. Coupling Finish Boring, key seat cut and fitting of motor half coupling is included in the scope of motor manufacturer. Pedestal Insulation Indication for Direction of Rotation Cable Glands Accessories Double Compression type. Motor Foundation Bolts, Fixing Bolts, Nuts and Washers. Earthing terminals Terminal Box Terminal Box On RHS of the motor looking from the DE, suitable for termination of XLPE cables with heat shrinkable cable end seals. TB shall be reversible type to suit cable entry from bottom or top. Fault Withstand Capacity Each terminal box shall have fault withstand capacity equal to at least rated short circuit level of the system voltage for 0.25 sec Extension of TB Shall be possible for accepting Aluminium cable, wherever required Cable Glands Double Compression Type Two. On the diagonally opposite sides of motor body. Insulated against Circulating Shaft Current. Arrow Block.
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Auxiliary Terminal Box
Separate terminal boxes to be provided for space heaters, RTDs for Winding/ Bearing Temperature Detectors, Vibration Monitors etc
Quality of Operation Standard Balancing IEC-34 / VDE 0530 / IS 325 Dynamically balanced with full key on the shaft end & fan Electrical Design Power Supply Class of Insulation Designed for operation with SF6/ VCB breakers. Class-F with Temp rise limited to Class B (as measured by resistance method). The insulation shall be vacuum pressure impregnation (VPI) type. Min Voltage for Start & Run up Starting Torque Starting torque to be decided depending upon the requirement of the specific application. Over speed capability Efficiency 120 % for 2 mins High efficiency motors with minimum 95% efficiency at full load conditions. Efficiency shall remain same from 50% to 100%. Space Heater Shall be provided for all MV motors. Heaters to be automatically switched OFF when the motor is switched ON. Online Vibration Monitoring Bearing Temperature Monitoring Winding Temperature Monitoring 3 nos RTDs each on the Stator & Rotor winding for Alarm & Trip On the DE end of the motors for ratings above 1000 KW Rating DE & NDE side Bearings for Alarm & Trip 80 % of Rated Voltage
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Differential Protection
Motors of rating 1000 kW and above shall be provided with differential protection
Performance B.
As per IS-12065 -1987
Low Voltage Squirrel Cage Induction Motors for fixed speed application Provision of over temperature protection (One PTC at hot spot per phase for 55KW and above and same shall be hooked up with Temperature scanner and to PLC/HMI). All LT AC motors shall be rated for 50 C ambient or above as per design ambient. Type test certificates shall be submitted for each frame. Routine tests shall be done during inspection at manufacturers shop. All foundation mounted motor shall be provided with base frame / sole plates, T-head nuts and bolts, anchor sleeves. 240V AC motor space heater shall be provided for motors of 55kW and above. Motors upto and including 200 kW will be LT . Motors of rating up to 110 KW rating will be fed from MCC. Motors of rating greater than 110KW rating shall be fed directly through double ended PDB powered from LCSS and / or PDB using a dedicated Motor control panel. The constant speed motors will be AC Squirrel Cage type. The common specification for all the motors is as follows: Arrangement....................: Single motor Termination......................: Through terminal box on side of the motor or on TOP as per detail engineering requirement. Paint Shade......................: RAL 7032 Couplings..........................: will be supplied by the mechanical supplier Accessories......................: As per motor list Applicable Standards.......: IEEEMA 19-2000(efficiency values) , IS: 325, IEC 60034-1 (performance), IS: 1231, IS: 8223 (dimensions) , IS: 12065 (noise level) , IS: 6362 (cooling),IPSS 1-03-001,IEC-34 & IEC-72. Balance specification shall be as per GTS GS-03.
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C) MOTOR CONTROL CENTER (MCC), MOTOR CONTROL PANEL (MCP) / POWER DISTRIBUTION BOARD (PDB) MCC / PDB : These panels shall be provided as per requirement and shall be located in ECR-1. These panels shall be free standing type, IP52 enclosure class built with CRCA sheets of not less than 2 mm thickness (1.6 mm for doors / covers), surface powder coated / 7 tank process finished : In PDB normally both the incomers shall be always ON, in case of failure of any one incomer the buscoupler will automatically close immediately. Non Draw-out type, single front Motor Control Centre (MCC) for control of drives of various rating of various technological units. Incomer ACB shall be drawout electrically operated type. MCC shall cater to all loads of motors, valve motorised actuators, damper motorised actuators etc. Each MCC shall be with One incomer and shall be fed from Purchaser Tenderers PDB. Feeders for Power distribution boards (PDB) for further power supply distribution to various loads of MCCs / Sub-PDB shall be taken from Purchasers LCSS at Welfare building sub-station. Lighting Distribution Board (MLDB) for Power supply to various Lighting fittings of TTP ECR. The MLDB incomer shall have dry type 415/415V isolation transformer ( with class-F insulated and temperature rise limited to class-B ) located in ventilated panel for very small rating and in ECR for small rating below 630KVA with min. 30% spare KVA capacity and with tappings of 2.5 %, 5% , 7.5 %. Number of MCCs shall be provided as per detail engineering requirements. Incomer shall be ACB for >= 800A and <=1000A. MCC distribution shall be done accordingly. MCC shall be provided with single incomer & single front. Incomer ACB wherever provided shall be with electrical and manual closing operation in draw-out configuration. MCC shall be compartmentalized, single front & non draw out type except for incomer ACB feeders. Marshalling panel (for RIO, PLC interfaces) shall be provided if required as part of each MCC suit. MCCB shall be provided up-to 630A for incomer/ outgoings. Above 630A, ACB shall be provided 20% spare feeders with minimum one feeder of each type/ rating shall be provided at all MCCs/ PDBs/ LDBs Continuous current rating of the incomer shall be corresponding to MD of the MCC. Main bus bar rating of MCC shall be equal to incomer rating. While calculating the maximum demand of MCC / MCP, 20% spare capacity shall be considered for customers future use, excluding the reserve capacity of the Transformer. Necessary derating shall be carried out (for ambient temperature, etc.) if required.
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MCC shall be Dust & vermin proof. Switch fuse unit shall not be used and MCCB / ACB shall be used instead, as required. Cable alley , gland plates and Terminals shall be suitable for Aluminium cable All MCCs shall be with Remote I/O board mounted in separate full panel in the MCC, duly wired up. Electronic relays with display shall be considered in place of thermal overload relays as follows : EOCR for OC protection for motors below 15 kW. EOCR for OC & EF, unbalance protection for motors above 15 kW & below 90 kw Composite motor protection relay with OL,OC,EF, Unbalance & locked rotor protection with digital display for motor rated 90 kW & above. MCC digital meters in outgoing feeders shall be as follows : Motors rating from 11kW up to 22KW shall be provided with CT in the middle phase for connecting to ammeter. However, Motors rating 30kW and above shall be provided with CT in all the three phases for connecting to ammeter. Motors with rating 11kW and above shall be provided with ammeter with dual range Incomers of MCP (132kW & above feeders) and all dedicated starter box/panel (for which power supply is fed from PDB/PCC) shall be provided with two nos control transformer (with change over switch). In MCC motor feeders, MPCB shall be used up to 11 KW motor rating and MCCB shall be used above 11 KW motor rating. Control transformer primary circuit shall have MPCB. Outgoing MCCB rating shall be minimum 1.6 to 2 times the motor rated current. For space heaters wherever provided, 240V motor space heater shall be given power from MCC as a separate power supply module with individual MCB & contactor for each motor space heater. This shall be as per TS. For all fans and other energy efficient drives with a rating between 90 to 200 KW, VFD (without any bypass facility) shall be provided instead of soft starter. Tenderer to specify these provisions as necessary. For ratings below 90 KW, soft starter shall be considered for all fans and other energy efficient drives with associated DOL bypass facility. All MCC/PDB power supply MCCB feeders shall have 3-phase and neutral brought out up to terminals. Final SLD shall be as approved by Employer / consultant based on detail engineering requirements. Balance specification shall be as per GTS GS-03. Necessary external TBs of each On/Off/Trip lamp (of each MCC panel motor feeder / module) should be provided to enable external cabling /
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connection of various motor On/Off/Trip lamp considered at say control desk / Local control box. All current meters at MCC panel or at field LCB / Desk should be digital type size 96x96. For MCC incomer panel and its auxiliary circuit, TBs for each relay / lamp circuit circuit in the control circuit to be provided . All MCC suit top surface bolts must be fully tightened before dispatch. All panel top should be cleaned at site by erection contractor and should also be checked for bolt tightness. All MCC panels and other panel rear side doors must be fully accessible for opening during maintenance. All electronic overload relays should preferably be dispatched separately in a case to prevent any theft at site after installation of MCC panel. As such, these parts can be site fitted easily by MCC supplier before charging and commissioning. Necessary wiring modification / correction work including any fixing / tightening work inside the MCC / PDB panel as required at site to enable proper panel charging / commissioning should be included in MCC suppliers scope. An Emergency push button (EPB) box with an indication lamp along with EPB near each motor to assure the maintenance personnel for safe maintenance work. The provision of lamp shall serve the purpose to ensure that a person engaged for motor / equipment maintenance is sure about any non-possibility of concerned motor starting while maintenance activity is ON. To do this, an EPB aux. relay (fed from 240VAC MCC control supply) to be provided in each MCC motor feeder / module with interface to MCC RIO panel by MCC supplier. Also, following is to be carried out : a) Connect N/C contact of EPB to aux. EPB relay at its MCC module b) Connect N/O contact of aux. EPB relay (at MCC module) to MCC control circuit c) Connect N/C aux. contact of the aux. EPB relay to 240VAC lamp at EPB box. d) Also, Connect N/C aux. contact of the EPB relay to MCC remote I/O unit as part of wiring in MCC panel by MCC supplier. MCC is to be supplied, with a full panel height plastic cover before putting in a wooden box for dispatch. This plastic shall be helpful in protecting against any dust entry while civil work / ducting work is in process at site.
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Scope of erection contractor should include proper site connection of various shipping unit of MCC such that there is no gap between connecting faces of each shipping unit. Balance specification of MCC shall be as per GTS GS-03 components like MCCB , AC
Components For different LT Panels : Kindly refer GTS GS-03 for details of Contactors, etc. 1. Numerical Protection relays
All protection relays shall be numerical type Flush mounted Mechanically operated flag indicators with all relays capable of being reset without opening casing Shall withstand impulse voltage in accordance with IEC recommendation. Test facility by plug from panel front. CT secondary shall be shorted on relay withdrawal. Diagram plate at the back of case to identify connections. For switchboards with three incomers and two buscouplers, Only one set of 51G and aux. relays should be provided for tripping incomer breaker number 2 & 3 Motor protection relay in MCC / MCP & Standalone Starter panels shall be microprocessor based suitable for 5A or, 1A and following protections: - Short circuit - Overload, Earth fault,Staling protection,Under voltage,Over speed - Number of starts per hours (Cold/Hot) This shall have facility to communicate with PLC and memory & feature for storing fault history and trending. - Thermal overload - Adjustable overload prealarm - Earth fault,Stalling,Unbalance,Short circuit,Single phase prevention - Under current,Too many starts ,Under voltage,Under voltage lockout - Breaker or contactor failure alarm - Trip failure alarm,Over temperature - Winding and bearing temperature (for motor of rating 160 KW and above). 2. Indicating Instruments Taut band type Size Incomer and Sectionalizer Outgoing
144 sq. mm 96 sq. mm

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Flush mounting : in front of the cubicle. Square dial with zero adjusting device for external operation . Accuracy class - 1.0 Ammeters shall be compatible with CTs of 5A secondary and read actual currents. For motor feeders ammeters shall have compressed scale upto 6 times of full load current after 1.2 times of full load current and shall have red mark on full load value. Shall not damage by passage of fault current or existence of over voltage for the maximum permitted duration of fault conditions. Voltmeters protected by fuses placed as close to the busbar as possible. 3. Control and Selector Switches All control selector switches shall be of sturdy design . Shall have modular construction with number of switching contacts for each position operated by a single shaft. Inscription for each position shall be provided. Stay-put or spring return arrangement shall be provided as per the circuit and control/operational requirement. The contacts shall be designed for higher contact reliability and electronics compatibility involving low voltage and small value of currents. The operating handle shall be robust and strong. One number of potential free switching contact for each position shall be provided as spare. Control switches for circuit breaker ON/OFF control 3 position spring return to neutral with lost motion device and pistol grip handle. Other control and selector switches - stay put type with wing type knobs. Complying to IEC 60947 2 NO + 2 NC contacts with minimum rating of All the selector switches shall be of 10 A rating 25A for sturdy applications . 1 NO & 1 NC contact / poles shall be potential free for PLC inputs . Push Buttons All push button switches including illuminated push buttons shall be of sturdy design Un-shrouded actuator for "START" application, Mushroom actuator for "EMERGENCY STOP" application and key "STOP" application for "LOCK-OUT" application shall be provided. Mushroom actuator for Emergency Stop shall be latched type. Press to latch in operated position and turn-to- release in unactuated position. Double break parallel contact design or other suitable design feature enhancing contact reliability required in circuits with electronic interfaces involving low voltages and small currents shall be adopted.
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Complying to IEC 60947 Size - 22.4 mm diameter Minimum 2 NO + 2NC contacts with following current ratings . - Continuous : 10 A - AC 11 : 0.5 amps at 240V - DC 11 : 0.5 amps at 110 V DC, L / R - 40 ms All contact faces of contacts shall be of silver or silver alloy. Facility of adding add on contact blocks to be provided Colour : ON RED OFF GREEN ACCEPT BLUE RESET BLACK TEST YELLOW The P.B. switches shall be with higher contact reliability, electronics compatibility . Balance component specification shall be as per GTS GS-03
D)
PROGRAMMABLE LOGIC CONTROLLERS AND AUTOMATION D1 Features of the Automation System:
Automation architecture shall have 2-levels of control, namely, Level-1 & Level-2 systems. Actual supplied automation system drawing (either for tendering or during engineering ) shall be submitted by Tenderer taking care of all requirements mentioned in this specification. The offered PLC system shall take care of all requirements of necessary interface / signalling requirements for all p[ump motors , valves etc. . The Level-1 control is based on PLCs and Drive system, which controls the actuating system and ensure fast dynamic performances. Level-2 control system (Process Control System) shall be a microprocessor based system and shall provide the set up functions for actuation of various equipment / machines. All the sequential, interlocking and referencing functions shall be done from PLC. PLC shall communicate with necessary RIOs, MCCs , VFDs , Soft starters, weigh panels, etc. on a field bus like Profibus / Modbus / Controlnet . Different PLCs , PCS , HMIs , etc. shall be interconnected through a high speed Ethernet bus. The system shall also be capable of communicating to other standalone purchasers plant controllers, e.g. PLC system for water system etc through common bus.
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Communication gateway shall be provided for communicating the system with Level-3 control system of the plant. The Automation system shall be based on Employer server configuration. The control and automation equipment related shall provide on line control functions for the process and equipment. PC based programming unit for monitoring / editing PLC program shall be provided in ECR with necessary ports / connectors. The main process and equipment control functions are:Sequential control of movement of the mechanical equipment Closed loop control functions as required. Logging of the process parameters. D2 Basic Configuration of automation:
Automation system shall generally be as per the GTS, TS and shall include the following: Level-1 system a. b. c. d. Level-1 System including PLC, Remote I/O unit, Terminal strips etc shall be as per GTS. Operating system shall be latest & development version Hot standby PLC (CPU, Power supply and communication modules) with dual redundant I/O communication bus and dual redundant Ethernet bus to be considered. Galvanic isolation (Opto or otherwise) of I/Os shall be provided Separate networks for L1 and L2 shall be provided connected to each other by different switches. Additionally, redundant network cable (for L1 and also for L2) shall be supplied and laid in separate cable route. All communication system like Ethernet / profibus / RIO panel link communication cable etc , cabling shall be done in 40mm GI pipe through out the plant area. All such conduits shall be laid in control / instrumentation cable tray. Minimum physical clearance from power cables shall be maintained as 300mm. PLC shall be as per GTS and of latest version. PLC Memory shall have minimum 40% spare capacity after loading of software & application. CPU load shall be restricted up to 60%. Data bus shall not exceed 50% during worst traffic condition. CPU load, Data bus loading, memory , Spare I/Os, Spare slots shall be inline with GTS. Type /make of PLC and drive controllers shall generally be limited to same type for the entire package. All HMIs / Engg. Stations should be PC based and should have dual redundant network adapters which will be connected with dual
e. f. g. h. i. j.
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k.
redundant Ethernet network for all types of data exchange, process control & monitoring purposes. Tenderer to include all regulated power supply requirement of sensors (especially 24VDC and 240VAC) along with its contact signal as supply part of all PLCs and all RIO panel. In case , 240VAC supply is not provided by supplier in PLC / RIO panel then necessary sensor main PDB with necessary MCB boxes in various sensor locations need to be provided separately. Automation System Redundancy concepts Each PLC system in all respects for machining line equipment , for aux. equipment shall be hot parallel redundant. Tenderer shall include hot redundant PLC system consisting of two CPUs, Power supplies, communication modules and redundant bus connection to VVVF drives, soft starters. The I/O cards in remote I/O cabinets shall not be redundant. The network equipments, printers, switching equipment, network cables, etc shall also be in the scope of the Tenderer. Human machine interface (HMI) for Level 1 supervisory control , shall be PC server based and shall be part of Level 1 system. These shall be in Hot standby, ensuring full redundancy for the HMI. Both the PCs shall be running independently & simultaneously & shall be monitoring the status of the other PC and of the network communication status. PC for HMI shall be of the latest specification available in the market at the time of supply. Network cables for Level 1 shall trace separate / alternate routes and will run through GI pipes distinctly colored and clad with heat resistant cable along with necessary identification of cable. - Automation System Spare concepts 20% spare I/Os shall be considered for each automation system and remote station (after commissioning) No. of spare Channel shall be 20 % for each PLC and remote station for future expansion. At least two spare slots shall also be available. Minimum 50 % spare memory capacity shall be built in the system after loading of application and system software Communication Network loading shall be limited to 50 % max - Automation Cable Selection Concept Twisted pair cables shall be used for communication between
d.
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panels inside a Room and FO cable shall be used for outside premise communication. Network cabling for Level 2 shall have ring configuration.
- Signal Interface for Transformers The status of the medium voltage switch gear will be displayed on the HMI-system. Therefore the switchgear equipment shall provide hardwired incoming signals for the connection to a remote interface panel . The Remote I/O panel modules /remote Interface will be installed in a seperate panel, both supplied by the Tenderer . Automation configuration diagram will be submitted showing details of hardware, communication media and speed, switches, control periphery of individual functional units, HMI, etc. area wise (such as ECRs, axle shop, Maintenance room , Office, Furnace, all internal & external connectivity by Tenderer as per detail engineering requirements for approval by Employer. Tenderer shall list all the software (run time, development, monitoring, Operating System, Antivirus software, Firewall) & hardware with numbers & where installed in the tender. Scope shall also include full documentation on software and hardware maintenance with product brochures and operator manuals. The source code for all application software used in the project will provided except of the mathematical models. Regarding mathematic process model the source code can not be provided. Software document containing complete development environment including libraries, well-commented source codes of the application software (except for knowhow part of the models) will be supplied to enable Employers engineers modify/recreate the Level-2 system at a later date. Necessary backup (including set up data, tuning data etc.) shall be provided after acceptance of hardware & software and Tenderer shall restore the backup and run the server with restored copy. Functional specification shall be supplied .
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Overall process control description for TTP system , aux. system shall be furnished with the offer. Similarly details of various automation features with a write up alongwith details of Report generation and Fault logging features shall also be furnished with the offer. Tenderer shall provide for software changes and modifications to remove bugs and to suit the technological requirement after commissioning for a period governed by the General Warrantee Clause of the project. e. f. PC / Laptop / Servers shall be of HP / DEL / COMPAQ / LENOVO make. Load cells shall be of HBM / SCHENCK / SARTORIVS / MECHATRONICS make.
E)
UNINTERRUPTED POWER SUPPLY SYSTEM Bidder shall include necessary UPS with isolation transformers and ACDB, maintenance free Ni-Cd Battery for common battery bank & battery charger for feeding the loads requiring UPS power supply. Shall be in line with GTS. Output frequency shall be 50 Hz 3% at synchronized condition. Separate UPS system shall be considered for each ECR . UPS loads shall include all PLCs, PCs, sensors like Pressure Transducers printers , technological etc , automation system
equipment , network equipment , FDA system and any other loads as shall be decided during detail engineering. Provision of parallel redundancy The different source for UPS should be power supply from a) different LCSS or b) if one of the 2 supplies can be from emergency power supply if available. Rectifier and Invertor shall be IGBT based and microprocessor controlled. Three separate sources of power supply shall be envisaged. Two for
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input supply to UPS modules and one for bypass supply. Bypass supply shall be through CVT / SCVS. Output THD shall be 1% for linear load & 2% for non linear load. Recovery time for 100% step load shall be less than 5 ms. Suitable filters shall be provided by the Bidder to maintain the input power factor 0.98 (Lagging)
F)
OPERATOR'S STATION Necessary local control stations shall be located at plant floor/near plant housing and provided with any key pad/display/monitor unit etc shall be provided. Local control stations for open area shall be provided with canopy. Emergency push button station: There will be one emergency push button station for isolation of AC motors wherever required consisting of red mushroom head lockable push button and with one no. indication lamp with minimum two auxiliary contacts required for interlocks/annunciation, physically located near each equipment. Emergency PB shall be hardware connected in control circuit and also shall be monitored through PLC. Balance specififation shall be as per GTS GS-03.
G)
CCVM system : Necessary Closed Circuit Television System including Cameras, Monitors shall be included in the scope of the Tenderer for various strategic locations in the plant in line with GTS complete with its protective housing, cooling unit, purge unit etc. Tenderer shall indicate the proposed quantity and locations of CCTV and its monitors. Preferred make shall be Philips / Bosch / Sony. Bidder to specify the location of CCVM camera considered in entire TTP area on a layout as part of their submitted offer. CCTV system shall have provision of changing viewing angle with respect to process/operation automatically (by programming).
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CCTV system shall have provision of zooming particular object automatically during operation. It shall be possible to view an operation from a larger distance with a distance view and also with focus from a very small distance to see vividly the exact tool operation. Camera location shall be as per process & operational requirement i.e. the coil processing sequence. Camera shall be capable of change its viewing angle with respect to the movement & stoppage of transfer/shuttle car. That means the vision angle coverage shall be double the allowable single vision angle by shifting the view from one angle to next angle. To view a vision for longer time duration , Operator shall have a button control to stop the camera viewing angle changing function as per his requirement. As mill bay ambient is 50 deg C ,so, permissible Camera operating safe temperature limit shall be greater than min. 55 deg. C or higher with provision of water cooling and air purging .
Necessary IP based Closed Circuit Video Monitoring consisting of IP based low light Cameras (MPEG-4 or H.264 , 25/30 FPS) with mouse operated remote PTZ control, 22 PC TFT Monitors, NVR with 1 G Optical LAN shall be included in the scope of the Tenderer for various strategic locations in the plant/ units. Necessary illumination and air purging and cooling requirement will be in the scope of the contractor. Final quantity for Camera and monitors at various locations shall be as per detail engineering requirements. For details of Closed Circuit Video Monitoring (C.C.T.V OR CCVM) System , refer GTS All CCTV equipment shall be connected to UPS supply. Quantity for monitors at various locations shall be as per detail engineering requirements. All CCVM shall be connected to UPS supply. Offered quantity shall be mentioned in the offer and same shall be discussed during tender discussion and finalised as minimum required quantity. Any further quantity shall be offered during detail engineering. 1) Cameras Compact colour cameras (MPEG-4 / H.264 , 25/30 FPS) with mouse operated PTZ Control. NVR with optical 1 G LAN Weather and dust proof camera housings IP 65 with water cooling and air purging
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Power supplies 220V/12VDC mounted in seperate PSU-box, power outlet and BNC-connector for test purposes Wall brackets with semi-fixed swivel head.
2) Monitors TFT -colour monitors 21 inch 3) Auxiliary Equipment Following will be used for distribution of video signals: Managable Network switch (L2,L3) Encoder for camera Furthermore following material shall be included: Sets of special video cable / UTP cable / FO cable . FO cable shall be used between switch to switch .UTP cable shall be used from switch to encoder / PC/ server Sets of BNC connectors Ceiling mounted monitor brackets CCTV software
4) System Description Cameras fitted with manual zoom - lenses are build into robust industrial design camera housings with protection degree IP 65. Housings are mounted on wall brackets with semi fixed swivel head . Camera housings are factory made , pre - wired for all cameras. Power supply to the camera and add - ons will be made via a camera PSU box. This box contains an isolation transformer 220 VAC for the 12 VDC power supply of the camera incl. protection devices. Furthermore for service convenience an additional 220 VAC outlet and video - BNC - connector is foreseen for easy connection of a service monitor. Video signal transmission to the quad in the ECR-1 is planned via coax cable. To allow the operator in the operator cabin an overall view of the actual line situation the monitor is planned as splitter , showing up to 4 camera pictures. The different video signals received from the cameras will be brought to the input terminals of the quad . All camera pictures of the relevant line section can be individually named. For a better check of an actual situation the operator will have the possibility to bring each splitter picture on a full screen by selecting the relevant button on the quad-unit. The quad-unit is located underneath the monitor.
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Each ECR-1 automation room shall be equipped with min. 1 TFTmonitor or more if required (for each zone area CCVM) , acting as splitter for a maximum of four video signals, selectable and with Video distribution. Further , minimum one monitor or more as necessary shall be located in ECR-1 main PLC and automation room also. A PC based server with necessary hard disk , PC etc shall be provided for storing the data for 30 days. Balance specififation shall be as per GTS GS-03. H) Electrics for Air Conditioning & Ventilation system Air Conditioning System of Premises: Accordingly, Electrics for Air-conditioning system will be provided as per TS/GTS inline with mechanical part of the tender. Scope includes Supply and installation of electrics for air-conditioning system for all premises in line with above table ( i.e. premises / Rooms for ECR control room_automation room, MCC , PDBs, Battery charger, ECR Room for Level-1 & 2 automation and Networking , UPS room, operator room ) and for all other required premises as per detail engineering requirement in line with GTS and TS. On /off /trip status of all motors & dampers and current (in amps) for motors of rating greater than equal to 11KW shall be hooked up with HMI system with HMI screens / PLC system of associated technological facility . Necessary interface with FDA system , technological system facility shall be provided. FDA system fire contact shall be multiplied and connected in the MCC for Premise Airconditioning system and used in trip circuit of each concerned MCC outgoing feeder. Ventilation System of Electrical Premises: Electrics for Ventilation system will be provided as per TS/GTS inline with mechanical part of the tender. Scope includes Supply and installation of electrics for ventilation system for all required premises (like pump house if any , Battery Room etc) as per detail engineering requirement in line with GS and TS. On /off /trip status of all motors & dampers and current (in amps) for motors of rating greater than equal to 11KW shall be hooked up with HMI system with HMI screens / PLC system of associated technological facility . Necessary interface with FDA system , technological system facility shall be provided. FDA system fire contact shall be multiplied and connected in the MCC for Premise Airconditioning system and used in trip circuit of each
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concerned MCC outgoing feeder. I) Electrics for Material Handling Facility Equipment handling facility to be provided (where EOT crane facility is not available, like pump houses etc.) as a permanent installation for maintenance. Necessary MCCB box shall be provided near the facility for isolation purpose. Balance part of specification for Material Handling Facility shall be as per GTS. Also, please refer specification of Handling & Hoisting equipments under mechnical part of tender specification. J) Illumination System Illumination, welding & power sockets shall be as per GTS and shall take care of the following : Emergency lighting board will be fed from emergency power source through a employers PDB to cater to dedicated emergency lighting loads. Scheme to be worked out during detail engineering. Emergency lighting will include 20-30 % of the required number of fittings in each premise. The emergency lighting shall include all fittings of ECR , , pump house if any and other premises as required. Illumination facility shall include premises under the scope with illumination equipment including its power supply equipment like each incoming line dry type isolation transformer (Isolation Transformer with Class-F insulation and temperature rise limited to class-B and with minimum 30% spare KVA capacity of the required KVA capacity) of LDB / Sub LDB / Feeder pillar , Distribution equipment line MCB board ,All types of required light fittings complete with all accessories , emergency lighting , Fans , 15/5A 240VAC power sockets , Chargeable battery operated Emergency light set (one for each ECR/ control room / automation room/MCC/PDB room , each manager room/ shift room, each cellar /pit , each pump house , electronic store room , tool room), other required illumination equipments for all premises under the scope, like ECR, PLC room , L2 automation room, computer room, UPS room , Battery room, MCC / PDB room, equipment Platforms if any , Equipment lighting, Ventilation and air conditioning premises including
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chiller plant & AHU rooms , Repair shop / rooms if any, illumination for CCTV, Special equipment lighting as required , Office / manager room, Electronic store room, maintenance room, shift room, utility rooms like toilets , stairs, walkway , area lighting in open area within battery limit, peripheral light and any road lighting inside the battery limit and any other premise as required although not specified. Cable size from LDB/SLDB to each light fitting shall be 3x2.5 sqmm flexible copper cable. All road lighting for existing roads up to TTP & inside TTP with all poles & fittings are in tenderers scope. All LDB / SLDB shall have bus bars with all incoming 4-pole ELCB / outgoing DP MCBs suitable for 9KA for one second. 100A welding switch socket outlets shall be provided such that the connecting cord of 50m length is able to reach entire forging line area . Cable size to be used shall be minimum 3x95 AYY suitable for 2 cables termination at each socket. 240 V AC 15/5A switch sockets shall be provided in all premises such that the connecting cord of 15 m length is able to reach all areas of the plant.Cable size to be used shall be minimum 3x4 sqmm copper. 240 V AC 15/5A switch sockets shall be provided for machining line bay end row (on lab side) & other open areas if necessary. Cable size to be used shall be minimum 3x4 sqmm copper. Balance specification shall be as
per GTS.
Sl. No. 1 2 3 4
Area Office buildings, control rooms Instrumentation rooms PLC, Computer room, Server room / Pulpits Laboratory building
Lux level 300 300 400500 300
Type of fittings CFL / Decorative TL fittings CFL / Decorative TL fittings CFL / Decorative TL fittings Recessed decorative Fluorescent tubes with electronic chokes HPSV
Compressed air station, Pump house, Cooling tower
150
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Sl. No.
Area and all tech. units/ working area.
Lux level
Type of fittings
6 7 8
Working platforms/floors Cable tunnels Battery room and other chemical rooms
100 60 100
HPSV Fluorescent / Bulk head Corrosion resistant Vapour proof fluorescent tubes with electronic chokes HPSV/ Fluorescent HPSV HPSV
9 10 11
Repair / Maintenance areas Covered storages Road, boundary wall, area lighting all around the Civil and structural buildings (all type)
150 100 20
12
Electrical rooms, MCC 200 rooms, Substation building, office and store for electrical rooms Transformer rooms Toilet blocks Medium height (8-10mtr) bldg. pump houses, shop floors 60 60 200
Fluorescent
13 14 15
Rail type fluorescent Rail type fluorescent Medium Bay - HPSV
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i. 1.
FIRE DETECTION AND ALARM SYSTEM EQUIPMENT FOR TTP General Microprocessor based fire detection and alarm system using distributed processing techniques will generally comprise of the following : Fire Detection and Alarm (FDA) System including Electrical contact interface ( H/W & S/W ) up with respective ventilation system control panels & fire protection systems and data exchange with purchasers network through Fibre optic LAN to Mills area and to central fire exchange station. Fire alarm control panel with Power supply equipment including battery and charger. One such panel for each unit duly networked through LAN to be connected to a local PC in each unit as well as networked with purchasers network including upto repeater panel to be located at central fire station. Central fire station from proposed CRM complex is approximately 2000 m. Cables from CRM shop to central fire station shall be supplied and laid by the contractor. The FDA system shall have all necessary hardware & software for activating automatic fire extinguishing system using direction valves for different zones premises. Further FDA shall provide for interlocks with purchasers ventilation system for switching of the system in case fire is detected. The FDA system link shall be established with mill FDA system and central fire station with all necessary interface hardware/ software / cables etc. All instrumentation points shall be addressable & controllable from FDA panels. Mimic panel with zone indication on plant layout in graphics. Communication network to interconnect all the fire alarm control panels to the Central fire alarm repeater panel and annunciation panel if any at welfare building. Heat Detectors with Fixed temperature (static) elements and Rate of Rise temperature elements. Manual Call Point with built-in addressable monitor modules Break Glass type / Pull Down type Alarm Sirens & Electronic Hooters All interface units including control & monitor modules Electronic earthing system including earth pits/ accessories, cables etc
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for FDA system / PCs and network. FDA panel shall connect to PC based Work Station at Fire Station thro LAN to provide data monitoring in graphics. All FDA panels shall be housed in AC environment. The Master Fire Alarm Control Panel and Local Fire Alarm Control Panel concept shall not be considered. All Panels shall be similar and shall cover different units independently. These Panels shall be networked with each other thro LAN and connect to local PC and Work Station at Fire Station. Electronic Earthing system with all accessories and fitting shall be provided for FDA panel and PC bases work Station. The FDA Panel shall have necessary Hardware and software to activate (operate) Automatic fire extinguishing system provided with directional valves for different zones/ premises. All instrumentation points actuated by the FDA system shall be addressable and controlled by FDA panel. The Detectors shall be Addressable, intelligent, interactive, having inbuilt microprocessor, memory and decision algorithm Ionization Type detectors shall not be considered. Photoelectric, Heat (rate of rise), multi criteria shall be considered for detection. Fire Detection , alarm system, Detectors & Control Panel shall be as per GTS .The main controller panel for each of the area/unit shall be located in the air conditioned automation rooms where the status can be continuously monitored & the controls shall be more reliable leading to accurate information of fire alarms. Besides normal working area sensors , separate sensors shall be provided for false ceiling area wherever provided . The detectors will be located with 5m spacing (both length wise and width wise) and will be grade-1. Fire Alarm Control Panel : Fire alarm control panel with Power supply equipment including battery and charger. One such panel for each unit duly networked through LAN to be connected to a local PC in each unit as well as networked with purchasers network. Each area shall be provided with main fire alarm control panel The fire alarm control panel will be intelligent type, with its own micro computer based master unit, communication processor, signaling modules and memory. It will be fully programmable and modular in design to take care of future expansion of the system. It shall be provided with suitable interface for connection of PC, VDU, Printer, annunciation panels and mimic panels.
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The fire alarm control panel shall have facility to process the input signals received from the fire alarm control panels and display the alarm on the mimic panel as well as on the graphic work station on a real time mode. The panel will provide comprehensive indication of panel status, power supply status, status of alarm zones and have easy test facilities. A small keypad on the panel will enable the operator to acknowledge alarms, test the system, isolate zones and reset the system etc. The system software will be designed specifically for fire detection application. For purpose of reliability and to prevent inadvertent changes system software will be stored in non-volatile memory (ROM). However the system can be reprogrammed by authorized persons. The fire alarm control panel shall have separate florescent display area to indicate the address of each fire zone and clear text about the location of alarm/trouble. The control panel shall have facility to create mimic detailing the areas covered by complete fire alarm system. The graphic work station shall form part of mimic. The graphic work station shall comprise of PC, Printer, Keypad, Mouse and other peripherals. This graphic work station will provide on line status of each detector connected to the system. The unit shall have self diagnostic feature with audio / visual indication for internal faults. One number hand held programming unit will also be supplied with the panel so that necessary changes in system configuration, parameters, logics etc. can be made at site. Contractor shall supply licensed software for the complete fire detection system. All panel shall be provided necessary interface unit for easily net-workable with other fire alarm panel and purchasers network. Control panel shall also have the following features :
Logging an alarm, time and action text on printers. Status check of disabled alarm addresses before they are restored. Storing of alarm and the possibility of internal organization of alarms. The possibility of expanding to a bigger system with several control panels and control and information units. Individually controlled, monitored alarm outputs for external hooters, lamps etc. Fire control panel shall have facility for all test features. The control panel shall have memory storage for last events and an
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alarm counter for number of alarms occurred after the control panel is installed. Power supply to the control panel shall be 240 V, 50 Hz, single phase AC supply and 24 V DC batteries back up for 48 hours and 1 hour alarm condition. The fire alarm control panel shall also provide the following features - Device Blink - For flashing LEDs on the Control detector. - Drift - For compensating the Compensation detector response due to environmental changes. - System Status - Documentation of various Report system parameter - Alarm - To eliminate generation of Verification false alarm due to dust / cigarette smoke - Periodic - For detector testing from the Detector Test panel. Which eliminates the need for testing the detectors in the field every now and then - Trouble - To remind the operator of the Remainder maintenance required at the individual detectors. - Give an indication to the - Detector operator that the detector maintenance requires cleaning. Alert The system display shall provide a back-lit alphanumeric Liquid Crystal Display (LCD). It shall also provide Light-Emitting-Diodes (LEDs) that shall indicate the status of the following system parameters: AC POWER, SYSTEM ALARM, DISPLAY TROUBLE and SIGNAL SILENCE. The system display shall provide a touch key pad with control capability to command all system functions, entry of any alphabetic or numeric information, and field programming. Two different pass word levels shall be accessible through the display interface assembly to prevent unauthorized system control or programming. The system display shall include the following operator control switches: SIGNAL SILENCE, LAMP TEST, RESET and ACKNOWLEDGE. The panel shall be armed with the necessary control and monitor modules & interfaces to operate auxiliary equipment like fire dampers,
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ventilation systems, pressurizing fans, solenoid valves of the fire fighting systems, emergency light, smoke vents etc., if required. Constructional features
b) Sheet steel clad, (minimum 2mm thick), dust and vermin proof, floor mounted with IP52 degree of protection. c) Shall be provided with incoming MCB, necessary stabilized DC power supplies. AC/DC power socket outlets etc. Panel will be illuminated with door limit switches. d) Panel will be provided with 2 nos. earthing bolts. e) Internal wiring of panel will be done using 1100 volts grade PVC insulated flexible copper conductors of size 1.5 sq.mm. f) Terminal blocks will be easily accessible for connection and maintenance. AC/DC power and control terminal blocks will be grouped and segregated. 20% spare terminal blocks will be provided. g) Panel will be provided with removable gland plate. h) Height of the panel will not exceed 2200mm. No equipment will be mounted below 300mm and above 1800mm. The panel will be provided with base channel of ISMC 75 and lifting bolts. i) Suitable plastic channels will be provided for internal wiring. j) All wires will be plainly and durably labeled at both ends with nonconducting materials for easy identification. k) Panels shall be UL/FM/VDS/LPC and also TAC approved. The control panel shall have necessary loop modules, alarm o/p modules and control output for various control functions. Each loop shall be able to take more than 100 detectors and an equal number of control / monitor modules. Control panel shall have facility to expand up to 10 modules. The control panel shall have facility to process the input signals and control all the input data received from addressable type detectors / addressable interface unit. The panel will provide comprehensive indication of panel status, power supply status, status of alarm zones and have easy test facilities. A small keypad on the panel will enable the operator to acknowledge alarms, test the system, isolate zones and reset the system etc. The control panel shall have the facility to transmit the complete status of the panel to the control panel. The system software will be designed specifically for fire detection application. For purpose of reliability and to prevent inadvertent changes system software will be stored in non-volatile memory (ROM). However
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the system can be reprogrammed by authorized persons. The panel will have adequate capacity so as to cover all zones of the plant complex and have minimum 20% extra capacity to cater to additional requirements. It will be designed for further expansion in future. Fire alarm control panel shall have number of electronic filters to ignore false alarm and increase sensitivity to real fires from sensors. The fire alarm control panel shall have separate florescent display area to indicate the address of each device and clear text about the location of alarm/trouble. The control panel shall have facility to create mimic detailing the areas covered by fire alarm system. The unit will have self diagnostic feature with audio/visual indication for internal faults. One number hand held programming unit will also be supplied with the panel so that necessary changes in system configuration, parameters, logics etc. can be made at site. All signal and control related to water spray system, gas system shall be obtained on main fire alarm panel, area wise. Power supply from each fire alarm panel shall be able to meet the power requirement of deluge valve , solenoid valve, local deluge valve panel, electrically and pneumatically operated valves of gas system, gas release panel. Necessary boosting, if required shall be considered by the contractor to meet the power requirement in integrated manner of the whole system. Additional features of the Control Panel: Programmable activation of control output relays for tripping ventilation system, AC system and closing of fire doors in the event of fire. Programmable activation of control output relays for solenoid valves of the water spray system / Gas based fire extinguishing system in the event of fire. Fire control panel shall have facility for test features. The sensitivity of each addressable detector shall be changeable from control panel from normal to low or normal to high. The sensitivity of each addressable detector shall be readable at the control panel. The status check of each detector, interface units for alarm, prior warning, trouble, disabling shall be possible from control panel. Each addressable detector, interface units can be disabled from panel for
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maintenance purpose and restore the same whenever required. Video Display Unit (Graphic Work Station) The VDU shall be a computer work station. It will be used for programming functions, alarm annunciation, commands and data retrieval. Two 21 inch color TFT monitors along with function key boards shall be used for graphic display of the Fire alarm system and its status. Latest version of VDU unit shall be supplied The VDU shall have for the following functions Alarm and returns to normal Commands, Reports Programming Time, day and date Mimic diagram display with alarm points. Alarms and all other change of status shall be displayed in the screen area reserved for the information. Upon receipt of alarm, an audible alarm shall sound and the condition and point type shall flash until acknowledged. Multiple levels of access to the system shall be provided for operators and supervisors via user defined passwords. Printer Printer used in the system shall be hard copy output device and shall provide real time records of the system events and provide system reports on demand. The printer shall automatically record all alarms, troubles, acknowledgements, return to normal and commands selected by the user. Alarm shall be highlighted differently than other messages and shall be recorded, including type, location, time, date and numerical address of alarm point. If an alarm is received during the preparation of reports, the printer shall interrupt the report to record the alarm and afterwards resume the report automatically. All changes to system programming shall be recorded automatically Repeater Panel and Annunciation panel
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The repeater panels will be wall mounting type of standard proven design. The panel will be suitable for top/bottom cable entry. Gland plates will be provided at the top and bottom. Necessary power supply will be derived from the main fire alarm panel including battery back up. Repeater panel will be provided with audiovisual fire and fault indication. Audiovisual display and alarm for faults, first alarm (audio-visual) for alert signal and second alarm (audio-visual) for confirmed fire signal will be provided and each will be distinctive and differentiable from each other. Repeater panel shall be provided at central fire station. Annunciation panel shall be provided in the welfare building. All the control and signal related to deluge annunciation panel through main fire alarm panel. Necessary interface unit shall be provided on this annunciation panel. Panel shall be provided with backup battery charger. These signals shall also be obtained on main fire alarm panel of the respective area. Self Addressable type Automatic Fire Detectors ( Intelligent type) Detectors will be addressable, intelligent, interactive complete with built in microprocessor, memory decision algorithm with suitable detector base, mounting MS Junction box with mounting arrangement and possess the following features Plug-in type with twist locks facility. Common base/interchangeable sensing head configuration. Visual alarm indication at the base for indication of alarm condition by means of LED glowing bright red under alarm conditions. Address numbers on the detector body will be provided. Self reset type. Suitable for operation at 24 V DC. All detectors will be complete with amplifiers with necessary electronic cards/modules for early detection of fire without giving false signals. The detector base will be suitable for connecting response indicator. Provided with in-built locking device to avoid unauthorized removal and pilferage of the detector. All detectors will be suitable for termination of 1.5 sq.mm copper cable. Enclosure as per class IP - 23. Local test facility. Low current consumption. Easy maintenance. Protection against accumulation/ingress of dust. No variation in sensitivity with change in ambient temperature, humidity or voltage variation.
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Detectors will be approved by either UL/FOC/LPC and by TAC. Remote manual or automatic testing of detectors will also be provided with all detectors. It will be possible to reset all detectors from panel after fault signal has been indicated. It shall be possible to adjust sensitivity of detectors through area panel or MFAP. Heat detector ( rate of rise cum fixed temperature) will be used for risks involving flammable fluids, paper and other easily ignited free burning materials. The photo-electric cum heat multisensor detectors will be used where risks involve materials which are likely to produce slow burning fires. Photo Electric Optical Smoke Detectors The detectors will operate on light scattering principle. The detector will comprise of an infra red LED light source and silicon photo diode receiving element. The receiving element will receive no light from the pulsating light source. When smoke enters the detector the light will be scattered on the receiving element. This element will then determine the amount of scattered light it receives and if this exceeds a preset level on two successive pulses, the detector will transmit the signal to the fire alarm panel. The detector will be responsive to smoke particle size 0.5 to 10 micro m range. Heat Detectors All heat detectors will be thermistor type and a combination of both fixed temperature and rate of rise type. The detectors will function with a dual action, using two distinct methods of fire detection viz. rate of rise and fixed temperature. The detectors will be "open circuit " devices, designed to close an electrical circuit upon activation. The rate of rise element and fixed temperature element of these detectors will be entirely independent of each other. The rate of rise element will be an air chamber, a flexible metal diaphragm and a moisture proof vent, carefully calibrated to ignore normal fluctuation in temperature. But when the temperature rise is more than 9 degree C per minute the detector responds. The fixed temperature feature is independent of the rate of rise element &
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responds (activates) when the temperature level exceeds a preset level of 60 deg C. Multisensor type ( photo electric cum heat detector) This type of detector combine the features of smoke detector ( photo electric optical) and heat detector as mentioned under A and B above. Multisensor type detector shall be capable to detect both smoke as well as fixed heat cum rate of rise temperature All detectors shall have approval from UL/FM/VDS/LPC and TAC. Addressable type Manual fire alarm call point These will be of robust construction, suitable for wall/column mounting and made of M.S. box with easily replaceable shatter proof glass window. M.S. box will have 3mm thick sheet steel. All devices such as automatic pull switch, circuitry etc. will be totally enclosed in the box. The break glass box will have a push button which, in normal condition, will be kept in depressed condition by the glass sheet fitted in the front of the box. Initiating a fire alarm simply requires to break the glass with a hammer provided with each call point. This will automatically release the push button due to spring action and transmit the alarm to the fire alarm panel as a result of the change over contact and indicate the location from where the fire alarm has been originated. The unit will be distinctively visible, have red exterior (red epoxy painted) with fire alarm symbol clearly marked on the cover of the box, with inscription "BREAK GLASS IN CASE OF FIRE". The hammer will be duly chained to the box with a stainless steel chain. The manual call point will be weather proof type and have a degree of protection IP-55. The unit will be provided with cable gland plate with knock out holes both at top & bottom and have provision for termination of 5 core, 2.5 sq.mm copper cable. Each box will have an identification number. MCP shall be approved from UL/FM/VDS/LPC and TAC.
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Response Indicator. The response indicator shall comprise of indicator lamp with flashing enclosed in a red plastic cover and fitted inside the M.S. BOX AND ENGRAVED FIRE on the plastic cover. Sirens / Alarm Hooter The siren shall be of rugged construction, have weather proof protection and suitable for outdoor mounting. It shall have adequate range to cover a radius up to 3 K.M and shall be dual tone. The operator at the fire station / control room shall have facility to energies the siren. The siren shall be suitable for 240 V +/-10%, 50 Hz +/-2Hz single phase A.C or 440V 50 Hz, 3 Phase AC via a suitable contractor for starting. Frequency shall be as per standards. The siren shall have rain canopy. The siren shall have IP-65 enclosure. The hooter will be of rugged construction, have weather proof protection and suitable for outdoor application. The hooter will be installed inside room or outside building of the shop complex. It will have adequate range to cover a radius of the plant. The operator at the fire station/ control room will have facility to energize the hooter. Sound level will be minimum 120 db from a distance of 30 meters from hooters. The hooter unit will consist of solid state circuitry on a printed circuit board, a loudspeaker and flashing lamp housed in weather proof, dust tight, wall mounted type enclosure. The hooter unit will derive power from fire alarm panel and operate on DC power. In event of fire, the hooter will raise an audio & visual alarm.
ii.
TELEPHONE CABLE NETWORK Ten (10) nos. telephone connections are to be provided from Purchasers existing Plant telephone system EPABX in Rolling mill area for communication a TTP. Telephone connections will be provided at various rooms of TTP as per detail engineering requirements. At each location, arrangement will be made for two telephone connections (i.e., with two rosette blocks and necessary cabling arrangement), one for Plant communication and another for canteen building communication. For providing telephone connection at required location inside battery limit, following will be provided.
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One (1) no. Distribution cabinet (DC) /Main Cable termination (CT) box of metallic body with required nos. of 25 pair tag blocks with label holder, 2/10 LSA plus disconnector modules mounted on a pre-fabricated stainless steel frame. DC will be installed inside Welfare building . Incoming telephone cables from Plant telephone cable network and distribution telephone cables inside will be terminated in the above DC/CT box and cross jumpered as per requirement . Required nos. of 25/10 Pairs CT Boxes with 20% spare termination capacity for distribution telephone cable network within Shop battery limit as well as other associated areas. Armoured jelly filled / armoured dry core multi-pair telephone cables with 20% spare pair capacity. For each telephone connection, two (2) pair armoured telephone cable will be provided from end CT box to subscriber location. Required quantities of Rossette Blocks (RJ11 type) suitable for termination of two (2) pair cable with suitable enclosure and mounting arrangement. Testing of telephone handsets with the Plant telephone system. Tenderers scope includes supply telephones , Distribution cabinet (DC), Main Cable termination (CT) box and all required cables , cabling accessories , erection and earthing materials of the TELEPHONE CABLE NETWORK System with its installation, testing and commissioning of the telephone system . Incoming telephone cables to the above DC / main CT Box from Plant telephone System will also be provided by the Tenderer. M. V.H.F. SYSTEM 1.0. General This section covers major features of V.H.F system to be supplied by Bidder . The Bidder shall refer to General Technical Specification for Telecommunication, V.H.F system for detailed specification of equipment / components. This Technical Specification (TS), General technical Specification (GTS) including Preferred Makes for Equipment and supplies and other attached documents considered, as a whole shall comprise the complete Tender Specification. These are complementary and anything laid
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down in one and not in other will be deemed as binding, as though laid down in the Tender specification as a whole. In case of conflict between the Technical specification and GTS, the Technical specification (TS) shall prevail. 2. Scope of Work The scope of work of Bidder shall cover design, basic and detailed engineering, supply, submission of drawings for approval, manufacture, testing, inspection by Purchaser/Consultant, packing, loading, forwarding, delivery at Plant site, loading/unloading, storage, handling of material / equipment for erection testing, commissioning, PG test, PAT/FAT and liquidating the all defects related to Communication & V.H.F equipment for complete & satisfactory operation of the system on TURN KEY basis. Any item or equipment not specifically mentioned but essential for proper installation, operation, maintenance and safety of plant, equipment and personnel shall be included by the Bidder in his scope of work The scope of work for this package shall include but not limited to the following: V.H.F. Communication system with the required number of Trans-receiver sets shall be provided. Each trans-receiver set shall be complete with transmitter, receiver, suitable antenna units, masts for antenna (as required), cables, connectors, power supply equipment, earthing of system, mounting accessories and all other erection accessories as required for the completeness of system. In addition to the above hand held trans-receiver sets shall be provided with DTMF dial pad to interface with telephone exchange of the Steel plant. Telephone interface equipment shall also be provided. The frequency allocation for operating V.H.F system shall be obtained by the Tenderer, a separate frequency preferably 149.75 M.Hz., from the Wireless Planning Commission, ministry of communication. The purchaser shall provide the necessary help to the Tenderer, if so needed for obtaining the same, without financial implication to the Purchaser. V.H.F Sets = 3, Base Station = 1(One) For other technical details of system and equipment refer GTS.
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N. 01.
LOUDSPEAKER INTERCOMMUNICATION (LSIS) SYSTEM. General This Technical Specification covers the technical requirement of LOUDSPEAKER INTERCOMMUNICATION (LSIS) System for TTP CRM-III of BSL under modernization. The systems are intended to provide instantaneous, reliable and effective communication as per the technological requirements between various process control points, control rooms, shift in charges, senior operation & maintenance personnel of the Plant complex in high noise level conditions (in the range of 90 to 110 db). 02. SCOPE OF WORK: The scope of work includes complete design, engineering, supply, and storage at site, erection, installation, testing, and commissioning of LOUDSPEAKER INTER COMMUNICATION (LSIS) SYSTEM. The system described in this specification & handing over the system in ready to switch on condition to purchaser on TURN KEY basis. The scope shall broadly cover the following and also shall include such of those items and accessories not mentioned here but required for satisfactory operation of the system. 04 The LSIS System shall essentially comprise the following: One Microprocessor based Central Control Unit(CCU) for selection & switching of calls as per communication matrix & also for making group calls. Required numbers of Wall / Desk top type Subscriber Stations with hand set, amplifiers, loud speakers, function switches & indication lamps etc. Power supply All types of required cables (including special cable, if any) & cabling accessories.
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Earthing system. The communication chart will be soft ware based & programmable at site & required Programming Unit for the same & same shall be included in tenderers scope. 04. List of subscribers stations for Loudspeaker intercommunication system shall be prepared by the contractor.
List of Subscriber Station for LSI System Station No. Location of Subscriber Station Type of stations
This shall be discussed in detailed manner during tender discussions and finalized. O5. For equipment & cables specifications and details, please refer General Technical Specification (GTS). O) CABLES 1. MV Cables (i) 11 kV (UE) XLPE / 6.6KV(UE) XLPE cables / Sl. No. 2. Parameter Reference standard Voltage Grade Note Description IS:8130 ,IS:5831 ,IS:3975,IS:1554, IS:3961 (Part-II) ,IS:7098 Part-I & II, IS: 613 ,IEC-60502 33kV (UE) / 6.6 kV (UE) / (11 kV (UE) if reqd. by Tenderer) Balance specification shall be as per GTS.
3. 4.
(ii)
LT cables All LT cables shall be inline with GTS, Clause 1.02.19.2. Except road lighting armoured cables which shall be burried , all other cables shall be unarmoured laid on trays / in conduits or RCC trenches.
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All Power cables shall be selected from core sizes of 6,10, 16, 25, 50, 70, 120, 150, 185 & 240 sq.mm for Aluminium conductor and 2.5 , 4 , 6,10, 16, 25, 50, 70, 120, 150, 185 & 240 sq.mm sq mm for Copper as required. Various imported equipment required copper cables shall also be selected accordingly. LT Flexible control cable of copper conductor : 1.1 kV grade, heavy duty type with finely stranded annealed tinned flexible copper conductor (Class-5) , ethylene propylene rubber (EPR) insulated and Extruded choloro-sulphorated poly- ethylene (CSP) sheathed with reinforcement of Nylon cord or cotton twine and conforming to IS : 9968 ( Part-I) 1988. Balance part of specification shall be as per GTS. Brief specification : (iii) General : Cable size for incomer of MCC & PDB shall be selected on the basis of current rating corresponding to MD and voltage drop. Cable size for LT motors shall be selected on the basis of rated nameplate current and starting & running voltage drop as per specification. Cable size for MV motors shall be selected on the basis of rated nameplate current, starting & running voltage drop as per specification and short circuit capacity of the system. The cable size shall be calculated based on the breaker opening time of 0.35 seconds. Communication bus shall be laid in GI pipe. The route for redundant communication bus shall be different. For power supply to moving mechanisms subject to vibrations, flexible copper cables preferably of single core should be used. In these cases, a separate core should be provided for earthing. For hoists with flexible / festoon cable system, power supply shall be through butyl rubber / EPR insulated PCP sheathed flexible cables. Cables used for circuits of tacho generators, brakes, solenoids, field windings and secondary windings of measuring transformers shall be copper conductor with crosssectional area not less than 2.5sq.mm per core.
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For control circuits, PVC insulated and PVC sheathed multicore cables with copper conductors having a minimum crosssectional area of 1.5 sq.mm per core shall be used. The number of cores may be standardized as 3, 5, 7, 10, 14, 19, and 24. For multi-core control and signal cables at least 20% spare cores shall be provided with minimum of one spare core. Sequential Length of the cabel shall be marked at every 1 meter interval for all cables. Outer sheeth of all LT cables shall be of FRLS (Flame retardant low smoke) type for cable to be laid in cable tunnels & cable basements. Each core of control cable with 7 core and above shall be numbered at every 1 meter interval. For signals like mA and mV, special screened/shielded cables shall be used.
P) Installation & installation Material Entire installation and erection including its supervision and erection engineering is included in Tenderers scope . This shall include erection of all such items supplied by Tenderer (including items not mentioned in TS but required for successful commissioning) as per battery limits. All panels & desks shall be neatly erected, minor civil work like chipping, making repairs etc. shall be in Tenderers scope. Tenderer shall seal the panels from bottom after cabling. All mounting / support structures & brackets etc shall also be in Tenderers scope. Scope includes supply and installation of cable supporting structures, cable trays in ECR, cable cellars, cable tunnel, cable channel or overhead cable bridge for interplant cabling as required. For installation work at site, the Tenderer will be fully responsible for arranging the required tools and tackles, welding sets, pipe bending machine, cable crimping tools, gauges, scaffoldings, ladders, power connections and any other item / equipment as required. Scope includes all cables accessories, erection accessories, all steel members (angle, channel, plate , steel sheet etc) for installation of electrical equipment / supporting equipments , erection and earthing materials including exposed conduits, cable trays, GI cable trays for illumination, cable supporting structure, cable joints, cable glands ( Double compression glands), Junction boxes, Pull boxes, fire wool , foundation and fixing bolts/nuts/washers , MV / LT / Control cable termination kits , Earth electrodes and earth pit materials. This will include required buried cable trench materials including excavation,
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back filling, and leveling of cable trenches, supply & installation hume pipes, GI pipes , bends , couplers, etc. for protection of cables at road crossings / under ground cable laying and other places where cables may be subjected to mechanical stress and damage, flexible hoses, cable lugs, cable tags, cable fasteners, insulating tapes, ferrules, cable markers, cable jointing & termination kits and materials, earthing strips of different sizes, junction boxes, pull boxes, heat resistant paints and all consumable materials for complete laying & termination of cables, erection of electrical equipment and earthing system etc. Some of items that may be required at site (not limited to following) are as follows : Cable Structures 3.0 mtr long, 750mm / 600mm wide/300mm wide/150mm wide, 50mm depth GI perforated tray. GI thickness 100 microns or as per TS. ISA 50 x 50 X 6mm, GI angles,ISMC 100 x 50 x 6mm GI channels , ISMC 100 x 100 x 8mm GI channels Earthing Material-65 x 8 mm/50 x 6 mm/25 x 3 mm GI flat, GI thickness 100 microns,10 /6 /2.5 sq.mm Multi strand GI wire GI Embeded PVC flexible pipe-25mm/30mm/40mm/50mm/70mm dia Normal PVC flexible pipe: 16mm dia GI conduit, Class : B 40/50mm/80 mm/100 mm dia . All GI exposed or embedded pipes shall be of 2mm thickness and shall be used for all cabling installation as per IS-1239 Part-I . Minimum size of GI pipe used shall be of 40mm diameter. GI 90 deg long Bend threading outside along with two sockets for each bend-32mm /40mm /50mm /80mm /100mm dia 32mm /40/50mm dia 2 or 3 inch long GI nipple with one side threaded (out side) along with two checknuts for each nipple. Reducer-50/40 ,40/32 Cadmiun coated Bolt, Nut with 2 washers - 12mm X 70mm,10mm X 50mm ,8mm X 50mm ,6mm X 50mm,6mm X 40mm,6mm X 25mm,8mm X 30mm,10mm X 30mm Fused Terminal blocks with 24VDC LED heavy duty GI Saddles with GI base-suitable for 25mm GI conduit/ for 32mm GI conduit/ for 40mm GI conduit / for 50mm GI conduit / for 80mm GI conduit/ for 100mm GI conduit Catridge ribbons for ferrule marking PVC ferrule sleeves-3.2mm /4.2mm Anchor fastner (back side nut type):8mm dia x 100mm long,10mm diax 100 mm long,8mm dia X 75 mm long,10mm diaX 75 mm long,12mm diaX 75 mm long
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Double compression brass Glands suitable for all power , control and signal cables of copper / aluminium conductor (Make: Electromag, CCI, Commet) Aluminum Lugs for all power , control and signal cables of copper / aluminium conductor (Make: Dowels, Commet, 3D, Kalter, Farward) Copper Lugs for all power , control and signal cables of copper / aluminium conductor Make: Dowells, Commet, 3D, Kalter, Farward) Long Neck Aluminium lugs for power cables of aluminium conductor HT termination Kits (indoor type) for MV grade End Termination Kit and Straight through jointing termination kits Boot less type tubuler / Head crimping type lugs- for 1.5 sq.mm single pole,1.5 sq.mm double pole,2.5 sq.mm single pole,2.5 sq.mm double pole,1.5 sq.mm Fork type Lugs,2.5 sq.mm Fork type Lugs ,2.5 sq.mm Ring type Lugs.,4 - 6 sq.mm Ring type Lugs.,10 sq.mm Ring type Lugs. 16mm PVC glands for Sensor cable termination/ PG9 glands for profibus cable /PG11 glands for profibus cable U shaped perforated Cable tray covers for covering upto 1.5 m in all risers at bay area & ECRs-150mm/300mm/600mm/750mm Bitumen compound for Unused conduit seeling/Jute for Unused conduit seeling/Conduit sealing compound along with gun/ 25 x 3 Aluminium flat for cable clamping & cables tags MS Chequered plate 6 mm thick/MS plate 8mm for motor gland plate/GI Sheet 24 or less gauge for Cables covering below baseframe/Painting for pull boxes etc.(Red oxide)/Painting for pull boxes etc.(Final), Nylon PVC ties white colour (100 nos each packet),M-seal,HT tape, 25mm wide,Gasket 25mm wide, ,Nomenclature painting , Safety equipments All equipment /panel testing at site ,Hi-pot test for HT/MV cables,
FRP (Fibre reinforced plastic) or light alloy material Junction boxes(JB) with IP65 or better protection for use in wet areas will be considered if required . Scope will also include soil resistivity measurement. Lightning protection system including all required erection materials, interconnected earthing strips for premises under the scope.
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Scope includes repair of any damaged equipment and touch up painting during handling and erection of equipment. Supply of all Cable accessories , erection accessories and consumables including Safety items like hand gloves, shock treatment charts, rubber mats (Insulating mat), danger/caution boards for Tenderers scope of work.Insulating mat shall be as per IS:156522006. The quantities of equipment, cables, cable terminations, straight through joints, cable supporting structures, earthing / lightning and erection materials, shall be as per actual requirement in accordance with the approved detail engineering drawings. After erection , all electrical structures , exposed GI pipes, motor base frames, panel base frame, Junction box, pull box, cable extension box, Support structures shall be coated by using primer first and further followed by painting . All GI pipes (Exposed and embedded) and all panel openings , Junction box openings, pull box opening shall be sealed after completion of installation. On completion of the installation but before energisation of the system, all installation will be physically checked and properly tested. These checks and tests will be conducted by the Tenderer under the supervision of Employer. The Tenderer will furnish the final status and test results. Any defect observed during such check and tests will be rectified by the Tenderer as part of this Tender. Necessary approval of statutory authority as per rules of State Government and Central Electricity Authority for the work under Tenderers scope, before energizing/charging the equipment will be obtained by Tenderer. However, Employer will extend all assistance in this regard, like submission of application, relevant documents and payment of statutory fees etc. The scope of work also includes deputation of expert for supervision of erection,, Actual erection, testing, commissioning, PAC/ FAC, PG test shall be in the scope of the Tenderer. Watch and ward for main stores, for electrical material storage separately near electrical erection contractors office, for areas where
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copper cables (prone to theft) are laid will be in Tenderers scope round the clock. Special care shall be taken during engineering of cable tray design and cable gallery design to take care of occurrence of major fire. Emergency exits in case of fire. Fire barriers & flame retardant paint shall be provided on cables. Provision in Cable tunnel for 2 nos. additional cable trays and 20% extra space on each cable tray for future use shall be provided, as far as possible. All network cables , RI/O cables in separate conduits with distinct colour. Glass braid shielding to be provided only for shielding of heat resistant cables. Asbestos shielding is not to be considered. All valve stands shall be supplied as pre-wired with copper cable to junction box (mounted on valve stand structure ) for external cable termination. Solenoid Valve connectors shall be with LED. Solenoids shall be controlled through potential free contacts. Balance part of specification shall be as per GTS. Q) Earthing / Lightning Protection System All required earthing and lightning protection system, as required, will be supplied as per scope by Tenderer complete with all accessories and earthing materials for various premises covered under Tenderers scope. Connection of all earthing to Employers primary earthing grid is in the scope of Tenderer. Static and electronic earthing value shall be less than 0.5 ohm and Power earthing value shall be less than 1 ohm. Earthing system shall be designed by Tenderer accordingly. Earthing systems primarily have to be designed for the purpose of securing life against electrical shock and at second to protect all connected electrical systems, based on short-circuit calculations of the feeding network.
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Entire system shall be earthed in accordance with the provisions of the relevant IS/ IEC/ other international standards recommendations & code of practice, so that the values of the step and contact potentials in case of faults are kept within safe permissible limits. Parts of all electrical equipment and machinery not intended to be alive shall have two separate and distinct earth connections each to conform to the stipulation of the relevant Electricity Rules and apparatus rated 240 V and below may have single earth connections. Lightning protection systems are also primarily designed to secure life against effects of lightning strokes and at second to prevent of damage to buildings, objects and equipment. Balance part of specification shall be as per GTS. R) Passive Fire Protection Passive fire protection will be provided in line with scope and GTS. Passive fire protection for cables shall be applied. Fire resistant boards at panel glands as required and at fire barrier walls as required. Fire resistant sealant on both side of the conduit shall be applied. between boards & cables, Fire resistant paint on cables 1.5 m on both sides of fire barrier walls (wall by Employer) will be provided. Fire resistant sealant for conduits on both sides where it connects ECR to cable tunnel / trench, Fire resistant paint on cables 1.5 m on both side of such conduits. Fire resistant paint may be applied for 1 m below/ out side the panel wherever practicable. Balance part of specification shall be as per GTS. S) Repair Network Repair network shall be provided for all area in the scope including cellars, basements, cable tunnels. In addition , repair network for Roll shop shall also be considered. Detail shall be as per TS/GTS. T) Special Tools & Tackles , Instruments Tenderer shall include in their offer necessary Special Tools and Tackles , instruments , Calibrators , records as may be required for successful commissioning and maintenance of the plant. A minimum list of special tools and tackles shall be as enclosed with this TS . Any further special tool required shall be provided by Tenderer and special tools brought by Tenderer at site for commissioning shall be
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deemed to be property of Employer. Minimum list covered under supplu by Tenderer shall be as follows : The following tools, special instruments give a guide line as to the equipment which will be used for the start up and commissioning as well as for the maintenance. The equipment is included in the Tenderers scope of supply, other tools and instruments for erection and commissioning are not included. This equipment will be put at the disposal of the commissioning engineers so that they can use these tools and instruments for their work. Afterwards these tools and instruments will remain with the customer for service and maintenance. The special instruments are such which are necessary for commissioning of electrical and electronic equipment and will be used for maintenance and service afterwards. Minimum One set shall be provided for Machining line area as per following: - Signal Generator - 8 channel thermal chart recorder / Hioki recorder - Megger (500V)- 1nos - Megger (1000V)- 1nos. - Circuit breaker operator handles - Test service kits for communication equipment - Kits for fibre optic cable installation and maintenance - Temperature controlled soldering iron - Analog high impedance multimeter (20 kohm/v) - De-soldering pump - Continuity tester - AC/DC tong tester 0-500A- 2nos. - Vibration meter - Breaker testing kit with report generation facility- 1 for each make of breaker - Breaker handling truck- One of each type for each electrical premise - AC/DC Clamp on Meter- 2nos. - Volt- Plantivolt / planti amp calibrator/ Simulator- 2 nos. - Phase Rotation Meter - DC Voltage Source(0 32 Volts, 2 Amps; 5 V, 5 Amps & 15 V, 0.5 Amps) - 40 pc Multi size Screw driver set with handle - Electricians tool kit - Torque Wrench with 250 mm extension rod and T30 bit set and socket set (8, 10, 13)DC Link Adjuster for drive dismantling - RJ connector crimpling tool
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Power driven screw driver -1 set Blower with heater Vacuum cleaner Tool kit with bag Drive module handling units as recommended by the drive manufacturer : 1 No. each type for each ECRs. - Test kit for testing of microprocessor based releases of 415 V circuit breakers - 4 and 1/2 digit Digital Multi-meter (FLUKE/AGILENT/ YOKOGAWA) 5 Nos. - Insulation tester, Motor monitor (capable of measuring resistance, inductance and insulation resistance) - Service Engineers Toolkit 2 sets each for following items 1. combination plier 2. Stripping plier 3. Half round plier with cutter 4. Long nose plier 5. Electronic gripping plier 6. Screw driver set - Torque wrench suitable for cable and panel termination - Hydraulic cable lug crimping tool - One piece crimping tool- each size - One piece connection tools for FO Ethernet cable - One piece connection tools for other network cable - Paperless Digital event & process recorder
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U. List of commissioning spares Minimum List of commissioning spares have been specified for the facility/ area. Minimum One set of following equipments shall be provided for TTP / aux. equipment. Any other commissioning spares ( as part of main supplies) as required for successful commissioning till PG test completion is in the scope of the Tenderer. : Sl. Description Quantity (total 1 set of specified set / no.) for Machining line / aux. equipment ) A 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 MCC MCCB of different rating MPCB different ratings Handles for MCCB of different rating Power Contactors of different ratings Moving contacts of Power contactors of different rating Fixed contacts of Power contactors of different rating Coil for Power contactors of different ratings Auxiliary contacts for power contactors Overload relays of different ratings Auxiliary contactor (2NO+2NC) Coils for auxiliary contactor Add on block for auxiliary contactors. Push buttons (start) Push buttons (stop) Contact block (2NO+2NC) for start PB Contact block (2NO+2NC) for stop PB Actuator head for start PB Actuator head for stop PB 2 No. of each rating 2 No. of each rating 2 No. of each rating/size 2No. of each rating 2 Nos. for different ratings 2 Nos. for different ratings 2 Nos. for different rating 10 Nos. for different ratings 3 Nos. of different rating 20 Nos. 20 Nos. 20 Nos. of different combinations 20 Nos. 20 Nos. 20Nos 20Nos 20 Nos 20 Nos
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Sl.
Description
Quantity (total 1 set of specified set / no.) for Machining line / aux. equipment )
19 20 21 22 23 24 B 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 C
Local-off-Remote selector switch Control switch spring return type MCBs Isolator / SFU unit of different rating HRC fuses of different rating Control transformer PLC and AUTOMATION SYSTEM Power supply unit communication module circuit breaker contactor relays control fuses Terminal boards CPU card Analog Input and Output card Digital Input and Output card Signal interface board Ribbon cable Connector Relay Boards Fuses CONTROL DESK /LOCAL STATION/ LOCAL CONTROL BOX Push buttons (start) Push buttons (stop) Contact block (2NO+2NC) for start PB Contact block (2NO+2NC) for stop PB Actuator head for start PB Actuator head for stop PB
10 Nos. 10 Nos. 10 Nos. 3 Nos 20 Nos. 2 Nos.
1 no. of each type 1 no. of each type 1 no. of each type 1 no. of each type 1 no. of each type 1 no. of each type 1 of each type 1 of each type 1 of each type 2 of each type 1 of each type 1 of each type 1 of each type 2 of each type 3 nos of each type used.
1 2 3 4 5 6
5 Nos. 5 Nos. 10Nos 10Nos 5 Nos 5 Nos

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Sl.
Description
7 8 9 10 11 D 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. E 1. 2. 3. 4. F 1. 2. 3. G 1. 2. H 1. I
Selector switch Control switch spring return type Complete Lamp unit Digital meter Emergency push button PDB Air circuit breaker Closing coil Tripping coil Contact main Contact aux Release MCCB Unit Contactor Coil Contactor Contacts O/L relay MCB / MPCB Indication Lamps Push Buttons ILLUMINATION SYSTEM Control gear unit for light fittings Tube light starter & choke MCB and MCCB Lamps CCVM Camera Pan / tilt head unit Lens For Remote I/O as applicable Power supply unit Input and output module Network Equipment Network bus connector
2 Nos. of each type 5 Nos. 10 nos. 1 no. of each type / rating 5 nos
2 of each type 2 of each type 1 of each type 2 of each type 1 of each type 2 of each type 6 of each type 6 of each type 2 of each type 12 of each type 12 of each type 12 of each type 6 sets of each type 24 sets 3 nos of each type 3 nos of each type 1 of each type 1 of each type 1 of each type 1 no of each type 2 of each type 2 nos of each type
One set of electronic cards of For each PLC/RIO and UPS system each type
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Sl.
Description
MCC Components
At least 50% used quantity of MCC components like selector switch handle, lamp cover for each color , lamp bulb , push button outer surface unit and digital meter glass cover should be separately supplied in a box as erection and commissioning spares as part of main MCC supply by supplier to help immediate replacement of broken front surface parts of MCC during erection
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07.02.07
Scope & Division List for Electrics & automation
Legend (T Tenderer, P - Employer, BD- Basic Data, BE Basic Engineering, DE Detail Engineering, E & C - Erection & Commissioning) Sl. No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Item 6.6 kV Switchboards of Employers HT sub-station and 415V LT switchboard of Employers LT substation PF / Harmonic Compensation as required Dry type Isolation transformer as required AC motors and Accessories including motor mounted ventilation Equipment as required BD T T T T BE DE SUP E & C P T T T T T T T T T T T T T P P T T T T T T T T T T T T P P T T T T T T T T T T T T P P T T T T T T T T T T T T
LTAC motors for energy efficient operation of rating T >=90 kW =<200 kW and accessories as required Fixed speed AC motors and accessories as required. T Power distribution board (PDBs) as required Motor control centers (MCCs) as required Lighting DB (LDB) as required T T T
Illumination fluorescent fittings and lamps as required T Illumination well glass / other light fittings and lamps T as required 15/5A 240VAC switch sockets as required T
FDA system with all accessories as per TS AND GTS T Field mounted devices /sensors and any special instruments as required with signal conditioning T electronics and lead cables as required Automation system covering basic control level (Level-1) with its application software and interface T hardware / software as required with all RIO panels Supervisory/ process control level (Level-2) as required with its application software and interface T hardware / software as required
15.
16.
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17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39.
Conversion equipment of compressed air from TOP T to dry process / instrumentation grade air as required Uninterrupted Power Supply system (UPS) and Accessories including battery, power supply T distribution boards, as required. Control desks /Post /EPB as required Local control Posts/stands as required / Local control boxes as required Maintenance aux. hoist for cellars etc if required with its ACB panel//MCCB box with accessories as required CCTV System with its camera, monitor , recorder and accessories as required LSIS , VHF & telephone system with all accessories as required Air Conditioning & Ventilation system PDB/MCC panel/ starter box as required T T T T T T
T T T T T T T T T T T T T T T T T T T T T T T
Air Conditioning & Ventilation system Local control T box as required Furniture equipment , rack console type table, operator chair, almirah, shoe, rack, cabinet, printer trolley as required LT power cables as required LT control cables as required Shielded / screened cables as required FO cable and twisted pair cables as required Data communication/ signal/ video cables / special cables as required Ladder Cable tray as required for the scope of work Perforated Cable tray as required for the scope of work Embedded GI pipe with bends / couplers as required in RCC block for the scope of work Exposed GI pipe with bends / couplers as required for the scope of work Power junction box with accessories as required Control junction box/ Pull box with accessories as required GI earth strip with accessories as required All steel members / Structural materials (angle, channel, plate , steel sheet etc) required for cable racks/hangers and support , base frame etc as
T T T T T T T T T T T T T T
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40.
41.
42.
43. 44. 45. 46. 47.
required for the scope of work All cable accessories ,erection accessories and other required erection and earthing materials including Safety/Equipment earthing and electronic earthing T including earth electrodes and copper cables for electronic earthing for Tenderers equipment Supply of furniture like console type table, rack, cabinet, printer trolley, operators chairs etc as required for ECR, Operator room of Axle machining T ,Equipment/Machine (under Tenderer scope of supply) Rooms Supply of all consumables as required for electrical and automation system up to successful commissioning. All necessary special tools tackles and testing equipment required for maintenance of the supplied system as specified Commissioning spares as required T
T T T T T T T T T
T T T
48.
Any insurance spares as required T Engineering drawings for Tenderers equipment system including as-built drawings as required Participation of Employers/ Employers representatives personnel during application software development for the automation system of Tenderer Providing training to Employers personnel on electrics & automation system supplied by the Tenderer at Manufacturers works, similar working plants as well as at site during commissioning.
Tenderers billing schedule shall be submitted after order placement as per above table items with breakup of each item under activity as applicable such as imported item category, indigenous item category , part of mechanical / lubrication hydraulic equipment supplies etc for approval/ clearance. NOTE : Certain items like list of 2 years spares / insurance spare, Establishing communication links with the Higher Level automation system (Level-3)/ ERP/ automation system of Employer and necessary interface for Instrumentation controls as required are part of TS.
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07.03
INSTRUMENTATION & CONTROL
07.03.01 001
General: This part of the specification covers the basic requirements for instrumentation and control system for Tertiary treatment plant (1 No.) in the new CRM complex of Bokaro Steel Plant (BSL) with a view to achieve safe, efficient and reliable operation of the process. This specification, read together with the Instrumentation & Automation parts of the General Technical Specification (No.GS03), General Conditions of Contract (GCC) and other commercial terms & conditions, shall form the Tender document, against which selected vendors (here-in-after called Tenderer) shall submit their complete & most competitive techno-commercial offers. Measurement and control equipment offered for the process shall be complete in all respect in line with this specification. Any equipment / accessories not explicitly indicated in this specification, but considered essential for proper functioning of technological equipment and process shall be included by Tenderer in their scope of work and supply. The instrumentation system shall be based on 4-20 mA DC signals, working generally on two-wire signal system. In addition to required measurements and controls, adequate sequential and safety interlocks, monitoring and display of all abnormal process conditions shall also be provided. All signals from field mounted instrumentation equipment (transmitters / converters/ switches etc.) of the plant shall be hooked up to a common PLC based automation system installed in tertiary treatment plant operators control cum MCC room. All field-mounted transmitters shall be Smart type. All equipment envisaged shall be suitable for round the clock operation throughout the year in industry environment. Field instrumentation equipment will comprise diaphragm sealed/ non-sealed pressure / differential pressure gauges, RTD/ temperature transmitters, rota meters, magnetic flow meters, turbidity meters, float & ultrasonic type level instruments for level measurement and signaling, pH meters and conductivity meters.
002
003
004
005
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006
Process instrumentation signals corresponding to various process parameters as per the list of measurements & controls will be displayed in the HMI of PLC based automation system. The details of PLC system as required has been described in the electrical part of TS. Power supply to instruments shall be 240 V AC, 1, 50 HZ through UPS system, Transmitter power supply shall be 24 V DC preferably loop powered. Armoured PVC insulated copper cables shall be employed for the instrumentation control & interconnection purpose. Analog Signal cables shall be armoured & shielded type. Suitable earthing system shall manufacturers recommendation. be provided as per the
007
008
009
010
All the instrumentation & control equipment shall be brand new & shall be supplied from the latest product ranges of reputed manufacturers as per the List of Preferred Makes, furnished in this Tender document. Purchaser/ Consultant reserve the right of selecting particular make and model of instrumentation equipment with a view of standardisation of the whole plant. Tenderer shall comply with such requirements. In case, certain instruments are offered by Tenderer as per his standard design and system requirement, whose make has not been indicated in the TS, Tenderer shall propose make of such items in the offer with credentials and catalogues for Purchaser/ Consultants consideration Tenderer shall execute complete instrumentation package on turnkey basis to the satisfaction of Purchaser/ Consultant. Tenderer shall comply with all the requirements of various clauses of Technical Specification e.g. General, Scope of Work and Supply; List of Measurement, Submission of Drawings & Documents; General Technical Specification (GTS), Supply of instruments from List of Preferred Makes and other related clauses/ annexure as stipulated in this Tender. All correspondences / documents shall be in English language and for all the data, drawings & documentation metric or SI units shall be followed
011
012
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07.03.02
Scope of work and supply Tenderers scope of work and supply shall include design; engineering; manufacture/ procurement; assembly; calibration; shop testing; inspection; painting; packing; supply, transportation & delivery to site including loading, unloading, storage & handling; of all instrumentation equipment / items including electrical accessories, cables, pipes, erection accessories, and all associated hardware, as required for completeness of instrumentation & automation system in all respect along with site fabrication, erection, testing and commissioning of the complete system of Tertiary treatment plant (TTP). In addition to the above, Tenderers responsibility shall also include erection, testing & commissioning of instrumentation equipment. The scope of work and supply shall include, but not limited to, the following:
i) ii) iii) iv) v) vi) vii) viii)
Instrumentation equipment as per the measurement list covered under clause number 03.00 of this TS. Fully wired Instrument / PLC panels / desks /cabinets for level / ultrasonic instruments Power supply / conversion equipment & electrical accessories. All types of control, signal, power and system cables as required for this package. Impulse pipes, isolation valves, fittings, erection hardware & accessories, as required for this package. Submission of drawings and documents as per clause no. 04.00 Arranging inspection at the manufacturers premises. Erection, testing, calibration and commissioning of the total equipment included in this specification. Successful Tenderer shall arrange tools, tackles and consumables as may be required for erection, testing and commissioning activities. Construction of Office cum Operators room with PLC panel, Electrical / MCC room, toilet room with all facilities, laboratory
ix)
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facilities, Chemical house for storing of chemicals, preparation of different chemical solutions and dosing pumps with standby arrangement and pipe lines for the same along with hoist for chemical handling, over head service water and drinking water tanks x) Preparation of earthing pit, supply of earthing materials including cables and installation of separate earthing system for case earthing, power and instrument signal earthing. Arrangement of and participation in inspection of Instrumentation by Purchaser/ Consultant is also included in Tenderers scope. List of recommended spares for two years normal operation & maintenance indicating unit rate with validity of 2 years. (To be decided by Purchaser for procurement at a later date) Supply of commissioning spares. Supply of all instrumentation equipment from list of preferred makes (GS-13) as enclosed with the General Technical Specification (GS03). Compliance with instrumentation General Technical Rules (GS-03) as enclosed with this Specification. List of Measurements & Controls: Following are the indicative list of measurements and Tenderer shall comply with the same. However, Tenderer shall offer all the measurements as may be required for efficient & satisfactory operation of the offered system, and indicate detailed list of the same in their offer. Unless otherwise stated, all measurement signals shall be hooked up to the PLC based automation system as envisaged common for electrical & instrumentation facilities & process parameters shall be displayed in the HMI. The process operating parameters indicated here are indicative. Tenderer shall provide the same as per the process requirement. The measurements signals shall be brought to the control room of RO plant building unless otherwise stated.
xi) xii)
xiii) xiv)
xv)
07.03.03
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I.
Measurement of pressure: a) b) c) d) e) f) g) h) i) j) k) l) m) n) o) Pressure gauge at effluent feed inlet to equalization tank at take-over point Pressure gauge at the inlet and outlet water line of Multigrade filters Pressure gauge at the inlet and outlet water line of Activated carbon filters Pressure gauge at the inlet and outlet water line of Cartridge filters Pressure gauge at the inlet and outlet water line of RO train. Pressure gauge at the delivery of each chemical dosing pumps Pressure gauge at the delivery of each filter air blowers Pressure gauge at the delivery of each degassed air blower Pressure gauge at the suction and discharge side of effluent feed pumps Pressure gauge at the suction and discharge side of clarified water pumps Pressure gauge at the suction and discharge side of cartridge filter feed pumps Pressure gauge at the suction and discharge side of degasified permeate transfer pumps. Pressure gauge at the suction and discharge side of each high pressure pumps. Sensing of low pressure at the header of running pumps including chemical dosing pumps with alarm annunciation on panel and starting of standby pumps. Sensing of high & low pressure at delivery of each high pressure pumps with high & low pressure alarm annunciation on panel. Pressure gauge with electric contact shall be employed for the purpose. Regulation of pressure at inlet of each RO train by self actuating type pressure control valves
p)
II.
Differential pressure measurement: a) b) c) d) Differential pressure measurement across each Multigrade filters along with high DP alarm annunciation on panel. Differential pressure measurement across each Activated carbon filters along with high DP alarm annunciation on panel. Differential pressure measurement across each Basket strainers along with high DP alarm annunciation on panel. Differential pressure measurement across cross flow filtration unit with high DP alarm annunciation on panel.
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e) f)
Differential pressure measurement across each Cartridge filters along with high DP alarm annunciation on panel. Differential pressure measurement between inlet water line and outlet concentrate water line of each RO train along with high DP alarm annunciation on panel.
Differential pressure gauge with electric contact shall be employed for the purpose. III. Measurement of Turbidity using panel mounted turbidity meter a) b) c) d) At effluent feed inlet to equalization tank at take-over point along with high feed turbidity alarm annunciation on panel. At activated carbon filter common outlet header. At cross flow filtration unit common outlet header with high turbidity alarm annunciation on panel. At Cartridge filter common outlet header.
IV.
Flow measurement: a) b) c) d) e) f) g) h) i) Flow measurement at the inlet to equalization tank at take-over point. Flow measurement at delivery header of Effluent feed pump with panel mounted flow indicator. Flow measurement at the outlet of filters Flow measurement at the outlet of cross filtration unit with panel mounted flow indicator, flow totalisers and high and low flow alarm annunciation. Flow measurement at the inlet of backwash water lines from overhead tank with panel mounted flow indicator, flow totalisers. Flow measurement at the outlet of UV sterilizer. Measurement of concentrate water flow at the outlet of each RO train with panel mounted flow indicator, flow totalisers and high and low flow alarm annunciation. Measurement of concentrate water flow at the outlet of each RO train. Flow measurement at delivery header of degasified permeate transfer pumps
Magnetic flow meters shall be employed for the purpose
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V.
Level measurement: a) High, low, low-low level measurements for equalization tanks, clarified water sumps, Filtrate tank, make-up water blending tank chemical dosing/ measuring tanks and backwash water overhead tank with sensing of low level with alarm annunciation on panel. Effluent feed pumps, clarified water pumps, cartridge filter feed pumps, chemical dosing pumps to be interlocked with low level. Sensing of high, low, low-low water level in degassed permeate tank with alarm annunciation on panel. In case of low level, degasified permeate pump shall trip.
b) c)
Ultrasonic level instruments shall be employed for the purpose VI. Measurement of temperature: a) b) Measurement of temperature at the outlet header of Cartridge filters with panel mounted indicator along with alarm annunciation for high temperature. Temperature measurement of degasified permeate make-up water with panel mounted indicator.
RTD/ temperature transmitters shall be employed for the purpose
VII. Measurement of pH: a) b) Measurement of pH at the inlet to equalization tank at takeover point with panel mounted indicator, high and low pH alarm annunciation. Measurement of pH at the outlet header of Cartridge filters with panel mounted indicator, high and low pH alarm annunciation. Acid dosing pumps shall be interlocked with high & low pH level. Measurement of pH of degasified permeate water with panel mounted pH indicator and high and low pH alarm annunciation. In case of high pH value, the alkali (pH correction) pump shall trip.
a)
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VIII. Measurement of conductivity a) b) c) Measurement of conductivity at the outlet header of Cartridge filters with panel mounted indicator and alarm annunciation for high conductivity. Measurement of conductivity at the outlet line of each RO train with panel mounted indicator and alarm annunciation for high conductivity. Measurement of conductivity of water in blending tank (makeup water tank) with panel mounted indicator and alarm annunciation for high conductivity.
IX.
Other measurements a) Complete measurements, controls, alarms and interlocks required for Cross flow filtration, Sludge dewatering plant and Zero Liquid discharge Plant to be provided by the Tenderer as the same is not included in the above list. All instrumentation, auto controls for Tertiary treatment plant other than those mentioned above shall be considered by the Bidder which is necessary for the system offered.
b)
Common Facilities For The TTP: A. Office cum Operators room with PLC panel, Electrical / MCC room, toilet room with all facilities, laboratory facilities, Chemical house for storing of chemicals, preparation of different chemical solutions and dosing pumps with standby arrangement and pipe lines for the same along with hoist for chemical handling, over head service water and drinking water tanks. Common treated effluent collection / mixing sump with outlet overflow channel. i) Measurement of pH shall be provided in this sump and the pH value shall be indicated / displayed at HMI at operators / control room. ii) Flow measuring instrument / device at the outlet channel shall be provided. This final flow measurement of the total treated effluent shall be indicated at the HMI with instant flow value and cumulative / sum flow value. C. Operators control station Operators HMI & PLC
B.
panel will be located at the Office cum

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Operators room, where all the pH indications, final flow measurement of total treated effluent discharged, Status of all drives / pumps ( whether running, stop, tripped) shall be indicated / shown at the control panel, sump low level / high level shall also be indicated / displayed at the control panel. 07.03.04 List of drawings & documents Following drawings and documents shall be submitted by the Tenderer for Instrumentation system: A) To be submitted along with offer 01 Process and instrumentation (P & I) diagram indicating all measurements, controls, etc, using ISA symbols and using suitable tag numbers against each instrumentation equipment. 02 List of measurements, controls along with BOQ and brief specification of each instrumentation item. 03 System configuration diagram of PLC system 04 Detailed technical literature of the instruments offered. 05 List of commissioning spares with details. 06 Recommended List of two years operation & maintenance spares with details & unit rates. To be submitted by the successful tenderer during detailed engineering: I) 01. For Approval : Finalised process and instrumentation (P & I) diagram indicating all measurements, controls, etc. using ISA symbols and using suitable tag numbers against each instrumentation equipment. Finalised list of measurements, along with BOQ and specification of each instrumentation item indicating make, model number, scale range, quantity, application and tag number (as per P&I diagram). Detailed specification datasheet for each instrumentation items & cables, filled in as per the format finalized for this plant. System configuration diagram of PLC system with BOQ of hardware & software items.. Single line power supply diagram with specification and bill of quantities of electrical accessories.
B)
02.
03. 04. 05.
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06. 07. 08. II) 01. 02. 03. 04. 05. 06. 07. 08. 09. 10. 11. 12. 13.
G.A drawing of the panels/ cabinets / desks. External connection diagram. Quality assurance plan (QAP) for each instrument & automation system item. For Scrutiny & Reference Input / output list Sizing calculation for the flow sensors / meters and control valves as employed in the process. G.A drawing of flow sensors / assembly and control valves. Disposition drawing of the panels/desks / cabinets in the control room. Cable routine diagram Cable schedule for instrumentation & PLC system. Panels/ desks /cabinets internal wiring & termination diagram. Detailed technical literature/ catalogue for each instrumentation item, highlighting the model number. Instrument Installation/ Hook up diagrams with bill of materials. Manufacturers test, calibration and guarantee certificates for all instruments Operation and maintenance manuals for instruments. As-built documentation. Soft copy of all the above drawings & documents in CDs / DVDs.
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08.00 CIVIL AND ARCHITECTURAL 08.01 CIVIL SCOPE OF WORK The scope of work includes all civil works required for proposed Tertiary Treatment Plant (TTP). The Tenderers scope shall include complete engineering and construction on a turnkey basis inclusive of detail design, basic engineering, detailed engineering, supply of all materials, construction and testing in respect of all facilities required for completion and handing over of the work as per technical specification. All civil works for the buildings, equipment foundations to be provided for the project shall be included but not limited to the following: a) RO plant building : Single storied RCC framed construction b) Chemical house : Double storied RCC framed construction with following facilities i) Acid and alkali resistant flooring shall be provided for the building ii) Foundation for tanks and pumps shall be applied with acid resistant paint iii) Staircase shall have acid and alkali resistant tiles iv) Drain channels shall be provided with acid and alkali resistant tiles c) Dewatering plant d) Zero liquid discharge plant e) Backwash water Overhead Tank : It shall be of RCC construction with staging height of minimum 15 m The tank shall be provided with Internal coating. f) Sumps, Pits, Tanks, HRSCC, Flash mixer : Internal coating / acid resistant tiles shall be provided g) Foundation for Pumps, Tanks, Equipments, etc. h) Blow down Collection Sump (near Battery limits) for each Chilled Water Plant i) Common Collection Sump (as per technological details) j) Auxiliaries Broad scope for civil works shall include but not limited to the following: Terracing of the land earmarked for the proposed plant including removal of debris / scraps to a designated place within a lead of 8 km.
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Site clearing including cutting of trees, bushes and removal of top unserviceable top soil and organis materials to a designated place within a lead of 8 km. Statutory clearance if required shall be in the scope of the successful tenderer. Earthwork for foundations, pits, trenches, basements, tunnels, drains, sumps, sewers, etc. Reinforced concrete for raft foundations, spread footings or strip footing, including piles and pile caps as required in foundations. Channels, tunnels, basements, pits, trenches, sumps, etc. Sub-grade work for all foundations, flooring, trenches, pits and other underground structures All doors, windows, gates, etc. Reinforced concrete work in columns, beams, floors, slabs, frames and other superstructures Reinforced concrete work in supporting structures of equipments All masonry work in superstructure and partitions All finishing work in flooring, wall-cladding and ceiling Screeding in sumps and building roofs shall be done with minimum M20 grade concrete All necessary waterproofing, acid proofing, and anti-corrosive treatment to building structures, foundations & sumps. All service pipelines, water supply, plumbing and other utility pipelines and electrical wiring within the ancillary and auxiliary buildings of RC/ Masonry construction, will be concealed within the masonry, concrete work etc. All auxiliary and ancillary buildings, housing, toilets/ drinking water facilities shall be provided with water storage tanks at roof of the building separately for drinking and sanitary purposes. All plumbing, rainwater drainage, sanitary sewerage works for all buildings, roadway, parking, paved areas and open spaces within the battery limits of this specification. Drain and sewer line shall be connected to the nearest existing manhole. Erection openings of suitable size need to be provided in the floor slab of operating platforms for future use wherever required. All acid prone areas and acid storage areas shall be provided with acid and alkali resistant tiles /bricks/paint in both horizontal and vertical surfaces as per requirement. Concrete pedestals for structural supports shall also be lined with acid and alkali resistant tiles up to required height. All exposed steel surfaces shall be coated with acid resistant epoxy based paints. Road inside the battery limit and connecting to the plant road shall be Rigid pavement with paving quality concrete having minimum flexiular strength 4.5 MPa as per IRC guide lines.
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08.02 8.02.01
All temporary buildings, offices, roads, tracks and services for construction of the proposed plant. Removal of all materials, cleaning, and handing over of site in a workable manner. Removal of Surplus Earth and Debris shall be done as per the instruction of the engineer, within a lead of 8km. Any other work not specifically excluded but required for successful completion of the project. DESIGN BASIS General a) This specification covers the design criteria for Civil Engineering Works. The term Design Criteria includes loading standards, permissible stresses, functional requirements and quality standards to be adopted as a basis for preparation of design and drawings by the Contractor. b) The design prepared by the Contractor shall not only provide for the requirements indicated in this specification but also consider the overall process requirements, service conditions. The design shall be compatible with the operating conditions in the plant and the atmospheric conditions prevalent at Bokaro Steel City. c) Standards and unification shall be carried out to the maximum extent possible and in the interest of standardization. BSL reserves the right of selecting particular make of materials and components. The Contractor shall supply materials / components of that particular make, if so required. d) All the buildings shall be designed as RCC framed construction with filler brick wall. All the water retaining structures shall be designed as unc e) racked structure as per the provisions of IS : 3370. All the trenches, pits and drains shall be of RCC construction. f) The Contractor shall indicate the quantities of major civil engineering works like excavation, PCC, RCC, Piling, reinforcing steel, inserts, shuttering, brickwork, flooring with PVC sheeting, concreting, tiles/ ceramic tiles, roadwork, etc. under his scope of work as indicated under APPENDIX-I. Contractor shall not make any additional claim if the total concrete quantity or quantity of any of the civil engineering items required for
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completion of the entire package as per terms of contract exceed the quantity indicated by the Contractor in Appendix -I of this section.
8.02.02
Standards a) The design criteria for civil engineering work shall be in accordance with this specification. Detailed instructions on such aspects as are not indicated herein shall be as per the latest standards, codes and recommendations of the Bureau of Indian Standards. In the absence of suitable Indian Standard specification and Codes of Practices other recognized international standards and codes may be followed with the prior approval of Purchaser. b) In case anything mentioned in this specification is at variance with Indian Standard (IS) specification or other codes of specification mentioned herein, the provisions of this specification shall prevail.
8.02.03
Soil Conditions The tenderer shall visit the site and ascertain for himself the existing ground conditions, requirement of site leveling, etc. The successful Contractor shall carry out Soil testing/ investigation of the proposed plant area. Soil investigations for the adjacent area were done by the owner. As per the soil report, Contractor may assume a safe bearing capacity of soil as 19 t/sq.m. and 28 t/sq.m at a depth of about 2.0 m and 3.5 m respectively from the virgin soil. This shall, however, be substantiated by the contractor through appropriate soil tests during design and execution of the plant and the foundations shall be designed as per the test results. No extra claim on soil condition will be entertained as soil testing is under the Contractors scope. Requirement of piles or open foundations shall also be established from the soil exploration. Should there be filled-up soil for a considerable depth in some areas, all heavy &/or important &/or plant structures shall be supported on bored cast-in-situ RCC piles and terminated within under lying weathered rock layer with a socket length not less than 3D (D is the diameter of the pile).The pile capacity considered for Estimation & Design purpose shall be confirmed by the executing agency by Load Test on Initial Trial
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Piles & Routine Load test on working piles. For detail specification of piling, its load test and integrity test refer to separate technical Specification for piling attached with General Civil Specification. 8.02.04 Plain Concrete and Reinforced Concrete For Structures And Foundations a) Concrete shall be dense, homogenous, smooth mass including required finishes, possessing required strength and resistance to weathering and abrasion for the structures and foundations. b) Design of all reinforced concrete structures shall be as per IS : 456-2000. For calculation purpose Limit State Design methods shall be adopted. c) Apart from the operating loads indicated by the equipment manufacturers, the design of buildings and structures shall be based on dead and imposed loads calculated according to IS:875 Part 1 to Part 3-1987 and load combination shall be as per IS:875 Part 5. d) Supporting structures and foundations for equipment which may cause vibration shall be designed for the dynamic effect of equipment together with the direct loads. The dynamic loads and other relevant data required for analyzing the dynamic effect shall be taken as per manufacturers recommendations. Adequate care shall be taken to ensure that the natural frequency of the supporting structure shall not be in resonance with the forced frequency. e) The design of buildings and structures shall take into account the loadings due to future extension of units and installation of additional equipment, where necessary in future in the units. f) The mix-design shall be adopted for proper strength, workability and service requirement. g) Additives and retarding agents for concreting, floor hardening additives, acid resisting and integral waterproofing compounds shall be added to the concrete depending upon requirements. h) Foundations
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i) ii)
The foundation or structures and equipment shall be proportioned to resist the worst conditions of loadings. Equipment requiring special foundations as a result of dynamic, unbalanced forces, shall be designed as per relevant codes of practice.
i) All water retaining structure shall be designed as uncracked section as per the provisions of IS:3370 on the water retaining face. 8.02.05 Design Calculations, Drawings And Documents a) Design Calculations, The design calculations (with STAAD analysis) along with design drawings (in AUTOCAD format) (both soft and hard copy) shall be submitted by Contractor for approval, prior to submission of construction drawings which shall include but not be limited to the following i) Super structure and foundation design The design calculation for all the foundations and superstructures for various units and all equipment foundations etc. The design calculations shall include static design calculations for all structures and foundations, dynamic analysis for all important structures and foundation subjected to impact vibrations etc induced by equipment and other external forces. ii) Drawings The Contractor shall prepare general layout drawings giving salient levels and dimensions of the whole area showing all over ground and underground services and facilities, buildings, roadways, railways etc. provided for co-ordination with the other areas of the steel plant. Detailed working drawings shall be prepared on the basis of the general layout drawings considering overall foundation layout for the equipment, building, services, etc. space requirement and clearances as necessary. The contractor shall ensure that no further drawing shall be required to be prepared by any other agency for successful implementation of the project. The
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Contractor shall submit a comprehensive and complete unit wise classified list of drawings in reproducible form. b) The Contractor shall submit for approval of the Purchaser Consultant, general arrangement and detailed working drawings for all concrete, reinforced concrete and other civil work as follows. Excavation drawings Foundation plans and sections. Loading drawings indicating superstructure loading, equipment loading, floor loadings, etc. Comprehensive anchor hole plan along with complete details of anchor bolts and anchor pockets for foundation for building columns and equipment etc. including schedule for bolts and anchor plates. Reinforcement details for all reinforced concrete works. Drawings or all types of bolts, inserts, embedment, covers, miscellaneous steel works etc. All drawings for masonry work, flooring, floor finishes, trenches, false flooring, false ceiling, partitions, etc. Drawings for paved areas, drains, sewer lines etc. as required.
Bar bending schedule shall be submitted for information and record. c) Design Features All civil designs shall be based on IS: 456-2000 for moderate exposure conditions and latest revisions of other relevant IS codes. 8.02.06 Construction Features All materials and workmanship shall be as per relevant IS codes and MECONS General Specification for Civil works CIVIL-GS-07. All RCC work is envisaged of M25 grade concrete. Mud mat shall be done with PCC of M7.5 grade. Flooring shall be done with M-20 grade concrete. Brickwork shall be with grade M5 bricks in cement mortar 1:6 PCC apron and RCC drain shall be provided all around the building
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Grouting below column bases shall be of M30 concrete Area paving shall be done with reflective type interlocking paver blocks of M-20 grade and of minimum thickness 65mm Inside surface of tank pedestal etc. to be provided with Anti corrosive epoxy painting / alkali / acid proof tiles as required for technical consideration. Tank should be provided with structural / RCC stair case, hand drilling and rungs.
MATERIAL & WORKMANSHIP 8.03.01 Local conditions The Contractor, before submitting his tender, shall visit the site and ascertain the local conditions, labour rules, availability of construction material, traffic restrictions, all obstructions and shall allow for any extras likely to be incurred due to all such conditions in his quoted prices. After the award of work no additional claims will be entertained on these accounts under any circumstances, whatsoever, from the Successful Contractor. 8.03.02 Setting out and leveling The Successful Contractor shall set out and level the work and will be responsible for the accuracy of the same. He is to provide all instruments and proper qualified staff with labour for getting his work checked by Engineer, if so desired by the Engineer. Such checking, if any, shall not, however, relieve the Successful Contractor in any way, of his responsibility for correct setting out. 8.03.03 Safety The Contractor shall take adequate precautions to ensure complete safety and preventions of accidents at site and shall be responsible for the same. The safety precautions shall conform to the safety regulations prescribed by the Safety Code for constructions, Safety regulations as in force in steel plants and relevant Indian Standard Codes, some of which are stated below: IS 3764:1992 IS 4014:1967 IS 4081:1986 IS 4138:1977
Safety Code for excavation work Safety Regulations for scaffolding work Safety Code for drilling and blasting operations Safety Code for working with compressed
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IS 7923:1985
air Safety Code for working with Constructions machinery
8.03.04
Rubbish The Contractor shall keep the site clear on a continuous basis of all rubbish etc. which may arise out of the work executed by him and dispose them suitably in allotted areas within a lead of 8 km.
8.03.05
Bench Marks, Reference Pillars etc. The Contractor shall protect all benchmark, and reference pillars / lines including ground water gauges from damage or movement during working. In case of any damage, the Contractor shall have to restore the same to its original condition at his own cost.
8.03.06
Standards Unless otherwise mentioned in the specifications, all applicable codes / standards as published by the Bureau of Indian Standards on the date of award of contract shall govern the work in respect of design, workmanship, quality and properties of materials, method of testing and other pertinent features. In case of variance between this specifications and IS Codes / Standards, the provisions of this specification shall prevail up to the extent of such variance.
8.03.07
Nearby Existing Structure Quite a few units are coming close to existing structures. Adequate protection shall be provided to the existing structures to ensure their safety during construction. If any structure / utility is damaged during construction, it shall be made good by the contractor at their own cost. If any utility or service line, over-ground or under-ground is found infringing with the new construction, it shall be suitably diverted / strengthened / modified with the prior approval of the Purchaser. Cost of such diversion / strengthening / modification shall be borne by the successful Tenderer.
8.03.08
Drawings Work shall be carried out as per drawings prepared by the Successful Contractor and approved by the Purchaser/Consultant.
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The drawings shall include General Arrangement, shuttering, excavation, anchorage plans, bolt plans, insert plan and details, conduit plans, etc required for execution of the job. Also the design calculations shall be submitted in requisite number of copies (as mentioned elsewhere) for the approval by the Purchaser / Consultant.
APPENDIX I Estimated Quantities for Civil Works 1. Excavation 2. PCC 3. RCC 4. Piling 5. Shuttering 6. Reinforcement Steel 7. Flooring with PVC sheeting 8. PCC /RCC Flooring 9. Acid resistant tiles/ ceramic flooring 10. Finishing 11. Inserts/ Bolts 12. Any miscellaneous items deemed necessary for successful completion of civil works of the proposed plant.
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08.04 08.04.01
ARCHITECTURE The Architectural design of the units will be developed considering the technical & functional requirements as per the relevant technological drawing for efficient operation, ensuring sufficient lighting & ventilation for conducive working environment satisfying the overall modern befitting building aesthetics. The design should follow the latest NBC norms and other relevant standards. Total window area shall be minimum of 15% of the floor area to ensure adequate natural lighting & ventilation. Necessary parking facility shall be provided for the staff wherever required. Surface drain and storm water drain shall be provided for quick and efficient draining of the rain water. Following Architectural drawings shall be provided for approval. a. b. c. d. e. Suitable Scale (Jointly agreed) 1 : 100 scale 1 : 100 scale 1 : 100 scale (thru stairs & toilets must) Part Section & Details, 1 : 50, 1:25, 1:10 or any other Schedule & detail of doors, suitable scale (jointly agreed) windows & Finishes, Detail of Water supply & Sanitary Fixtures & service lines Site Plan & Landscape drawings Floors + Roof Plans Elevations Sections
08.04.02
08.04.03
08.04.04
08.04.05
08.04.06
08.04.07
The bidders shall provide computer generated external 3D views taken from two different directions of all the units rendered in colour for approval along with the above drawings. Location & General Layout. The proposed Tertiary treatment plant is planned to be located by the side of Nitrogen Storage Vessel as shown in the enclosed drawing. The proposed area is dumped with lot of soil heaps, steel scraps and pipes etc. The proposed area has to be leveled by
08.05
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cutting or filling to the terrace level shown in the drawing. The proposed site is surrounded by railway tracks on all three sides. Sufficient space shall be maintained by the side of railway track while planning the facilities. Wire fencing / boundary wall shall be provided on the side of railway track for safety purpose. Cutting / filling shall be done by the successful bidder and the cut materials shall be disposed within the plant up to a distance of 8.0 kms. Serviceable material available in this area shall be dismantled and deposited at BSL stores. Underground facilities available if any shall be suitably protected during execution of work. Approximate 500 T of Pipes and scrap materials are lying in the area. The pipes are to be transported and kept stacked at a place decided by engineer in-charge within 8 km. The scrap material are to be transported and disposed off at a place decided by engineer in-charge within 8 km . Approach Road to the Tertiary Treatment Plant The approach road for the proposed tertiary treatment plant shall be developed as shown in the enclosed drawing. The approach road for the effluent treatment plant shall be extended by providing a railway level crossing at one side, approach road to the water supply system shall be extended by providing a railway level crossing at other side and the approach road for the Nitrogen storage tanks also shall be extended up to tertiary treatment plant. RCC approach road of 7.0/4.0 m wide with 2.0m berm on either side shall be provided up to the Tertiary treatment plant. Internal road within tertiary treatment plant shall be planned as per requirement.
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9.00 09.01
STEEL STRUCTURAL SCOPE OF WORK The scope of work for steel structures shall include complete design, supply, fabrication, erection, painting, testing, inspection and commissioning of all the structures for this package on turnkey basis. Brief description of work in the units is as follows but not limited to the following. a) RO Water Plant comprising frame work of steel columns, roof trusses, bracings, purlins, side runners ,hoists stair cases and all other strl elements for complete and smooth functioning of the requirement Monorails in RCC buildings, Pump houses etc supported with inserts. Platforms & ladders around RCC water tank etc Hand rails all around fire water reservoir Hand railing along stairs, around roof etc Miscellaneous monorails, platforms, stairs, hand railings, cross overs, brackets for supporting small dia pipes etc. Electro forged gratings / MS gratings Design Parameters Structures made of structural steel will be designed as per IS 8001984. Loading shall be taken as per IS 875 (latest) in addition to the technological loads indicated by the equipment manufacturer/ supplier. Seismic loads shall be taken as per IS 1893 (latest).
b) c) d) e) f) g) 09.02
09.03
Material for Construction The material for the structures to be designed shall be as follows:
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a) b) c) d)
All steel rolled sections and plates shall conform to IS2062 ( grade E250 and quality A and B). Chequered plate shall conform to IS 3502-1994 Steel tubes for hand railing shall conform to IS1161-1998. All roof and side cladding shall be with Permanent colour coated metal sheeting having troughed zinc-aluminium alloy coated of 150gsm and having fy-550MPa with a minimum base metal thickness of 0.5mm. The sheets shall be prmanently colour coated with PVF2 paint and shall generally meet the requirements of IS 14246. Method of Construction Steel structures to be fabricated will generally be of welded construction. Covered electrodes shall conform to AWS specification E6013 / E7018. Elements shall be fabricated in largest possible dimensions optimal with transport requirements so as to minimize site work. Site connections will be either by permanent bolts or erection bolts followed by site welding.
e)
09.04
Fabrication Fabrication of structures shall be as per IS800 and other relevant standards therein.
09.05
Inspection All structures will be offered for inspection to the client. Material certificate for the fabricated structures shall also be provided.
09.06
Erection Erection will be carried out as per applicable standards, drawings, specifications and regulations. The erection tolerances shall be within standard specified limits.
09.07
Painting The recommended painting system for general service
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requirements of steel structures covering surface preparation, application of primer coats, Intermediate coats (if necessary) and finish coats to develop minimum dry film thickness on steel surfaces is indicated below. Paint System a) b) c) Surface preparation shall be as per St-3 of Swedish standard SIS055900 Primer paint :- Two coats of zinc phosphate in phenolic alkyd medium (DFT = 35 microns/coat) Finish paint:- Two coats of synthetic enamel conforming to IS 29322003 (DFT= 35 microns/coat). Sheeting The sheeting shall be with Permanent Colour Coated metal sheets on roof and sides for all buildings etc .
09.08
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10.00
FIRE FIGHTING FACILITIES (Refer GS-10) In order to combat any occurrence of fire in Tertiary treatment Plant complex area, a proper Water hydrant system shall be provided as a fire fighting measure along with portable system as per technical specification and relevant norms. The system will in general conform to Tariff Advisory Committee/ NFPA guidelines and BIS. Facilities envisaged are following: i/ ii/ Fire Hydrant System Portable fire extinguishers
10.01
Fire Hydrant System To cater to the needs of water based fire-fighting system, an independent pressurized fire water piping network comprising internal/ external hydrants, hoses, hose reel, hose box, valves, nozzles, couplings and all other equipment will be provided by the successful Tenderer. Tenderer shall plan to extend fire fighting water with an isolation valve for the entire area (inside & outside up to peripheral area of the proposed building) from the existing fire water network of the integrated plant. Tenderer will indicate pipe size, end connection, MOC of pipeline, etc. at the tap-off point. Yard Hydrants shall be stand post type (stainless steel) with single outlet 63 mm size as per IS:5290 . Type-A. No. of Yard hydrants: 5. Internal Hydrants shall be single outlet (stainless steel) 63 mm sizes with instantaneous female coupling as per IS: 5290. No. of hydrants two per floor near landing/ staircase Each hydrant shall consist of valve, matching flange, CAF gasket, nuts, bolts, instantaneous spring lock type female outlets with blank cap & chain. The following specification of work will be considered:i) ii) Category at hazard Ordinary (as per FM/UL, TAC-2003) NFPA and
Nos. of Yard & Internal hydrants
- Shall be decided based on the detailed

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engineering by supplier and as approval iii) iv) v) vi) Min pressure at remotest hydrant - 3.5 Kg/cm
the per
Discharge at each hydrant point shall be minimum 600 lpm. Interval between internal hydrant Interval between yard hydrant - 30 m - 45 m
vii) Hoses
2x7.5m long RRL as per IS:636 Part-I with instantaneous male & female coupling for yard hydrant and 15m long RRL hose for internal hydrant. 1 No. of hose box for Internal as well as External hydrant each with landing valve to keep 2x7.5m hose branch pipe, nozzle & spanner etc.
viii) Hose box
Civil works pertaining to construction of valve pits, manholes, reconstruction of open drains, fittings, valves, underground buried pipelines, etc. such as excavation, diversion of pipes / cables, maintenance provision for new facilities, rerouting if required for new facilities, back filling, compacting, laying of encasing pipes below roads /railway tracks, generally with 1.5m earth cover, but maximum cover of 4m near crossing of other underground communications shall also be in the scope of the Successful tenderer. In case group of pipes are crossing road, RCC culverts to be provided below the roads and the same are included in the scope of the Successful tenderer The system will in general conform to Tariff Advisory Committee / NFPA guidelines and BIS. 10.01.01 SCOPE OF WORK AND SERVICES The scope of work covers on turnkey basis design & engineering, supply, erection, painting, testing, commissioning, and obtaining TAC approval and handing over of complete Fire Hydrant System. Two years operation and maintenance spares, necessary tools, spanners etc. required for regular operation/ maintenance of systems shall be supplied along with the equipment and shall be
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mentioned in the offer. Major works comprises of following: a) Fire Hydrant system consisting of internal as well as external hydrant for the entire area. One no. hose box shall be provided for each landing valves for keeping hose, branch pipe, nozzle, spanner, etc Piping, valves, sluices gates etc. All civil & structural works Shop and site painting for all equipments, pipes etc. Erection, testing, commissioning, Performance Guarantee test and Warranty for the complete fire hydrant system. All the requirements of TAC / NFPA for complete Fire Hydrant System shall be incorporated by the tenderer in their scope irrespective of whether the details are described in specification and/or shown in the drawings or not. PORTABLE FIRE EXTINGUISHERS INTRODUCTION SAIL BSL, Bokaro intends to setup a Tertiary Treatment plant for treated effluent from new Effluent treatment plant in new CRM area. The proposed plant is located adjacent to the new Effluent treatment plant 10.02.02 INTENT OF SPECIFICATION In order to combat any occurrence of fire, portable fire extinguishers of different type and capacity are proposed to be procured and erected at various plant premises in turn-key basis. The intent of this specification is to enable the tenderer to submit a comprehensive offer matching with the requirements specified in this document.
b) c) d) e)
f)
10.02 10.02.01
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10.02.03 001
INSTRUCTIONS TO TENDERERS Deviations from this specification shall be acceptable if such deviations do not affect the basic standards and duty requirements. However, these deviations shall be spelt out in the tender. All extinguishers shall be provided with relevant test certificates. Approval certificate from Chief Inspector of Explosives, Nagpur for Carbon-dioxide gas cylinders and Carbon-dioxide gas cartridge shall be submitted. IS approval certificate shall also be required for all the extinguishers.
002
003
If the tenderer needs any clarification, in respect of any point of this specification, he may do so by submitting a letter in duplicate to the purchaser sufficiently in advance before submitting the tender. Quantities of fire extinguishers indicated under clause No. 05.01 of this technical specification are tentative. The purchaser reserves the right to increase or decrease the number of fire extinguishers during the contract period. The purchaser also reserves the right to cancel any/or all the tenders without assigning any reasons.
004 005
006 007 008 009
The colour code and instructions on the extinguishers shall be as per relevant IS. Necessary tools, spanners etc. shall be supplied for regular operation and maintenance of the extinguishers. Necessary operating and maintenance manuals shall be supplied for each type of extinguishers. The prices for supply of extinguishers shall be quoted for delivery at purchaser's site. The tenderer shall include in their offers the itemized weights and prices of different types of extinguishers and spares including refills which shall remain valid throughout the contract period for the purpose of procurement of additional such items.
010
Time schedule for manufacture, inspection and delivery of extinguishers complete in all respects shall be indicated.
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011
All extinguishers shall be guaranteed for workmanship and performance for a period of one year from the date of installation after final acceptance. The fire extinguishers complete in all respects along with accessories shall be inspected by the purchaser/his representative. The successful tenderer shall give at least 30 days advance notice for inspection of the equipment in one lot. The tenderer shall furnish 10 copies of all relevant test certificates along with inspection call notice to the purchaser. The successful tenderer shall furnish the details required as per the formats for inspection calls, dispatch and packing procedures developed for the project by the purchaser. The successful tenderer shall show the performance test for each type of extinguishers at site and only after successful performance, extinguishers shall be accepted.
012
10.02.04
SCOPE OF WORK The scope of work shall include design, supply and erection of Portable fire extinguishers in accordance with this technical specification. The portable fire extinguishers shall be supplied with initial charge and necessary accessories.
10.02.05 001
TECHNICAL SPECIFICATION The scope of work covers supply and erection of following wall / column, portable fire extinguishers with initial charge, necessary accessories and their erection at various plant premises. The tentative quantities of fire extinguishers are given below: Sl. No. 1. 2. 3. Type of Extinguisher Carbon-dioxide Dry Chemical Powder Fire bucket with stand Capacit y 4.5 Kg 5.0 Kg 10 Ltrs. Number 10 20 2 set of 5 bucket
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002
STANDARDS The portable fire extinguishers shall conform to the following standards and shall bear IS markings on the body: 1. 2. Carbon-dioxide type (4.5 ): Dry Chemical Powder (5.0 & 25.0 Kg): IS:2878 IS:2171 2004 1999
003
MATERIAL OF CONSTRUCTION All the fire extinguishers shall be of welded construction except Carbon-dioxide type. In case of Carbon-dioxide extinguishers, the cylinders shall be of cold drawn seamless steel. Riveted joints will not be acceptable. All the extinguishers shall bear metallic parts viz. unions, caps, inner containers etc. as per IS. All the extinguishers shall be treated with lead-tin alloy for anti-rust, anti-corrosive treatment by electrolytic process or by dip coating process as per IS. All extinguishers shall be supplied along with the wall brackets/fasteners for wall mounted extinguishers. All the parts shall have IS approval. All the extinguishers shall bear IS marking on their body.
004
ERECTION OF EXTINGUISHERS All wall mounted portable extinguishers shall be supplied with mountings accessories and installed along the columns/walls near entry/exit at a height of approximately 1200 mm from the finished floor level. Wherever extinguishers are required to be installed on the steel columns of the building, the welding of the supporting fixture to columns shall be done by the successful tenderer. Necessary welding set for this job shall be arranged by the tenderer.
005
DISTRIBUTION OF FIRE EXTINGUISHERS The distribution of portable fire extinguishers in different premises will be indicated to the successful tenderer after placement of order.
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10.02.06
GUARANTEE The tenderer shall give the following material and performance guarantee for each fire extinguisher
001 002
Material guarantee The equipment shall be free from any defect due to faulty design, material and/or workmanship. Performance guarantee The equipment shall be guaranteed for trouble free operation for one year from date of commissioning of individual system. The defect liability period shall be one year from the date of issue of commissioning certificate for the system. INFORMATION TO BE SUPPLIED WITH TENDER Details of services rendered by supplier during guarantee/warranty period. Suppliers network for sales and services in India. Details of terms, conditions and for providing service to attend to periodical check-up and break downs if any after the expiry of the guarantee and warranty period. Test certificates shall be provided for the first fill of all the extinguishers.
10.02.07 001 002 003 004
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11.
PROJECT SCHEDULE & PROGRESS MONITORING The project shall be executed on Turnkey basis (including civil and structural work) within 15 months from Zero date which shall be reckoned as Effective date of contract for the package. Zero date and commissioning mentioned above and as shown in the schedule shall be same as defined in the technical and commercial part of the specification An indicative Implementation Schedule, in line with the total time period and indicating the major activities, is shown in drg. no. DRG. NO. MEC/S/E24F/11/PY/0/00/00/042A.01/R0 for reference purpose only.
11.01
11.02
Project Schedule
11.02.01 The Tenderer shall submit the following along with the offer :
i) .
An Overall project bar-chart schedule The overall bar-chart schedule should be planned in weeks. The heads to be covered in the schedules shall broadly be as follows :
Basic engineering and approval Preparation and issue of ordering / technical specifications for sub-vendors
Placement of orders on sub-vendors Detailed design and engineering including supply of feed-back data
Manufacture and supply of all equipment/ piping/ etc Fabrication and supply of technological structures
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Supply of Equipment Erection of equipment, piping, etc. Testing, trial runs and commissioning
The major milestones for the project are to be highlighted in the schedule. The requirement of building / foundation for erection work to be undertaken by the tenderer shall be clearly indicated in the schedule. ii) Construction facilities:
Provision of construction water @ 7 cum/day has been made kept for this package
Provision of 250 KVA of construction power has been made for this package
Area within Battery limit should be utilized for construction and storage area. However, if additional area outside the battery limit is available, the client may permit the bidder to utilize the same.
11.02.02 The Tenderer shall submit the following before finalization of contract: i) ii) iii) Deployment schedule of man power for construction / erection The list of construction / erection equipment and machinery, tools and tackles, etc, and details of deployment of the same The Off-site & On-site organization chart for execution of the project
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If simultaneous erection work is carried out along with civil and structural works, the movement of men, machine and materials at site shall be planned suitably.
11.02.03 The successful tenderer shall have to submit the following i) The feed-back data relating to the preparation of technical specification by Purchaser / consultant shall also be submitted progressively within 1 month from zero date for detail engineering by Purchaser. ii) The detailed project schedule both in hard and editable soft copy (in MS Project / Primavera) covering area-wise further details of project activities shall be submitted within 1 month from zero date - for approval and finalisation by the Purchaser / Consultant. iii) The format of progress report shall be discussed and finalised within 1 month from zero date. iv) The progress report (in approved format) shall be submitted every month. v) The updated detailed project schedule shall be submitted every month along with monthly progress report.
11.03
Progress Monitoring
The contractor shall submit a schedule for site-execution along with quantitative program of fortnightly physical targets for various disciplines of work, before start of site work.
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After start of site work the contractor shall submit fortnightly progress reports showing current status of various activities.
The fortnightly progress reports shall indicate progress of activities against targeted dates and targeted quantities. Reasons for shortfall, if any, shall be clearly brought out and proposed remedial measures to arrest the delays shall be indicated by the contractor in the progress report, wherever applicable.
Other information related to site activities as may be required by the purchaser and the consultant shall also be submitted by the contractor.
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12.00
PERFORMANCE GUARANTEES & ACCEPTANCE TEST (PAT) / COMMISSIONING
PRELIMINARY
12.01
The tenderer shall stand guarantee for design & engineering of the complete system, materials, workmanship and performance of every part of the equipment as a whole. Any part found defective during testing commissioning or normal operation during the warranty period including non-fulfillment of performance shall be replaced by the supplier at site free of cost. The tenderer shall clearly indicate the performance parameter to be guaranteed in their offer for the offered equipment. The tenderer shall guarantee for satisfactory and smooth operation as well as fulfillment of technical parameters of all equipment. Apart from performance guarantee of individual equipment following system guarantee shall also be met. 1. Power consumption should be minimized; hence preference will be given for higher efficiency equipment. Tenderer shall indicate and guarantee power consumption for all main pumps. The penalty clauses will be decided during tender negotiation. Tenderer should indicate and guarantee quality of treated water from TT plant. The penalty clauses will be decided during tender negotiation. The tenderer shall guarantee temperature, pressure and flow of all types of water as specified and to be supplied at battery limit. If required, the tenderer may increase capacity and head of pumps as well as may increase pipe diameters and staging height of OHT. The penalty clauses will be decided during tenderer negotiation. Chemical consumption should be minimized; hence preference will be given for minimum consumption of chemicals required. In case, the treatment programme provided by the tenderer fails or requires additional chemicals to achieve the guaranteed performance, the tenderer shall supply the necessary additional chemicals and shall undertake suitable measures for the successful execution of the modified programme without any additional cost implication to the Purchaser. 7. Performance Guarantee of R O Plant
12.02
12.03
2.
3.
4.
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System performance guarantee tests shall be conducted by the contractor to establish the rated output, pressure and quality parameters. The guaranteed consumption of chemical reagents shall also be demonstrated. Details of the performance tests and test procedures shall be submitted to the Purchaser and shall be mutually agreed upon. If, even with two repetitive tests and if necessary, by using additional operating personnel from the contractor's crew and at his own expenses, the performance values are not reached for reasons within the contractor's responsibility, the contractor shall undertake at his own cost such modification or replacement as are considered necessary to obtain the performance guarantee values and the responsibility to demonstrate performance guarantee shall continue to remain with the contractor till so established. Should the performance values fall below acceptable level, the unit/sub-unit/equipment shall be rejected by the Purchaser and the contractor shall be liable, at the option of the Purchaser, either to replace the unit/sub-unit/equipment or to pay compensation in addition to the liquidated damage as per contract or as may be agreed upon. 12.04 PERFORMANCE GUARANTEE TESTS Performance Guarantee tests of plant units shall be taken up within 30 days of issue of Successful Commissioning Certificate. (i) All equipment system shall be guaranteed for workmanship material and satisfactory performance in accordance with the specification. The guarantees for performance shall cover individual item/ system/ unit for their designed rating / output and for the stipulated period. The performance guarantee tests shall be completed within a time schedule to be mutually agreed between the purchaser/ consultant and successful tenderer. Details of the performance test procedures tests, test schedules for the demonstration of the performance guarantees shall be submitted to PURCHASER as a part of the project manual and during performance tests and shall take for responsibility of the operations. The PURCHASER shall make available necessary operating and maintenance personnel.
(ii)
(iii)
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(iv)
The successful tenderer shall supervise and direct the operation during performance tests and shall take for responsibility of the operations. The PURCHASER shall make available necessary operating and maintenance personnel. After commencing of tests, it shall be completed unless in the opinion of either the PURCHASER or Successful Tenderer, a safety hazard exists which necessitates shutdown. If for reasons for which the Successful Tenderer is responsible and unable to achieve the performance values as a whole or in part during the performance tests, the successful Tenderer shall repeat the tests of demonstrating the performance values. Before repeating the test, the successful tenderer shall take any and all measures as may be needed at his own cost in order that the performance values can be achieved. The observations of each performance tests shall be recorded and signed by PURCHASER/ CONSULTANT and the Successful Tenderer. If such test data conform the Performance test values agreed by both the parties the Successful Tenderer shall be entitled for the Performance Guarantee Certificate for the Purchase. If, even with two repetitive tests and if necessary, the using additional operating personnel form the Successful Tenderer at his own expense, the performance values are not reached for reasons within the successful Tenderers responsibility, the successful Tenderer shall undertake at his own cost such modification or replacement as are considered necessary to obtain the performance guarantee values as stipulated in the contract specification and the responsibility to demonstrate successful performance guarantee shall continue to remain with the Successful Tenderer till so established. For carrying out rectification work for achieving guaranteed performance values, the Successful Tenderer shall do so without hampering the normal production where possible. Should the performance values fall below acceptance level, the unit / sub-unit / equipment shall be rejected by the PURCHASER and the Successful Tenderer shall be liable at the option of the PURCHASER either to replace the unit / sub-unit / equipment or to pay the compensation in addition to the liquidated damage as per contract or as may be mutually agreed.
(v)
(vi)
(vii)
(viii)
(ix)
(x)
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(xi)
The successful Tenderer shall provide and install and calibrate all measuring instruments required for checking the guaranteed performance which are not included among the permanent measuring instruments of the unit/ sub-units. Such instruments shall be furnished by the successful Tenderer on a temporary basis for duration of performance tests. The Tenderer shall demonstrate the establishment of guarantee values within a period of six (6) months from the date of commissioning. In the event the guaranteed values are not attained within the aforementioned period of time, the Tenderer shall repeat the tests in another tree (3) months time for fulfilling the guaranteed values with advance intimation to the PURCHASER and without affecting the normal operation. The performance guarantees test shall be carried out for achieving the rated output and performance.
(xii)
12.05
PRELIMINARY ACCEPTANCE TEST (PAT) On completion of installation of equipment as per approved drawings/ documents the test for Preliminary Acceptance of the unit shall be carried out by the successful Tenderer jointly with purchasers representatives to find out whether the equipment / systems has been properly erected as per the approved erection drawings, instructions of purchaser, purchasers respective, manufacturers instructions and manuals. The defects observed in erection work / rectification work required shall be listed out jointly and the defect list shall be duly signed by all concerned. The contractor shall attend/rectify all observations of defect list point wise and shall duly inform purchaser/ purchasers representative are fully satisfied regarding the proper erection of the system and suitability for operation of the system. Preliminary Acceptance Test, cold trial / tests for the equipment /sub unit shall be carried out on integrated manner. Detailed programme of cold tests shall finalized by the successful tenderer will in advance in consultation with the purchasers. Cold tests shall comprise idle, no load, under load and full load tests and shall be carried out by the successful tenderer under his sole responsibility as well as employing his personnel Purchasers consultant and supervising personnel shall be present during the
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tests. Results of Cold tests shall be recorded jointly by the successful tenderer and purchaser The detailed procedure / format of PAT shall be furnished by the successful contractor for approval of purchaser/ purchasers representative. On successful completion of Preliminary Acceptance test (PAT) and liquidation of the defect, the trial for hot commissioning (successful commissioning) shall be carried out by the successful tenderer. The successful tenderer shall associate and indicate the guidelines/ instructions to the purchaser for successful commissioning. The issue of PAT certificate shall in no way relieve the contractor from his contractual obligation and guarantee for correct erection/smooth operation of the system. Following general checks shall be made for all equipment during PAT: Smooth running of all equipment and occurrence of any abnormal sound Alignment and leveling of all equipment Pressure testing/hydraulic testing as required First filling of grease and lubricants Checking the direction of rotation of electrical motor before coupling No load running/movement of all moving equipment Checking foundations/grouting and bolt tightness Overall dimensional checking and adherence to approved drawings/manufacturers instructions Checking of temperature rise in motor Vibrations/stability of supporting structures
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For other requirement, reference may be made to various clauses of GS-02.
12.06 (i)
COMMISSIONING Under successful commissioning, the tenderer shall commission the unit in an integrated manner under his overall responsibility. A detail program of commissioning shall be drawn up mutually with the purchaser in advance. Defects related to the scope of work and supplies of the Tenderer observed by the purchaser/ consultant during successful commissioning shall be rectified by the tenderer. The unit shall be deemed to be commissioned when it is able to meet the desired performance as agreed with the purchaser successfully and within six months the Preliminary Acceptance. Results of Successful Commissioning shall be recorded jointly by the tenderer and purchaser/ Consultant. Successful Commissioning Certificate shall be issued by the purchaser/ consultant to te Tenderer after completion of the Successful commissioning to the satisfaction of the purchaser/ consultant as well as after receipt of all final drawing / documents spares and consumables as well compliance of all observation and liquidation of defects made by the tenderer in respect of his scope of work and supplies. FINAL ACCEPTANCE Final acceptance certificate shall be issued by the Purchaser last when. (a) Performance guarantee test in respect of sub-units as well as the unit as a whole have been carried out and integrated performance guarantee values achieved. Performance of the unit has been established to be integrated with the electrical power system, inter-plant fluid system and auxiliaries serving the unit as well as preceding and succeeding plant units under normal operation. All other supplies have been completed
(ii)
(iii)
(iv) (v)
12.07
(b)
(c)
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(d) (e) (f) (g) (h)
Supply of spares has been completed The Contractor has met any and all other contractual obligations. All drawings/ documents including GA, assembly and component drawing incorporating latest to be submitted by the Contractor. The unit has operated satisfied for a period of 12 months for the data of commissioning. The Contractor has rectified in a definite manner all objection/ observations mentioned in the commissioning certificate.
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13.00
TECHNICAL DOCUMENTATION
13.01
GENERAL The technical drawings/ documents/ data will be submitted by the contractor in two stages in addition to those to be submitted along with the tenderer. (i) For approval: Based on which procurement and manufacturing activities can be taken up by the contractor. Necessary reference drawings to facilitate clearance of approval category drawings shall also be submitted. As final technical documents: For record and reference and to facilitate erection, testing, commissioning, operation and maintenance of plant and equipment supplied. All the drawings/ documents shall be in English language only and all dimensions/ weight shall be in SI/ metric units. The technical parameters/ details data/ drawings given by the contractor with the tender shall be considered tentative and these shall be subject to prior approval of Purchase during basic/ detailed engineering stage. All documents/ drawings/ performance curves/ manuals, etc. including the revised ones, design calculations, final drawings, asbuild drawings/ document will be submitted in required copies for purchasers approval /information/ review/ records. The contractor will furnish a comprehensive list of drawings/ documents/ manuals along with schedule of their submission for purchasers approval. Submission of drawings shall commence within 4 weeks of effective date of Contract and shall be submitted in a sequential order and completed within the agreed time frame. The drawings shall be deemed to have been submitted for approval if the deemed to have been submitted for approval if the drawings are approved as Noted/ Approved. Contractor will observe strict logical sequence in submission of drawings/ documents/ manuals for purchasers/ consultants approval. The respects to facilitate Purchasers/ consultants
(ii)
(iii) (iv)
(v)
(vi)
(vii)
(viii)
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approval. Each set of drawings submitted for approval shall be complete technical specification /parameters, detailed bill of materials giving quantities, material specifications, unit weight, total weight and applicable codes in respect of each item. Materials specifications should be complete (for example-Alloy forge steel 40 Cr, M028, IS:1570). Design calculation, wherever required by the purchaser/ consultant, will be submitted by the Contractor to facilitate approved of relevant drawings. (ix) The Contractor will be responsible for timely submission and arranging approval where approval is required form statutory authorities keeping in view the unit wise and overall project schedule. Approval/ comments on drawings/ documents will be given by the Purchaser/ Consultant within 15 days of receipt of drawings / document subject to their completeness and conformity to technical requirements of the contract. Two copies each of drawings/ documents submitted for approval shall be returned to the Contractor either Approved or with minor comments approved as Noted, or returned with major comments Commented /Not approved. In the latter cases, the Contractor will submit the revised drawings/ documents incorporating all comments/ correction with Revision No. for Purchasers /consultants final approval. The Contractor, however, will go ahead with procurement and manufacturing of components / equipment taking into account comments if any, given on the approved/ Approved as Noted drawings/ documents. Delay due to submission/ resubmission/ approval of drawings /documents will neither absolve the Contractor from completing the project within agreed time schedule nor his request at a later date for extension of delivery date on this account will be considered by the Purchaser. Any other incidental delays resulting due to insufficient number of copies submitted, incomplete information furnished, non-conformity with respect to other drawings found, etc. shall be to the account of the Contractor. The approval given on any drawing/ document will be only in respect of design parameter, general arrangement and rationality of the equipment/ system. The approval, however, shall not absolve the Contractor of his sole responsibilities/ obligations with regards to adequacies of design, final fitment of various parts/ components/ sub-assemblies, and satisfactory working.
(x)
(xi)
(xii)
(xiii)
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(xiv)
Any drawings/ documents/ catalogue/ manual/calculations, which are specifically not mentioned hare in but found essential for approval/ reference during basic and detailed engineering stage, will also be submitted by the Contractor. Characteristic and performance curve for various equipment such as pumps, motors, etc, as applicable, will be submitted. The Contractor will submit required copies of all final drawings/ documents along with one set of microfilms of silver halide archival quality. DRAWINGS AND DOCUMENTS Reference to be made GS-01, clause 06. Scope
(xv)
13.02
13.02.01
The Contractor shall supply design calculations, drawings, documents, schedules, specifications, manuals and reproducible to the Purchaser as part of the contract and within the contract price. These shall include, but not be limited to, all design calculations, scheme drawings, general arrangement and layout drawings, details and construction drawings, wearing parts drawings, specifications, bill of materials, manufacturers equipment catalogues and technical literature, test and inspection certificates operation and maintenance manuals, list of spare parts, as-built drawings, reproducible, etc. At each submission the Contractor shall submit prints/sets of all drawings and documents to the Purchaser as per GS-01, clause 06. The Contractor shall be liable for any discrepancies, errors or omissions in the drawings and other information supplied by him, irrespective of whether these have been approved by the Purchaser/Consultant or not, provided that such discrepancies, errors or omissions be not due to incorrect information or particulars furnished in writing to the Contractor by the Purchaser/ Consultant, unless the Contractor as designer and manufacturer of such equipment could have known or discovered the said discrepancies, errors and omissions. The Contractor shall submit the drawings and documents in logical sequence for the Purchasers/Consultants approval, and information/ review according to the agreed time schedule.
13.02.02
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13.02.04
Drawings and documents submitted by the Contractor for the Purchasers/Consultants approval, and information/review shall be certified as correct for use and shall bear the signatures of responsible persons of the Contractor whose names shall be notified in advance to the Purchaser by the Contractor in writing. The drawings and documents shall be sent for approval/information to the addresses of parties designated by the Purchaser in writing. The Contractor will be informed of the same in time by the Purchaser. Drawing List and Schedule The Contractor shall supply to the Purchaser within two weeks of the placement of order the list of drawings of all major facilities which the Contractor plans to furnish against the contract with a detailed schedule for submission of the drawings. The detailed time schedule for submission of drawings shall be in conformity with the overall completion schedule of the project. The Contractor shall update this list every two months interval in conformity with the progress of detailed engineering work and submit the updated list to the Purchaser. Drawing Format The format and size of various types of drawings will be as per GS01, clause 06. All drawings shall be dimensioned in the metric system and title and written notations shall be in English language. The title block of the drawing and drawing numbering scheme shall be as approved by the Purchaser/Consultant. All layout drawings shall be made with the north arrow pointing to the top of sheet. There shall be sufficient reference notes on the drawings to permit identification of all related drawings and documents which are required for proper understanding. Drawings and bills of materials shall give quantities of all materials required for the work and shall be cross-referenced for easy identification. The Contractors standard drawings used for the contract shall have information pertaining to the specific item under consideration properly identified to distinguish it from information pertaining to other items which may be contained on the same drawing.
13.02.05
13.03 13.03.01
13.03.01
13.04 13.04.01
13.04.02
13.04.03
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Standard drawings of the Contractor shall bear a reference in the drawings to the present contract only. Reference pertaining to other contracts entered into with other parties shall not appear in the drawings or any other documents submitted to the Purchaser. 13.04.05 When a drawing is revised by the Contractor, every change made shall be identified on the drawing (and not in the covering letters) by circling the changes made and placing the revision number in a small triangle so as to be easily recognizable. When a subsequent revision is made, the circles made for the previous revisions shall be erased and the current changes circled. However, all revision numbers in the small triangles shall be retained. In addition, a record of revisions along with the co-ordinates showing the location of revisions shall be indicated at the left hand bottom corner of the drawings as per standard practice. In case of revision of a drawing, for which a different number is allotted, the new drawing shall clearly indicate the number of the drawing, which it supersedes. General Arrangement and Layout Drawings The Contractor shall submit general arrangement and layout drawings including cross-sections for approval of the Purchaser/Consultant prior to commencement of detailing and manufacture. General arrangement and layout drawings for equipment shall include equipment outlines, overall dimensions, locations of equipment, centre lines and working point elevations and functional clearances. Assembly, sub-assembly and sectional drawings shall be furnished detailing various components along with their material of construction. These drawings shall be sufficiently detailed such that if the Purchaser so desires, he can procure spares and replacements from a suitable component manufacturer. Details of mechanical equipment shall include grade of finish, heat treatment and tolerances. General arrangement and layout drawings for piping work shall include physical location of pumps, equipment, valves and instruments on the general pipeline routing. For electrical system, layout drawings shall indicate locations of all electrical equipment, including motors, controls, limit switches, motor list with ratings, list of electromagnetic valves, single-line interlocking and sequence diagrams for control, signaling and communication system, location of devices on switch-gear control
13.05 13.05.01
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panels, desks etc. including sectional views. The details furnished shall include complete cabling drawings giving details of power and control cables, terminal details, layout of trenches and cable racks, conduits, etc. The details are as indicated in chapter 07.00 13.05.05 General arrangement drawings for instrumentation shall include the control schemes and instrumentation flow diagrams and sequence logic diagrams and GA drawings of instruments and control panels. In addition, the drawings shall be furnished as indicated at chapter 07.00. The details furnished shall be accompanied by necessary design data and design calculations (in A4 size sheets) and shall conform to applicable specifications and acceptable codes of practice. The Contractor shall furnish comprehensive performance data including characteristic curves, efficiency, power, NPSH and other pertinent curves for approval of the Purchaser/Consultant. With the delivery of equipment, the Contractor shall submit all test and inspection certificates including material test certificates along with invoices. Another eight (8) sets of test and inspection certificates arranged in classified manner in bound volumes shall be furnished after completion of work for records before Preliminary Acceptance. A list of wearing parts such as bearings, glands, gaskets, bolts, chains, etc. shall be furnished showing quantities supplied and installed, dimensions, materials of construction and expected life. The information furnished shall include complete specifications for all wearing parts indicating their grade of finish, heat treatment, tolerances, etc. along with their manufacturing drawings. The Contractor shall submit certified foundation outline drawings including dimensioned anchor/foundation bolt location plan and loading drawings for equipment foundations and structures giving the size and specifications of all foundation/anchor bolts, sleeves, inserts, supports, and other materials which have to be imbedded in concrete. The Contractor shall furnish erection drawings showing all details and particulars in sequence required for erection and installation of the plant, equipment and piping works. Instructions for re-conservation during storage of individual equipment along with manufacturers recommended frequency for re-conservation/preservation shall be indicated.
13.05.06
13.05.07
13.05.08
13.05.09
13.05.10
13.05.11
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13.05.12
Bills of materials shall be supplied along with the drawings to which they pertain. BOM shall include list of equipment and materials covered in the drawings along with their brief specification, quantity, identification number, and reference drawings/applicable Standard Code. The Contractor shall supply a comprehensive list of spares clearly identifying commissioning spares, spares for two years normal operation and maintenance and insurance spares. The spare parts list shall be accompanied by manufacturers specifications, identification number, and reference drawing number and manufacturers catalogues. Approval of Drawings Approval of Contractors drawings and documents shall amount to their checking for conformity with applicable specifications and general fitment in the system covered. Approval by the Purchaser/Consultant does not include checking for drafting errors. Approval of Contractors drawings shall not relieve the Contractor of his responsibility to comply with the intent of the contract. Manufacture / fabrication /procurement prior to approval of drawings and documents shall be at the Contractors risk. The Contractor shall submit drawings for approval in number of prints as specified. If the drawing is approved, one print stamped Approved will be returned to the Contractor. If the drawing is Not Approved or Approved as Noted, one marked up print with appropriate comments and status duly stamped will be returned to the Contractor for correction and resubmission. The Contractor shall resubmit the revised drawing after incorporating all the comments within one week of the receipt of the commented drawing for approval by the Purchaser/Consultant. Upon approval by the Purchaser/Consultant, the drawings shall become Contract drawings and thereafter the Contractor shall not depart from them in anyway whatsoever except with the written consent of the Purchaser/Consultant. Should it be found at any time after approval has been accorded by the Purchaser/Consultant that any design, drawings or documents submitted by the Contractor are not consistent with any design,
13.05.13
13.06 13.06.01
13.06.02
13.06.03
13.06.04
13.06.05
13.06.06
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drawing or documents submitted or approved earlier or deviate from any aspect of the Contract Document, then such alterations or additions as may be deemed necessary by the Purchaser/Consultant shall be made therein by the Contractor and the work shall be carried out accordingly. 13.06.07 The responsibility for approval of drawings in time for meeting the completion schedule of the project shall solely lie on the Contractor. Delay in approval of drawings shall not be entertained as a cause of any delay in commissioning of the project. Operation and Maintenance Manuals The Contractor shall supply Operation and Maintenance Manuals in durable bound volumes with elaborate instructions for erection, operation and maintenance of the plant and equipment as per GS01, clause 06. The manual shall present the following categories of information in practical, complete and comprehensive manner prepared for use by operation and maintenance personnel: i ii Instructions for initial installation. Instructions for operation, preventive maintenance, and repairs including check list for trouble shooting. Recommended inspection points and frequency of inspection. Ordering information for all replaceable parts. Lubrication chart.
13.07 13.07.01
13.07.02
iii iv v 13.07.03
As far as possible electrical maintenance manual shall be supplied separately and shall contain similar details about fault finding and rectification along with necessary technical literature, characteristic curves and manufacturers catalogues. The manual shall include lists of various electrical components and protective devices, preventive maintenance schedules and final setting values of all control and regulation equipment. The information shall be presented in a logical and orderly sequence. The general description of the equipment including significant technical characteristics shall be included to familiarize
13.07.04
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operating and maintenance personnel with the equipment. 13.07.05 Drawings and other illustrations shall be included or copies of relevant drawings shall be appended with the manual. Test and adjustment instructions, as appropriate, shall be identified to the specific equipment. Drawings and Documents at Completion of Work The Contractor shall supply soft copy on CD, one reproducible polyester film and eight (8) prints of as-built drawings of each original drawing, specification, bill of materials, etc. made by the Contractor or his sub-contractors incorporating modifications, if any, carried out during the execution of work including those made at site during construction, erection and start-up. One set of design data and design calculations made by the Contractor or his sub-contractors shall be furnished in soft copy on CD, in the form of transparencies of A4 size polyester film sheets and eight (8) sets of hard copies on plain paper neatly filed in hard binders and suitably indexed to facilitate reference for undertaking modification and extension work at a future date. The design calculations for different disciplines, e. g. hydraulics, structural steel works, civil engineering works, electrical system, etc. shall be submitted in separate volumes. Data, Drawings and Information to be Submitted a) b) c) Drawings shall be prepared as per the Clause No. 06.01 of GS-01 of General Specification No. MEC/GS/133A/11/38/01. For approval of drawings/ documents, refer Clause No. 06.02 of GS-01 of General Specification No. MEC/GS/133A/11/38/01. The successful Tenderer shall submit requisite no. of sets of drawings/ document to Purchaser / Consultant for approval in line with the Clause No. 06.03 of GS-01 of General Specification No. MEC/GS/133A/11/38/01. Tenderer shall submit following information which will include the following along with the Offer Prices as per SBD
13.08 13.08.01
13.08.02
13.09
d)
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Filled up questionnaires as per Annexure-I List of Deviations - Appendix-I List of Commissioning spares -Appendix-II List of Special Tools & & Tackles - Appendix-III List of Insurance Spares - Appendix-IV List of Spares for two years of operation & Maintenance Appendix-V Additional obligations (of Purchaser) desired by the Tenderer Appendix-VI List of equipment to be imported - Appendix-VII Construction Power, Water, Office Space & Storage area required - Appendix-VIII Estimated Numbers of drawings - Appendix-IX Estimated Quantities for equipment - Appendix-X Estimated Quantities for Pipe-works, Civil-works, works - Appendix-XI Structural
QAP of all items as mentioned in GS-05 of General Specification No. MEC/GS/133A/11/38/01. List of erection & fabrication equipment to be mobilized during erection/ fabrication. No. of skilled/ un-skilled persons to be deployed for the project with break-up of fitters, welders, riggers etc. Any other information, not mentioned in this TS but relevant to the Tender
e) f)
Data/ information for which formats are not enclosed/ referred in TS, the Tenderer shall furnish in their own formats. Tender with incomplete information is liable to be rejected.
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13.10 (i)
Data drawings to be furnished by the tenderer with the offer Plan and cross-sectional drawing for the installations with major dimensions, technical characteristics and operating parameters. GA and cross sectional drawing of all units showing the disposition of all equipment, piping, valves, electrical equipment, material handling facilities, ventilation equipment with dimensions. (ii) (ii) (iii) Layout drawing showing the battery limits and various pipelines. General description of design considerations and assumptions as applicable. P & I diagram of each circuit of the complete water supply system showing all the consumers, flow rate, pipe diameters, broad parameters of each equipment, instruments, interlocks, water losses etc. Duly filled in data sheets for various pumps, blowers, filters, valves and other equipments as specified in GTS as well as various data of different equipments as specified in various clauses of GTS and this specification. Predicted characteristic curves of various pump GA drgs. of major equipment Write -up detailing the control logic in the entire treatment system. List of special tools and tackles. List of commissioning spares. List of spares for two years of normal operation and maintenance with item wise prices. Methodology on project implementation along with Bar chart Details of various drives, instruments, handling & hoisting facilities, air conditioning & ventilation facilities, etc. Tentative Bill of Quantities covering all equipments, valves, strainers, pipelines, etc. and associated civil, structural, electrics, instrumentation, handling & hoisting facilities, air conditioning and ventilation facilities etc.
(iv)
(v) (vi) (vii) (viii) (ix) (x) (xi) (xii)
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(xiii) (xiv) (xv) (xvi)
Pipeline materials and specifications considered for various systems. Equipment list covering motors with ratings, limit switches, brakes etc. Single line diagram & dimensions of MCC. Tests proposed to be conducted for performance guarantee of individual equipment as well as the system as a whole, for further details refer GS-02. Drawings/ Documents to be Furnished after Placement of Order Drgs/ documents for approval of Purchaser/ Consultant List of drawings Layout drawing showing battery limits and coordinated plane of units and facilities including requirements of utilities with their parameters of the battery limits. Plan and cross-sectional drawings of the installation with major dimensions, technical characteristics and operating parameters. Cross sectional drawings showing pipe supports from shop columns/pipe trestles. Plan, Elevation & Cross section drawing of complete tertiary treatment plant complex including pipelines.
13.11
13.11.01 (i) (ii)
(iii)
(iv)
GA drawings for units/ equipment with technical parameters, dimensions, material of construction, weight of equipment and complete bill of materials for each equipments. Specifications of equipment, pipe, valves & fittings etc. Data sheets, characteristic curves and technical details of all the equipments, valves and pipings. Make & G.A. and cross section drawings of all bought-out items. Isometric drawings for pipelines.
(v) (vi) (vii) (viii)
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(ix)
Process & instrumentation diagrams for the tertiary treatment systems indicating location of all instruments, alarms and interlocks functions using ISA symbols. List of instruments comprising bill of materials and instrumentation data sheets. Water mass balance diagram. Layout of piping system indicating pipe routing, location of supports, valves and other fittings as required. P&ID and list of safety interlocks Control philosophy of water system Test procedures for preliminary and final acceptance tests. Quality Assurance Plan.
(x) (xi) (xii) (xiii) (xiv) (xv) (xvi)
(xvii) All equipment and piping sizing calculations. (xviii) GA drawings and details of air conditioning & ventilation facilities and material handling facilities etc. (xix) (xx) GA drawings of material handling equipments. Test certificates for the following: a) b) c) d) (xxi) Material test certificate for all major equipment and their components. Hydraulic test of equipment, pipe fittings & valves. Static and dynamic balancing of all rotary parts/ equipments Semi-permeable membrane
Single line diagram and component list of MCC.
(xxii) GA drawings of MCC, motors, brake panel etc. (xxiii) Schematic drgs. (xxiv) Technical plan of MCC. (xxv) Cable schedule and interconnection diagram.
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(xxvi) Motor data sheets. (xxvii) Layout drawings of equipment and cables including cable supporting structures. (xxviii) Earthing layout drawings. (xxix) Structural design drawings: design calculations (xxx) Any other documents /drawings that may be needed at the time of approval of drawings. (xxxi) Certificates inline with GS-05 of General Specification No. MEC/GS/133A/11/38/01. (xxxii) Progress report as per Clause No. 07.00 of GS-01 of General Specification No. MEC/GS/133A/11/38/01.
13.11.02 (i) (ii) (iii) (iv) (v) (vi) (vii) (viii) (ix) (x)
Drawings/ Documents to be submitted along with delivery of equipment for record purposes. All the drawings/ documents mentioned above Spare parts list and price of each part. Operating and maintenance manual Instruction for erection and commissioning. Manufacturers test certificates. Lubrication schedule and quantity and quality of lubricant for one years normal operation. Various equipment assembly drawings and bill of material. Weld procedure. Hydraulic test logs. Equipment GA drawings and bill of materials.
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(xi) (xii) (xiii) (xiv) (xv) (xvi)
Characteristics curves of the pumps, motors, blowers and other equipments. Operation and maintenance manuals for all equipments, valves and complete treatment system along with soft copies. Test and calibration certificates. Warranty/ guarantee certificates. Technical literature, catalogues and manufacturers drawings for all brought out equipment, valves and other items. All inspection/ test report/ certificates.
(xvii) Any other drawing/ documents as required by the Purchaser. (xviii) Material test certificates. (xix) (xx) (xxi) Archival quality microfilm for all the drawings. Any other drawings/ documents mentioned in technical specification or technical rules to tender. Detailed manufacturing drawings for fast wearing parts, gear boxes and other imported components. For Civil, Structural, Electrical, Instrumentation, Ventilation, Material Handling etc. refer respective chapters. Preparation and submission of monthly progress report in a format to be mutually agreed between the Purchaser/Consultant and the Tenderer. By Successful Tenderer for Final Technical Documentation The contractor shall furnish operation and maintenance instruction manuals presenting the following basic categories of information in a practical, complete and comprehensive manner for use by operation and maintenance personnel. A general description of the equipment including significant technical characteristics shall also be included Instructions for initial installation/erection
13.11.03
13.11.04
13.11.05
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Instructions for operation, maintenance and repair Recommended inspection points and period of inspection Ordering information for all replaceable parts Lubrication chart List of consumables, chemicals and their consumption per annum
Supply of necessary technical literature, drawings and documents such as general arrangement drawings, equipment layout & plan drawings, P&I diagram for the system, erection and operation and maintenance manuals including bought out items, specification of lubricants, chemicals and reagents and other consumables, as required. Design calculation and basis for selection of various equipments. Documentary proof from membrane manufacturer/ software projections regarding selection of RO membranes, (number, array, flux rate, Beta factor, LSI etc.) shall be provided. (i) (ii) (iii) (iv) (v) (vi) (vii) (viii) (ix) List of drawings/ documents for the project Operating and maintenance manual. Erection manual- containing instructions for assembly, erection, testing & commissioning. Recommended spare parts list and price. Drawings/ catalogues/ technical literature for brought out items/ components etc. All inspection / test report/ certificates. Test and calibration certificates. Warranty/ guarantee certificates Lubrication schedule and quantity and quality of lubricant for one years normal operation.
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(x)
Any other drawing/ documents as required by the Purchaser
13.12
List of Civil, Electrical & Instrumentation Drawings and Documents for Approval/ Information shall be as indicated in respective chapters.
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14.00
QUALITY SYSTEM, SHOP TESTING, INSPSECTION & TEST OF PLANT & EQUIPMENT AT MANUFACTURER'S PREMISES AND PAINTING GENERAL Inspection & testing of plant & equipment shall be carried out by Consultant / Purchaser at the works of successful tenderer during manufacturing and / or on final product to ensure conformity of the same with the acceptable criteria of technical specifications, approved drawings, manufacturing drawings and applicable national / international standards. QUALITY SYSTEM REQUIREMENTS The successful tenderer must recognize the importance of quality and follow defined quality programme in all stages of manufacturing and quality control activities of the product. Tenderer shall define and implement the tasks and controls that will provide needed assurance, in case manufacturing of product is sub-contracted either partly or fully and/or for the procured components of the product. All bought-out equipment or component shall be procured from vendors which are duly approved by the project authority. Consultant / Purchaser reserve the right to verify the quality programme of tenderer & its vendors/sub- vendors to assure the effectiveness of the programme to meet the intended and specified quality of the product.
14.01 14.01.01
14.02
14.03 14.03.01
QUALITY ASSURANCE PLAN (QAP) The successful tenderer shall furnish Quality Assurance Plan (QAP) for respective equipment after completion of detailed engineering and finalization of billing schedule / equipment identification number for Consultant's approval at least one month prior to start of manufacturing. QAP shall be prepared & furnished by Contractor in Form Nos. 11.20(DQM)F-09,10 , 11 (specimen blank enclosed) for structural & mechanical equipment, electrical equipment and refractory materials respectively , primarily for bought-out items. QAPs must be submitted in six ( 6 ) sets for approval shall be duly stamped and singed by the tenderer. QAP submitted in any format other than those mentioned above shall not be accepted.
14.03.02
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14.03.03
The successful tenderer shall indicate procurement source and furnish to Consultant, during the submission of QAP, copies of P.O., Sub-P.O., T.S., approved GA drawings/ data sheets & detailed manufacturing drawings, as backup reference materials for scrutiny & final approval by Consultant. The submission & subsequent approval of QAPs shall be ensured to be restricted to one round only. Inspection and test requirements shall be decided with due consideration of factors like safety, duty cycle, operating conditions, equipment life, environmental conditions, place of installation and statutory regulations, as applicable, for a particular equipment. Any, additional type or special tests or routine tests if found necessary to establish the intended quality after detailed engineering then the same shall have to be incorporated in the QAP without any commercial implication. Detailed QAP shall be prepared by the successful tenderer in consultation with their Sub-contractors / Manufacturers to avoid any complicacy later . CALIBRATION OF MEASURING EQUIPMENT All the measuring equipment used for inspection & testing shall be calibrated and appropriate accuracy class of measuring equipment shall be used. Calibration standards used for calibration of measuring equipment shall be traceable to national standards of National Physical Laboratory (NPL), New Delhi with unbroken chains of comparison. Valid calibration certificate for all measuring equipment used during inspection and testing at manufacturers works, with traceability to national standards of NPL / NABL accredited laboratories shall be furnished prior to undertaking inspection by Consultant/ Purchaser. Calibration certificate shall also indicate reference no. of calibration standards calibrated by NPL / NABL accredited laboratories and copies of such calibration certificates of calibration standards shall be included in the compiled dossiers of inspection/test results.
14.03.04
14.03.05
14.04 14.04.01
14.04.02
14.05 14.05.01
TEST CERTIFICATES AND DOCUMENTS For each of the items being manufactured as per approved QAP, following test certificates and documents, as applicable for each of the equipment, in requisite copies including original, duly endorsed
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by the Manufacturer/successful tenderer with appropriate linkage to project, purchase order and acceptance criteria etc shall be submitted to Consultant/ Purchaser. i) Raw materials identification & physical and chemical test certificates for all materials used in manufacture of the equipment (except IS: 2062-1999 Gr. A & IS: 210-1993, FG-150). WPS, PQR & WPQ documents as per applicable code. Details of stage-wise inspection & rectification records for fabricated items, castings, forgings and machined articles. Control dimension chart with records of alignment, square ness etc. Manufacturer's material and performance/relevant test certificates for all bought-out items. Details of heat-treatment and stress relieving charts as per specification. Non-Destructive Test reports as per respective code. Static/dynamic balancing certificate for rotating components / machines. Hardness test certificate. Pressure / Leakage Test Certificates. Performance Test Certificates for all characteristics. Routine / type / calibration /acceptance / special test (Type Tests etc) certificates for electrical items. Surface preparation and painting certificates. Certificates from competent authority for the items coming under statutory regulations. Where physical and chemical test certificates of material are not available, the successful tenderer /Sub-contractor shall arrange to have specimens and test samples of the materials, tested in his own laboratory at his cost and submit the copies of test results in requisite numbers to Consultant/Purchaser for review. Number of
ii) iii) iv) v) vi) vii) viii) ix) x) xi) xii) xiii) xiv)
14.05.02
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test samples against each heat/cast/lot or batch of materials, as applicable shall be as per relevant Indian or International Standards. 14.05.03 Where facilities for testing do not exist in the successful tenderer / Sub-contractor's laboratories or in case of any dispute, samples and test pieces shall be drawn by the successful tenderer/Sub-contractor in presence of Consultant / Purchaser and sealed sample shall be sent to any Govt. approved /NABL accredited laboratory for necessary tests at contractors own cost. The Consultant / Purchaser shall have the right to be present and witness all tests being carried out by the successful tenderer / Subcontractor at their own laboratory or approved laboratories. Also, the Inspection Agency shall reserve the right to call for confirmatory test on samples, at his discretion. Internal Inspection by Successful Tenderer / Manufacturer Inspection and tests shall be carried out by Tenderer / Their Vendors in accordance with approved drawings, T.S., P.O., and approved QAP. They shall maintain records of each inspection and test carried out and signed documents shall be submitted to Purchaser/Consultant for verification. The successful tenderer shall carry out their internal inspection & obtain clearance from statutory bodies e.g. IBR, CCE, TAC, Weights & Measures, safety, IE rules etc. prior to offering any equipment for Purchaser/Consultant's inspection in accordance with approved QAP. The successful tenderer / their Vendors shall identify all the inspected equipment/component/raw materials & shall maintain the record of status of inspection viz. inspected & found acceptable, require rectification/rework, rejected etc. The successful tenderer shall establish and maintain procedures to ensure that the product that does not conform to specified requirements, is prevented from inadvertent use or installation. The description of non-conformity that has been accepted subsequently by Consultant/ Purchaser by concession and/or of repairs shall be recorded. Repaired and reworked product shall be offered for re- inspection to
14.05.04
14.06 14.06.01
14.06.02
14.06.03
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Consultant/ Purchaser along-with records of corrective action taken. 14.07 Manufacturing and Inspection Schedule All contractors shall submit the schedule for manufacturing and inspection indicating equipment / components, sub- assembly/ assembly. Date of approval of drawings / data sheets. Address of manufacturer with contact person and scheduled date of inspection. Such reports shall be submitted to respective Consultant Inspecting Offices with a copy to Inspection coordinating office once in a month. These monthly reports shall state the planning for next three months. Submission of first reports must commence one month prior to commencement of manufacturing activities of the product. 14.08 Method of Undertaking Consultant/Purchaser Inspection & Testing By
14.08.01
Inspection call shall be given only on readiness of the equipment/ assembly/ sub-assembly & after approval of all relevant drawings and QAP. In case, equipment/ assembly/ sub-assembly offered for inspection are found not ready, all the cost of visit of Consultant's engineer shall have to be borne by the successful tenderer. If the equipment/assembly / sub-assembly after inspection found not acceptable, require rework and involve Consultant's re- inspection, all the cost of such re-inspections shall also have to be borne by the successful tenderer,.
14.08.02
Inspection call shall be floated to Consultant, in the enclosed Form No.11.20(DQM)F-05/2.REV-0 duly filled in, with ten days (10) clear margin, enclosing all documents like test Certificates, Internal Inspection Reports, P.O., Sub-P.O., T.S., Approved QAP, approved GA drawings/ data sheets and manufacturing drawings. Inspection calls without above documents shall be treated as invalid and shall be ignored. The hard copy of such documents must also accompany a CD ( comprising computer readable files ) containing the identical documents . For imported items 21 days notice period shall be given in order to organize the inspection, if Purchaser so desire. The successful tenderer shall offer substantial quantities for economical inspection consistent with the size of order. On receipt of the Inspection call, pertaining to particular package / equipment / item, QA & Inspection group of Consultant, Ranchi (
14.08.03
14.08.04
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Overall co-ordinating office for Inspection activities ) shall organize inspection visit or will issue Inspection assignment to other Consultants office ( based on nearness to the vendor's manufacturing works / relevant job expertise ). For further inspection pertaining to the same package / equipment / item, successful tenderer may forward the subsequent inspection calls to the respective Consultants offices ( as identified per initial assignment ), with a copy to QA & Inspection Section, Ranchi. 14.09 14.09.01 Obligations of Successful Tendrer The successful tenderer shall provide all facilities and ensure full and free access of the Inspection Engineer of Purchaser/Consultant to their own or their Sub-Contractor's premises at any time, during contract period, to facilitate him to carry out inspection & testing of the product during or after manufacture of the same. The successful tenderer shall delegate a Representative / Coordinator to deal with Consultant/ Purchaser on all inspection matters. Representative of successful tenderer shall be present during all inspection at Sub-Contractor's works. The successful tenderer shall comply with instructions of Consultant/ Purchaser fully and with promptitude. The successful tenderer / Sub-Contractor shall provide all instruments, tools, necessary testing & other inspection facilities to Consultant / Purchaser free of cost for carrying out inspection. The cost of testing welds by ultrasonic, radiographic and dye penetration tests etc. in the fabrication workshop shall be borne by the successful tenderer .These tests need to be witnessed by ASNT/ISNT Level-II qualified NDT personals The successful tenderer shall ensure that the equipment / assembly / component of the plant and equipment required to be inspected, are not dismantled or dispatched before inspection. The successful tenderer shall not offer equipment for inspection in painted condition unless otherwise agreed in writing by Consultant/ Purchaser. The successful tenderer shall ensure that the equipment and materials once rejected by the Consultant/Purchaser, are not re-used in the manufacture of the plant and equipment. Where parts rejected
14.09.02
14.09.03
14.09.04
14.09.05
14.09.06
14.09.07
14.09.08
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during inspection have been rectified as per agreed procedures laid down in advance, such parts shall be segregated for separate inspection and approval, before being used in the work. 14.10 14.10.01 Stamping And Issue of Inspection Documents Inspection Memo:- For rejected items/items, which do not conform to Technical Specification in one or more quality characteristics requiring rectification / rework, Inspection Memo shall be issued indicating therein the details of observation & remarks. All the non-conformities with respect to specification of the product shall be indicated in the Inspection Memo for further quality control by successful tenderer. Inspection Certificate:- On satisfactory completion of final inspection & testing, all accepted plant & equipment shall be stamped suitably and Inspection Certificate shall be issued by the Consultant for the accepted items. General Clause Inspection & tests carried out by Consultant / Purchaser shall not absolve the responsibility of the successful tenderer/ Manufacturer to provide acceptable product as per the terms of contract nor shall it preclude subsequent rejection. Purchaser/ Consultant reserve the right to inspect any product at any stage of manufacturing beyond pre-identified stages & hold points of approved QAP Shop Testing Testing and inspection of equipment, pipes and materials shall be carried out at the works of the Contractor or his sub-Contractor during manufacturing and on final product to ensure conformity of the same with acceptable criteria of Technical Specifications, approved drawings, authenticated manufacturing drawings and reference Indian/ International standards. The Contractor shall furnish Quality Assurance Plan (QAP) for each equipment and material for Employers/Consultants approval at least two months prior to start of manufacturing.
14.10.02
14.11 14.11.01
14.11.02
14.12 14.12.1
14.12.2
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14.12.3
Tests to be conducted at the shop for various assemblies/subassemblies of equipment shall include, but not be limited to the following: i) ii) iii) iv) v) vi) vii) Material test. Tests during manufacture/fabrication. Dimensional checking. Hydraulic test at the shop. Static/dynamic balancing test for all moving parts. Performance test. Any other test as required to prove the functional requirement of various parts of equipment/system.
14.12.4
Pump Tests a) Pump casings shall be subjected to hydrostatic test at 150% of the shut-off head or 200% of the pump rated head whichever is higher. The hydrostatic pressure shall be held for not less than 30 minutes. Impeller and pump rotating assembly shall be dynamically balanced. Performance tests shall be carried out on pumps in accordance with the code for acceptance test for centrifugal, mixed flow and axial pumps Class C as per IS 9137 : 1978 (reaffirmed in 1993). Tests shall be carried on each pump. Performance test shall be carried out to determine the following: i) The discharge against the specified head when running at the specified speed under the specified suction head. The power absorbed by the pump at the shaft (BKW) under the duty conditions. NPSH required.
b)
c)
ii)
iii)
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14.12.5
Valve Tests i) ii) During testing there shall be no visible evidence of structural damage to any of the valve components. Motorized valves shall be tested with their actuators, with a differential head equivalent to their maximum working pressure, to demonstrate that the actuators are capable of opening and closing the valves under maximum unbalanced head condition within the specified opening or closing speed. All tests shall be carried out as per applicable Indian/reputed International Standard Codes. The following tests shall be carried out for butterfly valves a) b) c) d) v) Seat leakage test at rated pressure. Body hydrostatic tests 1.5 times the rate pressure. Disc strength test at body test pressure. Valve operation with and without actuator.
iii) iv)
The following tests shall be carried out for sluice valves a) b) c) Seat leakage test at rated pressure. Body hydrostatic tests 1.5 times the rate pressure. Valve operation.
vi)
The following tests shall be carried out for non-return valves a) b) c) Seat leakage test at rated pressure. Body hydrostatic tests 1.5 times the rate pressure. Valve operation.
14.12.6
Sluice Gate Tests i) Seat Clearance Check With the gate fully closed, the clearance between seating faces when checked with the thickness gauge, shall not exceed 0.1 mm. ii) Movement Tests Each gate shall be shop operated three times from the fully
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open position to the fully closed position and return to fully open status, under no flow conditions, to demonstrate that the assembly is workable. iii) Leakage Tests With the gate in closed position, design pressure shall be applied for a period of not less than 5 minutes to the unseating side of the sluice gate and the leakage shall not exceed the maximum leakage permissible as per IS 13349 : iv) Hydrostatic Test A differential of one and a half times the design pressure shall be applied to the unseating side of the gate. Under these conditions, no part of the gate shall show any deflection or deformation. 14.12.7 Pipe Tests i) Various tests to be carried out by the manufacturer to ensure high quality product shall include, but not be limited to the following: a) b) c) d) e) f) ii) Visual inspection. Dimensional check. Chemical analysis Non-destructive tests Mechanical properties tests. Hydrostatic test.
Plate and skelp to be used for manufacture of pipes shall be visually inspected for any surface defects. All pipes shall be visually examined and shall be free of defects in the finished conditions. Dimensional check shall be made for outside diameter, wall. Thickness, length, weight, straightness, out-of-roundness, bevel angle, bead height, etc. The accuracy of all measuring instruments used for acceptance or rejection shall be verified at least every operating shift. a) The pipes shall be substantially rounded. The difference between maximum and minimum inside diameters at any cross section shall not exceed 1% of
iii)
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the nominal diameter of the cross section under consideration subject to a maximum of 10mm. b) Tolerances on outside diameter, wall thickness and straightness shall be in line with the provisions of IS:3589. Pipe ends shall be beveled as per IS:3589.
c) iv)
The manufacturer shall furnish the result of chemical analysis and mechanical properties tests of the pipe material demonstrating conformance with specified limits in IS 3589 :1991. Non-destructive Tests 15% of the weld seams of the pipes fabricated from mild steel plates shall be subjected to ultrasonic tests for cracks, lack of complete penetration or complete fusion and discontinuities. In addition, the skelp end weld in finished spiral welded pipe shall also be inspected.
v)
vi)
Hydrostatic Tests a) Each length of the pipe shall withstand, without leakage, hydrostatic test pressure. The test procedure, pressure and duration of test shall be as per the applicable standard code. In order to ensure that every length of pipe is tested to the required test pressure, each tester shall be equipped with a recording gauge that will record the test pressure and the duration of time the pressure is applied to each length of pipe, or shall be equipped with some positive and automatic interlocking device to prevent the pipe being classified as tested until the test requirements (pressure and time) have been complied with. Such records or charts shall be available for examination at the manufacturer' works by the Employer' inspectors.
b)
14.12.8
For each of the items being manufactured / supplied, the following test certificates and documents, as applicable, in requisite copies including original shall be submitted to the Inspection Agency. All test certificates shall be endorsed by the manufacturer and the Contractor with linkage to the project, purchase order and
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acceptance criteria. i) Raw materials identification and physical and chemical test certificates for all materials used in manufacture of the equipment/pipe. Welding procedures and welders Certificates, as per applicable code. qualification test
ii)
iii)
Static/dynamic balancing certificate for rotating components/ machines. Pressure test certificates. Performance tests certificates for all characteristics.
iv) v) 14.12.9
Inspection at manufacturers works shall not relieve the Contractor of responsibility for replacing at his own cost any defective part/material and repairing equipment for defective workmanship that may be discovered at site at a later date. Shop Painting (also refer GS-09) Painting with surface preparation shall be provided to protect outside surface of all carbon steel which are subject to atmospheric action. Painting shall provide a continuous adherent film of adequate thickness on the surface being treated and protect it from attack due to continuous exposure in tropical atmosphere prevailing at the site. The complete paint system for any item shall include i) ii) surface preparation of steel substrate, application of primer coats, intermediate coats and finish coats of specified paints of approved quality.
14.13 14.13.1
14.13.2
14.13.3
Surface Preparation a) Surface preparation, being a pre-requisite for any paint application, shall be such as to clean the surface thoroughly of any materials which may be conducive to premature failure of the paint substrate. b) All surfaces shall be cleaned of loose substances and foreign materials, such as dirt, rust, scale, oil, grease, welding flux, etc. in order that the prime coat is rigidly anchored to the virgin metal
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surface. The surface preparation shall be as per Swedish Standard SIS 055900 or German Standard DIN 55928 (Part 4) or BS 4232 or IS 1477 Part I). Procedures for surface preparation shall cover solvent cleaning, hand tool cleaning, power tool cleaning and sand blast cleaning or combination thereof in order to attain desired surface quality as required by the specific primer paint. 14.13.4 Surface shall be prepared to achieve grade Sa 2 1/2 of SIS Standard by sand blasting. After surface preparation, equipment shall be painted with two coats of two-pack air drying epoxy polyamide resin based red oxide zinc phosphate primer as per IS 2074 : 1992. one coat of two-pack air drying high-build epoxy resin based intermediate paint with micaceous iron oxide (MIO). two coats of two-pack air drying epoxy polyamide enamel paint suitably pigmented. Dry film thickness (DFT) of each coat of primer, intermediate and finish paints shall be 30, 100 and 40 microns respectively. 14.13.5 a) Paint Application Paint shall be applied in accordance with manufacturers recommendations as supplemented by this specification. The work shall generally be carried out as per IS 1477 (Part II). Paint shall not be applied in rain, wind, fog or at relative humidity of 80% and above or when the surface temperature is below dew point resulting in condensation of moisture. Paint shall generally not be applied when the ambient temperature is 50 C and below. Each coat of paint shall be continuous, free of pores and of even film thickness without thin spots. Each coat of paint shall be allowed to dry sufficiently before application of the next coat to avoid damage such as lifting or loss of adhesion. Colour Code Shades of finish coat to be applied shall be as per IS 5 and of wide acceptability in water supply works. Prior approval shall be taken
i)
ii)
iii)
b)
c)
d)
14.13.6
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from the Purchaser after placement of order before adopting final colour shade for any particular item being painted. 14.14 14.14.1 Packing and Delivery The Contractor shall provide for secured packing of all equipment to protect from damage during transit from point of manufacture up to the site of erection under conditions which may involve multiple handling, storage and exposure to heat, moisture, rains, etc. The Contractor shall refer to the guidelines in this regard ass enshrined in GCC. All equipment and parts shall be tagged with reference to the assembly drawings and corresponding part numbers before packing and dispatch. All openings in valves, pipes and other materials shall be protected by suitable covers or plugs. All packages shall be clearly and properly marked in English language with indelible paint by stenciling. The identification marks indicating the name and address of the consignee shall be clearly marked on two sides and top of each package. Gross and net weights, outer dimensions and volumetric measurements shall be included in the marking. Eye bolts, lifting hooks or brackets shall be provided for lifting the boxes, crates and packages. Every crate or package shall contain a packing list in a waterproof envelope. A duplicate copy of the packing list shall be sent by post to the Employer. All items of equipment shall be clearly marked for identification against the packing list. Cases containing rubber rings, bolts and other small items shall not normally weigh more than 50 kg gross per case. Electrical equipment shall be enclosed in sealed air-tight package with hygroscopic material, before being placed in packing cases on shock absorbent materials and secured by means of battens. The Contractor shall be responsible for checking all the materials delivered to the site and shall keep the Employer fully informed of the state of deliveries. The Contractor shall carry out proper unloading, preservation, maintenance, storage and security of materials delivered to the site.
14.14.2
14.14.3
14.14.4
14.14.5
14.14.6
14.14.7
14.14.8
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14.14.9
The Contractor shall erect and maintain on the site any temporary storage facility as required and approved by the Purchaser.
14.15
LIST OF MAJOR INSPECTING OFFICES OF MECON SL. NO 1. AREA OF OPERATION
DETAILED ADDRESS BANGALORE
D.G.M.(I/C) Inspection Section MECON Ltd., 89, South End Road, Basavanagudi, Bangalore-560 004 (Karnataka) Gram : MECONIND Fax : 080-26576352 Phone : 080-26571661- 68 / 26576476 E-mail : bangalore@mecon.co.in 2. BHILAI
Karnataka, A.P.& Kerala
Dy.General Manager MECON Ltd., Ispat Bhawan, Ist floor, Bhilai-490 001 (Chhattisgarh. ) Gram : MECON Fax : 0788-2224452 Phone : 0788-2220107/ 2224101/ 2224454 E-mail : bhilai@mecon.co.in 3. CHENNAI
Bhilai, Nagpur, Raipur, Bilaspur, Bhopal,Satna & Katni
DGM I/C
Chennai & total Tamil Nadu

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MECON Ltd., House No. J-5, Plot No. 3552, 6th Avenue, Annanagar East, Chennai- 600 102 Gram : MECONIND Fax : 044-26261474 Phone : 044-26261911,26261914 E-mail : chennai@mecon.co.in KOLKATA (Controlled through Ranchi) Kolkata, Howrah, Bhubaneswar, Cuttack & Baripada
4.
GM MECON Ltd., 50, Chowringhee Road, Kolkata- 700 071 (W.B.)
Fax : 033-22824441 Phone : 033-22822381 to 82, 22824591 E-mail :kolkata@mecon.co.in mec_cal@datatone.in MUMBAI Maharastra,Gujarat & Goa
DGM(I/C) Inspection Section, MECON Ltd., 3rd Floor, Tower No. 7, International Infotech Park, Vashi Railway Station Complex, Vashi, Navi Mumbai-400 703 Fax : 022-27812275 Phone : 022-27812155 to 58 E-mail : mecon@bom5.vsnl.net.in mumbai@mecon.co.in
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6.
NEW DELHI Delhi, Punjab, Rajasthan
DGM (I/C) Inspection Section, MECON Ltd., Scope Minar, 13th & 15th Floor, North Tower, Laxmi Nagar, Delhi-110 092 Fax : 011-22401203, 22041214 Phone : 011-22041201/ 22041315/22041468/ 22041238 E-mail : delhi@mecon.co.in 7. RANCHI
DGM (I/C) QA & Inspection Section MECON Ltd., Ranchi-834 002 (Jharkhand) Fax : 0651-2482189 / 2482214 Phone : 0651-2481002/2481216 Extn : 7330 2482183 (P & T) Direct E-mail : insp@ranchi.mecon.co.in
Ranchi, Dhanbad, Jamshedpur, Allahabad, Naini and all over India, if need arises for whatever reason.
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15.0
PREFERRED MAKE Make of major equipment has been included in GS-13. The equipment for which make has neither indicated in GS-13 nor in this TS will be approved by the purchaser on request of the contractor. The contractor will submit list of such equipment with makes for purchasers approval.
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16.00
LIST OF DRAWINGS
Sl. No. 1 2
Drawing no. MEC/11/40/E24F/TS/WS/ 042A/0001 (R0) MEC/11/40/E24F/TS/WS/ 042A/0002 (R0)
Description Area layout Tertiary Treatment Plant Scheme Diagram for TTP
Remarks
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Annexure - I QUESTIONNAIRE TO BE FILLED IN BY TENDERER The tenderer shall fill this questionnaire and submit with his offer. This information in this form is to facilitate tender processing even though it may be duplicate information presented else where in his offer. 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 1.11 1.12 1.13 1.14 1.15 1.16 1.17 General: Tenderers name and address: Quotation No. & Date: Storage arrangement at site: Previous experience for similar project Deviation from technical specification: Time schedule in the form of bar chart for Basic Engineering, Design Engineering, Manufacture, Supply, Erection, Testing. List of drawings furnished with tender: List of catalogue/manufacture data enclosed: List of testing equipment envisaged for site testing: Make of all bought out items: List of commissioning spares as will be required: List of construction & erection equipment to be brought to site. List of special Tools & Tackles Fabrication & erection procedure to be followed. Power requirement for construction. List of spares for 2 years smooth operation for fabricated and bought out items.
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1.18
Tenderer to indicate list of drawings/document to be submitted under approval/reference category after being awarded the contract. Data sheet for all items to be filled up either in consultants format (wherever applicable) or in Tenderers format. QAP for all items to be filled up by Tenderer separately in consultants format. Organisation chart for Design & Engineering, Project monitoring and site activities including technical personnel, skilled & unskilled employees. Estimated Quantities for Pipe-works, Civil, Structural, Electrical, Instrumentation & Control Any other relevant information.
1.19 1.20 1.21
1.23 1.22
Signature of Tenderer
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APPENDIX-I
TENDERER TO INDICATE THE LIST OF DEVIATIONS SL. NO. REF. CLAUSE OF TS DETAILS OF DEVIATIONS REASONS
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APPENDIX-II
TENDERER TO INDICATE LIST OF COMMISSIONING SPARES SL. NO. EQUIPMENT DESCRIPTION OF SPARE QUANTITY
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APPENDIX-III
TENDERER TO INDICATE LIST OF SPECIAL TOOLS & TACKLES SL. NO. TOOLS/ TACKLES DESCRIPTION / SPECIFICATION APPLICATION QUANTITY
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APPENDIX-IV
TENDERER TO INDICATE LIST OF INSURANCE SPARES SL. NO. DESCRIPTION OF ITEM QUANTITY
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APPENDIX-V
TENDERER TO INDICATE LIST OF SPARES FOR TWO YEARS OF OPERATION & MAINTENANCE SL. EQUIPMENT DESCRIPTION QTY RECOMMENDED REMARKS NO. OF SPARE INSTALLED QUANTITY
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APPENDIX-VI
ADDITIONAL OBLIGATIONS (OF PURCHASER) DESIRED BY THE TENDERER SL. NO. NATURE OF WORK/ FACILITIES DESIRED REASONS
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APPENDIX-VII
TENDERER TO INDICATE LIST OF EQUIPMENT TO BE IMPORTED SL. NO. DESCRIPTION/ EQUIPMENT MAKE REMARKS
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APPENDIX-VIII
TENDERER TO INDICATE REQUIREMENT OF CONSTRUCTION POWER, WATER, OFFICE SPACE, STORAGE AREA SL. NO. 1 2 3 4 DESCRIPTION POWER WATER AREA OF OFFICE STORAGE AREA REQUIREMENT REMARKS
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APPENDIX-IX
TENDERER TO INDICATE ESTIMATED NOS. OF DRG. UNDER FOLLOWING HEADS (A1 EQUIVALENT) SL. NO. 1 2 a) b) c) d) 3 4 5 6 7 8 DESCRIPTION PIPE WORKS & PIPE TUNNEL TERTIARY TREATMENT PLANT COMPLEX PRE-TREATMENT PLANT SLUDGE DEWATERING PLANT TERTIARY TREATMENT & RO PLANT ZERO DISCHARGE PLANT STRUCTURAL CIVIL INSTRUMENTATION & CONTROL AUTOMATION SYSTEM ELECTRICAL MATERIAL HANDLING NO. OF DRAWINGS REMARKS
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APPENDIX-X
TENDERER TO INDICATE ESTIMATED QUANTITIES I. ESTIMATED QUANTITIES FOR EQUIPMENT MECHANICAL, ELECTRICAL & INSTRUMENTS SL. NO. 1. 2. 3. 4. 5. 6. 7. 8. * DESCRIPTION/ EQUIPMENT MATERIAL/ SPECIFICATION QTY. TOTAL WT. (IN TONS) UNIT RATE REMARK
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APPENDIX-XI ESTIMATED QUANTITIES FOR PIPE WORKS SL. NO. 1. 2. 3. 4. 5. DESCRIPTION/ EQUIPMENT Pipes Pipe Supports Pipe Fittings Valves Miscellaneous MATERIAL/ SPECIFICATION QTY TOTAL WT. (IN TONS) UNIT RATE REMARK
ESTIMATED QUANTITIES FOR CIVIL WORKS
ESTIMATED QUANTITIES FOR STRUCTURAL WORKS
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Form No. 11.20(DQM)F-05/2 Rev.0 Page No. 1 of 1 INSPECTION CALL PROFORMA

Inspection Call No. Project Contractor Sub-Contractor with address, Fax & Ph. No. Proposed Date of Inspection Manufacturer's Off-day List of items offered for inspection Item Item Description Identication No. Purchaser Contractor's Order No. & Date Place of Inspection with address, Fax & Ph. No. Name & Designation of Contact Person with Ph. No. Date :
Drawing No. with Revision
Drawing QAP No. & Approval Status A/AAN/INF Status Quantity (No./M) with tonnage Total Ordered Total Accepted Offered
A = Approved, AAN = Approved as Noted, INF = Information Category List of documents & Test Certificates enclosed in four (4) sets. Description Ref No. & Date
Description
Ref No. & Date
for Contractor/Sub-Contractor
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STEEL AUTHORITY OF INDIA LIMITED EXPANSION OF BOKARO STEEL PLANT TO 7.0 MT TERTIARY TREATMENT PLANT OF CRM - III
INDICATIVE IMPLEMENTATION SCHEDULE
ID 1 Task Name Dur (w) -1 1 2 3 4 5 Year 1 6 7 8 9 10 11 12 13 14 15 16
BSL Expansion - Tertiary Treatment Plant for new CRM III Effective Date of Contract (Zero-date) Basic Engineering & Approval Submission of Feed-back Data for Utilities & services Tendering & Ordering on Sub-vendors Detailed Engineering & Approval Civil Work Fabrication & Erection of Structures Delivery of Equipment Erection of Equipment including piping work Testing & Commissioning - Tertiary Treatment Plant
Task
65 w 0w 13 w
0w
13 w 26 w 39 w 26 w 22 w 22 w 8w
Milestone Summary
10
11
File: BSL_Exp_Tertiary Treatment_TS_sch_Jan13.mpp
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STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL LIMITED, BOKARO 7.

MECON LIMITED RANCHI 834 002

2012 MECON LIMITED ALL RIGHTS RESERVED

TERTIARY TREATMENT PLANT

2013 MECON LIMITED ALL RIGHTS RESERVED

2013 MECON LIMITED ALL RIGHTS RESERVED

TERTIARY TREATMENT PLANT

TERTIARY TREATMENT PLANT

2013 MECON LIMITED ALL RIGHTS RESERVED

TERTIARY TREATMENT PLANT

2013 MECON LIMITED ALL RIGHTS RESERVED

TERTIARY TREATMENT PLANT

2013 MECON LIMITED ALL RIGHTS RESERVED

2013 MECON LIMITED ALL RIGHTS RESERVED

2013 MECON LIMITED ALL RIGHTS RESERVED

TERTIARY TREATMENT PLANT

2013 MECON LIMITED ALL RIGHTS RESERVED

TERTIARY TREATMENT PLANT

2013 MECON LIMITED ALL RIGHTS RESERVED

TERTIARY TREATMENT PLANT

2013 MECON LIMITED ALL RIGHTS RESERVED

TERTIARY TREATMENT PLANT

01.16.06 a) b) c) d) 01.16.07 a) b) c) 01.16.08 a) b) c) 01.16.09 a) b) c) 01.16.10 a)

2013 MECON LIMITED ALL RIGHTS RESERVED

TERTIARY TREATMENT PLANT

2013 MECON LIMITED ALL RIGHTS RESERVED

2013 MECON LIMITED ALL RIGHTS RESERVED

TERTIARY TREATMENT PLANT

TERTIARY TREATMENT PLANT

2013 MECON LIMITED ALL RIGHTS RESERVED

TERTIARY TREATMENT PLANT

2013 MECON LIMITED ALL RIGHTS RESERVED

TERTIARY TREATMENT PLANT

2013 MECON LIMITED ALL RIGHTS RESERVED

TERTIARY TREATMENT PLANT

2013 MECON LIMITED ALL RIGHTS RESERVED

TERTIARY TREATMENT PLANT

2013 MECON LIMITED ALL RIGHTS RESERVED

TERTIARY TREATMENT PLANT

2013 MECON LIMITED ALL RIGHTS RESERVED

2013 MECON LIMITED ALL RIGHTS RESERVED

TERTIARY TREATMENT PLANT

2013 MECON LIMITED ALL RIGHTS RESERVED

TERTIARY TREATMENT PLANT

X+2547, 70 Y+8842 To be 70 decided during DE

TERTIARY TREATMENT PLANT

TERTIARY TREATMENT PLANT

DN150. (Please refer Scheme MEC/11/40/E24F/TS/WS/042A/0002 (R 0)).

2013 MECON LIMITED ALL RIGHTS RESERVED

TERTIARY TREATMENT PLANT

TERTIARY TREATMENT PLANT

TERTIARY TREATMENT PLANT

2013 MECON LIMITED ALL RIGHTS RESERVED

TERTIARY TREATMENT PLANT

To be decided during DE To be decided during DE

2013 MECON LIMITED ALL RIGHTS RESERVED

TERTIARY TREATMENT PLANT

pH correction system with static mixer

2013 MECON LIMITED ALL RIGHTS RESERVED

TERTIARY TREATMENT PLANT

2013 MECON LIMITED ALL RIGHTS RESERVED

TERTIARY TREATMENT PLANT

TERTIARY TREATMENT PLANT