Stgspecification 140417234455 Phpapp01

ULTRATECH CEMENT LIMITED, BIRLA WHITE
CEMENT - III, KHARIA KHANGAR, JODHPUR,

RAJASTHAN
TENDER DOCUMENT OF 1X21 MW CPP
SECTION 4 TECHNICAL SPECIFICATION
4.2
DETAILED TECHNICAL SPECIFICATION

TURBINE AND AUXILIARIES
4.2.1
General
FOR
STEAM
This section of the technical specification defines minimum technical

requirements for design, manufacturing, supply, installation, erection,
testing and commissioning of the steam turbo-generator system with all
the accessories and auxiliaries.
4.2.2
Conditions of Service
4.2.2.1
The steam turbo generator will be installed in a separate powerhouse,

along with the entire auxiliary equipment and systems. The Powerhouse
will be provided with EOT crane for the maintenance purpose of the
turbo generator.
4.2.2.2
The turbine control shall be located in the control room, located

adjacent to the turbo generator, whereas important indicating
instruments shall be provided near the turbine in the local gauge board.
Emergency stop arrangements shall be provided in the local gauge
board.
4.2.3
Design and Engineering
4.2.3.1
The SUPPLIER must offer a very reliable and efficient system with
state-of-the-art proven design with good performance over a long
period. The SUPPLIER shall offer the system including (but not limited
to) the following design and engineering features:
-
Highest possible thermal and energy efficiency.
State-of-the-art technology and well proven in actual operation

over a long period.
Rugged, conservatively designed, proven components and

systems.
Minimum outage for field maintenance and routine inspection.
Better operability at various load conditions.
Advanced instrumentation, control systems, shut-down and

protection system, very reliable online supervisory and
surveillance system, with diagnostics.
Minimum requirement of operating and maintenance man-
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power and amenability to unattended automatic operation.
site.
Suitability for harsh tropical ambient conditions prevailing at
Simple design and ease of installation.
The SUPPLIER may incorporate additional features and improvements

to enhance the efficiency and reliability of the system.
4.2.3.2
The turbine shall be horizontal, single cylinder, bleed cum condensing

type. Provision for required numbers of bleed shall be envisaged. The
High Pressure (HP) bleed steam will meet the feed water heating
requirements in HP feed water heaters. Medium Pressure (MP) bleed
steam from the turbine will meet the steam requirements of the deaerator. The LP bleed steam will meet the LP feed water heater steam
requirements. Necessary spray water pressure reducing station and
desuperheater, if required in the bleed steam line, shall be provided by
the SUPPLIER. The requirement and sizing of the Desuperheating
stations in the extraction lines shall be decided based on the possible
operation of the turbogenerator from 30 % to 100 % load.
4.2.3.3
All casings and stator blade carriers shall be horizontally split or

otherwise and the design shall be such as to permit examination of the
blading without disturbing shaft alignment or causing damage to the
blades. The design of the casing and the supports shall be such as to
permit free thermal expansion in all directions. The casing shall also
permit the inspection of the bearings without dismantling of the casing.
The bleed branches shall be located on the lower half of the casing.
The low pressure casing shall have a bottom exhaust arrangement
configuration and the exhaust casing shall be suitable for connection to
the condenser without air leakage and suitable for maintaining the
condenser vacuum. The turbine exhaust hood shall be provided with
exhaust water spray system to protect the turbine against excessive
temperature due to windage at no load and low load conditions. The
spray system shall be provided with complete spray nozzles, automatic
spray control valve, interconnecting piping, all necessary controls,
instrumentation and fittings.
4.2.3.4
The turbine shall have solidly forged and machined rotor with integral
disks. The rotor after fully machined and bladed shall be dynamic
balanced accurately in the shop and shall be given a overspeed test
under vacuum. None of the critical speeds of the rotor shall fall within
the range of 20% above and 20% below the normal running speed of
the rotor. The SUPPLIER, shall analyze the complete coupled train for
both lateral and torsional vibrations, and ensure proper separation
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margins. The rotor shall be designed to withstand the maximum shock
loading that may occur during any power system disturbance.
Such shock loading values shall be taken for the design of the gear box
and the generator rotor. SUPPLIER shall specify clearly the
construction of the rotor, the heat treatment proposed and the
procedure for inspecting the shaft to ensure soundness and
homogeneity of the material in the QAP. The material of construction
shall be consistent with proven practices and standards.
To bring the turbine rotor from full speed to rest as quickly as possible,
whenever required a vacuum breaker valve capable of being operated
remotely from the control room and capable of operating in conjunction
with the turbine over speed protection system with necessary interlocks
and logics shall be provided. (This valve will be located in the exhaust
duct connecting the turbine and the Air cooled condenser). The valve
shall have the facility for local manual operation.
4.2.3.5
The blading shall be designed to withstand all vibrations, thermal

shocks, and other loading that may be experienced during service and
system disturbances. The blades shall be machined from forged bars or
die forged and the materials used shall be chromium steels suitable for
the temperatures encountered, resistant against corrosion and erosion
and consistent with proven experience and standards. In the low
pressure stages, if warranted where the moisture percentage is higher,
additional protection against erosion shall be provided.
The blading depending on the staging shall be adequately fastened as
per the standard practice of the SUPPLIER, but such methods of fixing
the blades shall be a proven one by long use in operation. The rotating
blades are either shrouded or tied with lacing wires depending on the
stresses and the excitation frequencies.
4.2.3.6
Gland Sealing System

The glands shall preferably be of labyrinth type and sealed with steam.
The gland packing shall be of 13% chromium stainless steel. The
labyrinths shall be of multi-section spring backed type which would
allow for any temporary deformation of the rotor shaft without
overheating the rotor due to friction. Any other sealing system
compatible with the operating conditions may also be furnished, but
however the details of the offered system shall be furnished by the
supplier. The complete piping, valves, pressure gauges, regulators etc.
required for the end seals shall be provided by the SUPPLIER. During
the normal operation of the turbine the source of sealing steam will be
from the turbine. If external sealing steam is required also during the
normal running, it should be specified by the supplier. Required gland
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steam condenser with 2 x 100 % capacity AC motor driven exhausters
shall be provided. Suction fans, wherever provided shall have one 100
% capacity operating fan and one 100 % capacity standby fan. All
piping and components of shaft seal system shall be sized for 150
percent of the calculated new clearance leakages.
The cooling medium shall be the condensate from Air cooled condenser.
The shell side shall be designed for the maximum steam pressure from
gland and for full vacuum. The tube side shall be designed for the cold
shutoff pressure of the condensate extraction pumps. The gland steam
condenser shall be provided with all instruments and accessories
including thermal relief valve.
4.2.3.7
Bearings
The Turbine shall be provided with liberally rated hydrodynamic radial
and thrust bearings. The radial bearings shall be split for ease of
assembly, and of the sleeve or pad type, with steel shell backed,
babbitted replaceable pads. These bearings shall be equipped with anti
rotation pins and shall be positively secured in the axial direction. The
thrust bearings shall be of, Mitchell tilting pad type, the steel backed
babbitted multiple segment, designed for equal thrust capacity in both
directions. A liberal flow of lube oil under pressure shall be supplied to
all the bearings for lubrication and cooling.
All bearings shall be accessible without having to remove cylinder
covers. The metal temperatures of all the bearings shall be monitored
by thermocouples with extension right into the white metal layer.
Provision shall be made for measuring the temperature of the oil leaving
the bearings.
4.2.3.8
Lubrication and control oil system
4.2.3.8.1
A pressure lubrication and control oil system shall be furnished for the
turbo generator unit to supply oil at the required pressure to the steam
turbine, gear box, generator and governing system. The lubrication oil
system shall supply oil to the turbine generator under all the load
conditions, including the turning gear operation. The oil system of the
turbo generator shall be designed with adequate redundancy and
emergency provisions such that a failure of a single active component
will not prevent the safe operation or a safe shutdown of the turbo
generator. Oil in the reservoir shall be maintained at an appropriate
temperature when the TG set is idle by providing suitable electric
heaters and temperature controls if required.
For the hottest ambient conditions to be encountered at the site the oil
outlet temperature at any bearing shall neither exceed the maximum
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permissible temperature for the bearing metal nor the maximum safe
operational temperature of the oil.
4.2.3.8.2
The oil system shall include the following:

-
One hundred percent (100 %) capacity centrifugal type AC driven

Main oil pump
One (1) No. of one hundred (100 %) capacity A.C motor driven
auxiliary oil pump of centrifugal type, arranged to cut in
automatically if the oil pressure falls to a preset value. This pump
shall also meet the requirements during the start up and shutdown.
One (1) D.C motor driven, centrifugal type, emergency oil pump of
adequate capacity to provide adequate lubrication in the event of a
failure of the A.C motor driven pump(s). This pump also shall cut in
automatically at a pre set value of the oil pressure. The minimum
capacity of this pump shall be to ensure a safe shutdown of the
turbogenerator.
2 x 100% (1AC+1DC) Jacking oil pump with all piping, valves,

instruments, etc.
Two 100 % capacity (one working and one standby) water cooled
oil coolers.
Two 100 % duty oil filters arranged in such a way that it is possible
to clean one oil filter while the other is in service. The filters and the
coolers shall be arranged with continuous flow transfer valves.
Oil storage and settling tank with adequate reservoir capacity,

strainers, level indicators with float switches and alarm contacts,
vent and oil mist eliminators and 2x100% capacity vapour exhaust
fans.
Flow and temperature indication for oil from every bearing.
LVDH for oil purification including interconnecting piping and valves.
Oil clarification system (ELC machine of 100 LPH capacity)
Emergency gravity lube system designed for lubrication up to

coasting down period of turbine & additional margin in overhead
tank to address the emergency in case of delay in EOP start up
Collecting oil tank with oil transfer pump. The oil from the collecting
oil tank will be pumped to the main oil tank, upstream of the inlet
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strainer. Collecting oil tank capacity shall be the same as Main oil
tank.
If the system envisages separate control oil circuit from the lube oil
system, there shall be independent two nos. of control oil pumps and 2
x 100 % duplex oil filters for the control oil circuit.
The Main and Auxiliary oil pumps and the emergency oil pumps shall be
arranged to have flooded suction.
Supply of the flushing oil and the first fill up of lube oil for the turbine
and accessories shall be the responsibility of the SUPPLIER and
preferably from the Indian market.
4.2.3.8.3
Oil coolers
The oil coolers shall be water cooled with a duplex arrangement and
changeover valves. The coolers shall be of shell and tube type with
removable tube bundle. The tube material shall be SS304. The coolers
shall be constructed in accordance with TEMA class C. The provided
surface area shall be adequate to cool the oil with inlet cooling water
even with the indicated percentage of the tubes plugged (margin
specified else where in the tender specification). The coolers shall be
amenable for easy inspection and maintenance and cleaning of one
cooler while the other one is in service shall be possible. The oil cooler
shell side shall be designed for cold shut off head of the oil pump and
tube side shall be designed for a pressure of 6 kg/cm (g). Necessary
lifting lugs shall be provided. There shall be isolating valves on either
side of the oil coolers (Upstream insolating v/v shall gate v/v and down
stream v/v shall be glove v/v) in cooling water line.
4.2.3.8.4
Filters
Full flow twin oil filters shall be used, for the lube oil, downstream of
the coolers and shall be piped in a parallel arrangement with a
continuous flow transfer valve. Filter cartridges shall have a minimum
collapsing differential pressure of 3.5 kg/cm. The minimum design
pressure for the filters shall be the maximum discharge pressure of the
oil pumps. Differential pressure gauge with alarm shall be provided
across the filters. The filters shall be either common or separate for the
lube and control oil circuits.
Oil filters shall be arranged in such a way that it is possible to clean one
oil filter while the other is in service. The filters and the coolers shall be
arranged with continuous flow transfer valves. The filter grade for the
control oil shall be 10 Microns nominal. If a common filter is used for
lube and control oil, the filter grade shall be 10 microns nominal.
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4.2.3.8.5
Oil reservoir
The interior of oil reservoirs shall be desalted and rust proofed with a
permanent coating. Reservoirs with top mounted equipment shall have
sufficient rigidity. The cover plate shall be adequately stiffened to carry
the load. All openings for piping shall be made dust and water proof.
The oil reservoir shall be so located to permit draining of the contents
by gravity and shall be equipped with fine and coarse mesh strainers.
The oil drained shall be collected in a drain oil tank/collecting tank of
suitable capacity located on the ground floor of the TG building and two
numbers of drain oil pumps shall be provided to pump the oil back to
the oil reservoir (in case of overflow from the oil reservoir) to outside
the TG building for disposal.
The reservoir shall be of adequate capacity. The reservoir shall be
provided with 2x100 % oil vapour extractors, with oil separator, for
proper ventilation. All necessary piping connections, valves and fittings,
level switches and level gauges shall be provided. Corrosion allowance
of 3 mm shall be considered while designing the system.
All necessary piping, valves and fittings shall be provided for the
complete oil system shall be provided by the SUPPLIER. The complete
piping shall meet the requirements of API 614. The flanges provided in
the stainless steel oil lines downstream of oil filter shall be LJFF type if
the flange is of carbon steel material or SORF if the flange is of stainless
steel material. If stainless steel material is used they shall confirm to
SA 182 F 304 specification.
4.2.3.8.6
Oil purifier and ELC Machine

A centrifugal type oil purifier shall be provided for the removal of water,
sediments and other oxidation products from the Lube oil system on a
continuous basis. The purifier shall be a separate complete package,
mounted on a skid, complete by itself with drive motor, piping, valves
and fittings. Feed to the purifier shall be from the drain end of the
reservoir and its operation shall be independent of the oil system.
In Addition to the above Electrostatic liquid cleaner machine of 100 LPH
shall be provided.
4.2.3.8.7
Emergency Oil Tank

Emergency gravity lubricating system shall be provided to assure the
lubrication at the time of emergency due to the failure of the DC
operated lube oil pump. This system shall draw lube oil from an
overhead tank, under gravity, and shall be designed to supply oil for the
coasting down period of the machine.
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The overhead tank shall be SS and the complete piping shall be of SS
304 material. The tank elevation shall be finalized based on the oil
pressure requirements at the bearings.
The system shall be designed with continuous overflow circulation of oil
to avoid sludge formation in the tank. The Vent / overflow of the
emergency overhead oil tank shall be brought down to the oil reservoir
or to the collecting tank, if a separate tank is provided for collecting the
oil overflow from the emergency oil tank. This is required to ensure that
there is no dust ingress into the oil system while the oil is drained from
the emergency oil tank.
4.2.3.8.8
Collecting/ Settling oil tank

The settling oil tank shall be located on the ground floor for draining the
oil from the oil coolers, oil filters and generally from the piping and
equipment of the oil system. The drain lines shall be of carbon steel
and shall be routed from the respective equipment and other draining
points to the tank. The tank shall be epoxy coated on the inside.
There shall be two transfer pump, gear or centrifugal type, for the
transfer of the oil from the settling tank to the main oil tank.
4.2.3.9
Steam Turbine Governing System

The turbine governing system shall be electro-hydraulic designed for
high accuracy, speed and sensitivity of response. The electrical/
electronic and hydraulic components of the control system shall be
selected on the basis of reliability over a wide range of operating
conditions. All components used shall be well proven to assure overall
system reliability and shall be designed for easy and quick replacement
when necessary. The governor shall be configurable in the field.
The governor shall ensure controlled acceleration of the turbo generator
and shall prevent over speed without tripping the unit under any
operating condition or in the event of maximum load rejection. The
governor shall have linear droop characteristics with a suitable range for
stable operation and shall have provision for adjusting the droop in fine
steps.
The governing system shall have the following important functions:
-
Speed control
Over speed control
Load control
Inlet Steam pressure control
The governor shall be configured to incorporate the following controls

while operating in parallel with the grid:
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4.2.3.10
a.
Load set point shall remain unaffected for the variation of

frequency between 47.5 Hz and 52.5 Hz
b.
The turbine inlet steam pressure shall be maintained at the set

value by controlling the power export to the grid.
External Forces and Moments

The SUPPLIER shall furnish the allowable forces and moments on the
turbine nozzles. As a minimum requirement the turbine shall be
designed to withstand the external forces and moments calculated in
accordance with the requirements of NEMA SM 23. The SUPPLIER
shall also furnish the thermal expansion movements on each of the
nozzles in the turbine.
4.2.3.11
Thermal Insulation and Lagging

The steam turbine and the other high temperature parts, including
piping supplied, shall be insulated with low conductivity inert material,
where required, reinforced by stainless steel wire net between applied
layers. The insulation shall be so arranged that it can be removed for
access to the flange bolting, control valves and other parts that require
periodic maintenance. The insulation shall be designed, such that the
outer surface temperature of the insulation does not exceed 20 Deg. C
above the ambient temperature.
For turbine casing only glass fiber insulation removable pads shall be
considered, with surface cladding with suitable material.
Pre molded pipe section insulation of glass fiber material shall be
considered for turbine Steam pressure cycle with aluminum cladding of
material code L 100 & L150
4.2.4
Capacity and Performance Requirement
4.2.4.1
Turbine Generator Rating

The turbine rating and other performance criteria shall be as specified in
the section on Performance Guarantee.
4.2.4.2
Bleeds
The turbine shall be provided with required number of bleeds, as
mentioned elsewhere in the specification.
4.2.4.3
Economic Load
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The specific steam consumption shall be the lowest for operating loads
between 80 to 100%.
4.2.4.4
Over Loading
The system offered shall be suitable for an overload specified in the
specification on continuous basis.
4.2.4.5
No load and Minimum load operation

The turbine shall be capable of operating under no load condition
during loss of load for a maximum period of 60 minutes. The minimum
load at which the turbine is required to operate continuously shall be
15% of the designed capacity.
4.2.4.6
Specific steam consumption

This guaranteed specific steam consumption / heat rate shall be for the
economic load and the testing shall be as per IEC Recommendations
Publication 46.
4.2.4.7
Governing Characteristics
When the machine is operating with rated steam conditions and at
rated speed, and the maximum load is thrown of, the operation of the
electronic speed governor shall prevent the speed rising to a value at
which the over-speed trip is set to operate. The speed governor droop,
i.e. permanent speed variation from no load to rated output etc., shall
be within the limits specified in IEC Recommendations Publication 45.
4.2.4.8
Parallel operation
The characteristics of the turbine shall be such that the turbine
generator set can be run in parallel with the State power grid and / or
with the machine to be added later on and possess no abnormal
features either individually or collectively.
4.2.4.9
Speed adjustment
The turbine speed at no load shall be adjustable between 6% below
and 6% above rated speed. Means are to be provided whereby the
speed of the turbine at no load can be raised in a controlled manner for
the purpose of testing the over speed trip mechanism and provision
made to ensure that such means do not interfere with the action of the
speed governor in normal operation. The device to raise speed at no
load must incorporate limiting means to prevent it from reaching a
dangerous speed.
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4.2.4.10
Over speed trip

In addition to the speed governor and electronic over speed relay with
02 of 03 logic (wood word make Protec 203), the turbine and generator
shall be protected against excessive overspeed by a separately actuated
(Mechanical trip device) overspeed device which operates the trip
system. In the event of sudden load rejection, should the speed
governor fail to meet the requirements the overspeed trip shall operate
to prevent any damage. The overspeed trip setting shall be stated by
the SUPPLIER in the operating instructions. The over speed trip
mechanism shall be capable of being reset when the speed of the turbine has decreased to a speed not lower than the rated speed.
4.2.4.11
Trip system
The turbine shall be provided with a trip system for the complete and
rapid closure of steam valves effectively preventing all steam admission
to the turbine independently of the closure of the governing valves. In
order to avoid sudden re-admission of steam to the turbine the trip
system shall be fitted with interlocking devices so that trip resetting
cannot take place until steam admission can only be achieved as per
normal starting up procedure. Essential trip circuits to be provided are:
-
4.2.4.12
Steam inlet pressure falling below pre-determined level.

Steam temperature falling below pre-determined level.
Steam inlet pressure raising above pre-determined level.
Steam temperature raising above pre-determined level.
Excessive wheel chamber pressure.
Turbine differential casing expansion.
Condenser vacuum falling below pre-determined level.
Lubricating oil pressure falling below pre-determined level.
Axial thrust wear trip.
High temperature trip for LP stage steam flow.
High turbine bearing vibration.
High turbine bearing temperature.
Low control oil pressure.
Maximum speed
An overspeed test of the turbine rotor shall be carried out preferably at
the SUPPLIER's works. The overspeed tests shall be at a speed
exceeding by 2% the maximum calculated overspeed that would occur
if the speed governor failed and if the maximum overspeed was limited
by the action of the overspeed trip device only. The duration of the over
speed test shall be less than 2 minutes. The overspeed shall not be
more than 20% of the rated speed. Supplier shall indicate all over
speed trip set point.
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4.2.4.13
Vibration
The foremost in the Turbine Supervisory Instrumentation system is the
vibration measurement which provides the basic protection to the
Turbogenerator. The system of vibration measurement shall include
shaft radial vibrations at the radial bearings, axial displacement and
thrust position, Speed and differential Expansions. The shaft radial
vibration measurement shall employ proximity probes in the X-Y
configuration in two orthogonal directions in each bearing. For the
measurement of the thrust position two proximity probes shall be
employed in a dual voting arrangement.
Vibration measuring and monitoring systems of reputed make (Bently
Nevada make of the latest 3500 series system is preferred) shall be
provided for measuring the shaft vibration of turbine, gearbox and
generator. All the bearings of the turbine, gear box and generator shall
be provided with the probes for measurement. The maximum allowable
vibration under any specified operating conditions shall be indicated by
the SUPPLIER.
The detailed specification is indicated in
Instrumentation section.
4.2.4.14
Critical speed
The critical speed for the combined turbine and generator train shall be
sufficiently away from the rated speed to avoid any adverse effect on
the operation of the unit over the range of operating speeds.
4.2.4.15
Hydraulic test
All parts subjected to steam pressure shall be tested hydraulically for a
pressure of 1.5 times the working pressure. For those parts which are
made of materials which may be damaged by such tests the test
pressure shall be agreed by the OWNER and the SUPPLIER during
tender stage.
4.2.4.16
Materials of construction
The selection of materials for parts of the machine shall be based on
the experience of the SUPPLIER and experimentally determined data
and shall conform that under conditions of stress, temperature and time
the components will not fracture or deform to a greater extent than is
permissible. The materials selected shall be clearly indicated in the
turbine and auxiliaries data sheets.
4.2.4.17
Variation of steam pressure and turbine

The turbine shall be capable of accepting variations from the rated
conditions within the limits specified by IEC Recommendation
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Publication 45 except inlet high high pressure trip.
4.2.4.18
Limit of lubricating oil temperature

The SUPPLIER shall furnish the permissible temperature for the
bearing metal.
4.2.4.19
Noise
The turbine and gear box shall be provided with acoustic enclosure to
reduce the noise level to the specified limits of 80 dB (A) at 1 m
distance from the equipment. Acoustic enclosure should include fire
protection & fire alarm system with sufficient movable path inside the
enclosure.
Measurement shall be made with the machine running under normal
operating conditions at not less than 8 points evenly spaced around the
machine and auxiliaries, approx, 1 meter from the periphery and at the
heights of the center lines of main and auxiliary machines.
Noise measurements shall also be made during running tests in
SUPPLIERs works so that any corrective action, which appears to be
necessary, can be carried out in advance of operation at site.
4.2.5
Safety
4.2.5.1
All controls shall operate in a fail safe mode.
4.2.5.2
All coupling and gears shall be provided with adequate guards.
4.2.5.3
Piping shall be arranged in such a manner as to avoid tripping or

overhead problems. Piping or tubing of insufficient mechanical strength
which is standing or hanging shall be protected from personnel traffic.
4.2.5.4
Surface temperature on any point shall not exceed 60 Deg C.
4.2.5.5
Very high standard of safety shall be built into the set with high degree
of redundancy.
4.2.6
Gearing
4.2.6.1
Gear Box
The gear and pinion teeth shall be case carburized and ground to an
accuracy class of 4 or higher to DIN Standards. The hardness of the
teeth shall not be less than 58 in the Rockwell Hardness Scale. The
overlap ratio shall be adequate to ensure a quiet operation. The gears
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shall be dynamically balanced before assembly.
A turbine directly driving the alternator with out a gear box in between
is also acceptable.
The gear box shall be capable of transmitting the maximum rating of
the set and be able to withstand 20% overspeed over a period of
minimum five (5) minutes. The gear box shall also be designed for the
short circuit condition of the generator. All bearings of the gear box
shall be readily renewable and shall be possible to inspect the bearings
and the gears readily without disturbing the shaft alignment.
Illuminated sight glasses shall be provided to inspect the lube oil drain
from each individual bearing. The gear box design shall be as per the
requirements of AGMA with service factor of 1.6.
The flexible couplings between the turbine and the gear box and
between the gear box and the generator shall be of reputed make. The
power rating of the coupling shall be at least equal to the turbine rated
power times the service factor in accordance with AGMA 514. Easily
removable coupling guard shall be placed over each of the exposed
coupling. Easily removable coupling guard shall be placed over each of
the exposed coupling. Couplings shall be designed to allow for removal
of any rotor without opening adjacent turbine casings. The housing
shall be provided with breather.
4.2.6.2
Barring Gear
The turbine shall be provided with a barring gear of mechanical type
driven by an A.C motor, to rotate the turbine and generator after
shutdown to prevent thermal distortion of the rotor. The barring gear
shall be capable of starting the rotor from rest and run it continuously
at low speeds. The barring gear shall be interlocked with the lubrication
system to prevent its operation without lubrication.
The system shall be capable of Auto & Manual engagement and automatic disengagement when the turbine speed goes above the normal
barring gear speed. The system shall also have facility for manual
turning in case of A.C supply failure. The turbine panel shall be provided
with necessary push buttons, alarms and switches for the operation of
the barring gear.
4.2.7
Base Frame
Suitable base frame either common or individual shall be provided for
the turbine, generator and the gear box. Provisions shall be made to
level each piece of equipment separately. The leveling pads shall be
accessible for field leveling after installations with the equipment
mounted and the base plate on the foundation.
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4.2.8
Turbine Starting Time

The turbine shall have the following starting time from stand still to full
load:
Cold start
Hot Start after 8 Hrs Shutdown
4.2.9
90 Minutes
20 Minutes
Turbine external piping

The turbine external piping shall include the piping and its accessories
as indicated in this tender document.
4.2.10
Piping, Valves and Specialties
4.2.10.1
General
The scope of work covered by this specification includes design,
engineering, supply, fabrication, delivery, unloading, handling at site,
erection, cleaning, testing, painting and commissioning of all piping
system complete with accessories within the terminal points indicated
elsewhere in the specification. The piping provided shall be complete in
all respects including valves, specialties, supports, thermal insulation
etc. as required.
4.2.10.1.1
The flow diagrams enclosed in the tender document are only intended
to indicate the general scope and nature of work to be carried out and
do not indicate the exact quantum of work to be carried out by the
SUPPLIER.
4.2.10.2
Scope of Supply
4.2.10.2.1
For all the piping systems included in SUPPLIERS scope of supply

shall include but not limited to:
a.
Pipes, Tubes, Headers and Manifolds.
b.
Bends, Elbows, Returns, Tees, Laterals, Crosses, Reduces,

Caps and Closures, Full & Half Couplings, Plugs, Sleeves &
Saddles, Stubs & Bosses, Reinforcement pads,
Unions,
Weldolets, Sockolets, Threadolets and other similar fittings.
c.
Valves
d.
Flanges, Gaskets and Fasteners.
e.
Complete assemblies of supports, anchors, guides, restraints
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etc, including welded attachments etc.
f.
Auxiliary Steel, Concrete Foundations, Pedestals etc. as

required for Hangers, Supports, Guides, Restraints, Anchors
etc.
g.
All Paints, Varnishes, Primers, Thinners and other Painting

Materials.
h.
Weather hoods for Pipes, Crossing Ceilings and Walls.
i.
valve
All instrument impulse piping and fittings upto the last root
j.
In case of temperature measurement points, SUPPLIERS

scope includes the supply of thermowell stubs with plugs.
k.
All approach platforms for all valves & instrument shall be

provided with proper stair case (Cage ladder shall not be
used).
4.2.10.2.2
SUPPLIER shall supply all necessary drains and vents including antiflash funnels as required for the safe and effective draining / venting of
the piping systems. It must be noted that the flow diagrams may not
indicate all the drains and vents that would be required. It is
SUPPLIER's responsibility to identify the requirements of drains and
vent whether the same have been shown in the flow diagrams or not
and supply the necessary pipework, fittings, hangers and supports etc.
The drains and vents indicated on the flow diagrams shall however be
regarded as minimum requirements. The drains and vents shall be led
upto the nearest floor drain in case of cold water systems and upto the
flash tank in case of steam and hot water systems, all as erected by the
Supplier.
4.2.10.2.3
Wherever uninsulated pipes cross walls or roofs, the necessary weather

hoods shall be supplied by the SUPPLIER as directed by OWNER.
Where required, SUPPLIER shall make openings in floors, walls,
gratings etc. for routing the pipes and provide proper finishing after
piping is erected.
4.2.10.3
Design Requirements
4.2.10.3.1
The equipment and work under this specification shall conform to the
following standards / codes:
a.
b.
Indian Boiler Regulations.

Indian Regulations of Inspector of Explosives.
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c.
Applicable Standards for Structural Steel.

i.
IS:800 :
ii.
IS:2062:
Codes of Practice for use of Structural

Steel in general Building Construction.
Structural Steel (Fusion Welding Quality)
d.
American National Standard ASME code for Power Piping " ASME B 31.1 and all other associated ASME Standards.
e.
Manufacturer's Standardization Society (MSS) USA Standard
Practices.
f.
American Society of Testing and Materials (ASTM)
Specifications.
g.
American Society of Mechanical Engineers (ASME) Codes.
h.
Pipe Fabrication Institute (PFI) USA, Standards.
i.
American Petroleum Institute Standards (API).
4.2.10.3.2
While routing piping, the following requirements shall be taken into

account by the SUPPLIER:
4.2.10.3.3
All piping shall be routed so as to avoid interference with other pipes

and their hangers and supports, electrical cable trays, ventilation
ducting, structural members, equipment etc. Adequate clearances shall
be ensured with respect to the above to accommodate insulation and
pipe movements.
4.2.10.3.4
All piping shall be grouped where practicable and shall be routed to

present a neat appearance.
4.2.10.3.5
The piping shall be arranged to provide clearance for the removal of

equipment requiring maintenance and for easy access to valves and
other piping accessories required for operation and maintenance.
4.2.10.3.6
Piping shall generally be routed above ground but where specifically

indicated / approved by the CONSULTANT, the pipes may be arranged
in trenches or buried. Pipes at working temperatures above the
ambient shall however not be buried.
4.2.10.3.7
Wherever pipes are to be bent, the bends shall be free from wrinkles
and bulges. The bends shall be made by cold bending.
4.2.10.3.8
Overhead piping shall have a minimum vertical clearance of 2.3 meters

above walkways and working areas and 8 meters above roadways
unless otherwise approved by the CONSULTANT.
4.2.10.3.9
Drains shall be provided at all low points and vent at all high points as
per actual layout regardless of whether the same have been shown in
the flow diagrams or not. Pipelines shall be sloped towards the drain
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points.
4.2.10.3.10 Provision shall be made while preparing piping layout to accept control
valves, flow measuring elements and any other on line speciality or
equipment supplied by others. Sufficient upstream and down stream
lengths shall be provided for flow measuring devices, control valves,
desuperheaters and other specialities as required by the Suppliers.
4.2.10.3.11 At all screwed valves and screwed connections on equipment, unions
shall be provided to facilitate disassembly. Likewise, unions shall also
be provided at suitable points on straight lengths of screwed pipelines.
4.2.10.3.12 All local instruments shall be located on pipelines as to render them
observable from the nearest available platforms and accessible for
maintenance.
4.2.10.3.13 Piping with operating temperatures above or below the ambient shall be
routed so as to provide adequate flexibility for the pipes.
4.2.10.3.14 Tap-off on main lines for field routed pipework, if not indicated on
OWNER's layout drawings, shall be suitably located by SUPPLIER to
suit the layout evolved by him.
4.2.10.3.15 All steam tracer lines shall be provided with expansion loops to take
care of differential expansion between the tracer and main line.
4.2.10.3.16 Stubs for instrumentation, drains, vents etc. wherever not located on
OWNER's piping layout drawings shall be suitably located by
SUPPLIER in accordance with the flow diagrams and layouts.
4.2.10.3.17 At all intersection joints, it is SUPPLIER's responsibility to design and
provide suitable reinforcements as per the applicable codes and
standards.
4.2.10.3.18 SUPPLIER is responsible for the complete design and engineering of
all supports, guides, restraints and anchors as required for the piping
systems erected by him. SUPPLIER's scope of work shall include but
not be limited to the location of all required hangers, supports, anchors,
restraints etc. and the design and detailed engineering of individual
components of the assemblies as also all associated steel work,
concrete pedestals, foundations, welded attachments to piping etc.
which form a part of hanger / support system. While the designs shall
conform to applicable codes and standards and shall be consistent with
inter national practice. Information contained in OWNER's drawings
regarding support location, type and detail etc. may be used for
guidance. This does not however relieve the SUPPLIER of his
responsibility for the design and engineering of the support system.
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4.2.10.3.19 The design and engineering of all temporary pipe work as required for
erection, cleaning, flushing, blowing out, testing and commissioning of
the piping systems installed by the SUPPLIER is the responsibility of
the SUPPLIER.
4.2.10.3.20 Pipelines of NB 40 size and below are regarded as field run piping. It is
SUPPLIERs responsibility to plan suitable layouts for these systems insite as per the requirements of this specification and in consultation
with OWNER
and/ or CONSULTANT. SUPPLIER shall prepare
isometric drawings indicating the layout of field run pipe work.
4.2.10.3.21 The SUPPLIER shall design and prepare all fabrication isometric
drawings for all IBR piping and NB 50 and above Non-IBR piping.
SUPPLIER shall also submit orthographic drawing with Bill of Material
for Non-IBR piping of
size NB 40 and below.
4.2.10.3.22 The SUPPLIER shall ensure that the design and reinforcement for
branches shall be calculated as per ASME B 31.1 and in addition, it has
to be checked for statutory requirement of Indian Boiler Regulations.
For piping reinforcement regulation 362 shall be used. The SUPPLIER
shall furnish the calculations for reinforcement for nozzle openings and
calculations for welded attachments carried out on the piping.
4.2.10.3.23 In case of branch welding for temperature above 250 deg C, no pad
shall be used for pressure reinforcement and external reinforcement.
Also the specific local stress calculation for safety valve stubs, anchor
stubs, etc for external loading shall be included as per ASME/ IBR to be
included.
4.2.10.3.24 All pipe to pipe joints shall be by butt welding only and no couplings
shall be used.
4.2.10.3.25 All flanges of pressure class 300 and less than 900 shall be of weld neck
type. For class 900 and above the flanges shall be WNRTJ type.
4.2.10.3.26 Pipe fittings like elbows, equal tees and reducers shall be as given
below:
a)
b)
For pipe size 65 NB and above shall be butt welded type.

For 50 NB and below shall be socket welded type.
4.2.10.3.27 Branch connections:

Equal Branch:
a)
b)
NB 65 & Above - BW equal tee as per ASME B 16.9

NB 50 & Below - SW equal tee as per ASME B 16.11
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Unequal Branch:
a.
Branch up to NB 50 SW half coupling as per ASME B 16.11 to

be used, for run pipe size NB 65 and above.
b.
Branch NB 65 and above, branch piping with suitable

reinforcement shall be used. However no reinforcement pads
shall be used for applications with design temperature
exceeding 300 Deg.C.
c.
Equal tee with reducing coupling or reducer to be used for run

size NB 50 and below.
d.
No branch welding shall be used for equal branch, and only

tees as per ASME B 16.9 or ASME B 16.11 to be used.
4.2.10.3.28
All pressure tappings for pressure applications above 40 Kg/Sq.Cm

shall be of size NB 25 with two root valves. For pressures 40
Kg/Sq.Cm and less the size shall be NB 15 with one root valve. For
temperature above 400C irrespective of pressures, the root valve size
shall be NB 25.
4.2.10.3.29
All thermowell boss shall be one (1) inch NPT.
4.2.10.3.30
Pipe Sizing and Layout
4.2.10.3.30.1 The design of the piping system shall be based on the ASME B31.1
code. In addition the statutory requirements of the IBR shall also be
taken care of wherever required. Flexibility analysis shall be made for
all piping systems with operating temperatures above 100 Deg.C.
The correct locations of hangers and supports, with as applicable
spring stiffnesses, shall be considered for the flexibility analysis.
Suitable expansion loops, restraints and anchors shall be provided so
as to ensure compliance with the applicable codes and to limit the
stress and reactions to within the allowable values.
4.2.10.3.30.2 All piping shall be sized considering the allowable velocity and
allowable pressure drop in the system. The indicative flow velocities
in pipes shall be limited to the following values. However, if the
available pressure drop is to be maintained, the piping system may
have to be selected even with a lower velocity than the minimum
indicated.
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Allowable velocities for sizing of pipes
Nominal pipe size
In mm
Saturated
steam
at
atmospheric pressure
Saturated steam at
0-1 kg/sq.cm.(g)
Saturated steam at
1.1 - 7 kg/sq.cm.(g)
Saturated steam over
7 kg/sq.cm.(g)
Superheated steam at
0 7 kg/sq.cm.(g)
Average velocity in Meter / Second

Below 50 mm 50 to 150mm 200
15 - 20
17 - 30
20 - 30
15 - 22
20 - 33
25 - 43
15 - 25
20 - 35
30 - 50
20 - 30
25 - 40
30 - 50
20 - 33
28 - 43
35 - 55
22 - 33
30 - 50
40 - 61
22 - 35
35 - 61
50 - 76
7
0.6
0.3
0.9
1.0
0.9
1.0
-
10 -15
0.4 - 0.6
0.6 - 0.9
0.7 - 1.3
0.3 - 0.4
1.2 - 2.1
1.5 - 2.1
1.5 - 2.4
1.0
1.3 - 2.0
18
0.6
0.6
0.9
0.4
1.5
1.8
1.5
1.2
1.8
1.5 - 2.4
2.1 - 2.4
sub -
7.1 35 kg/sq.cm.(g)
35.1 - 70 kg/sq.cm.(g)
Superheated steam over
70 kg/sq.cm.(g)
Compressed air
Pump suction, condensate
Pump suction, boiler feed
Pump suction, general service
Pump suction, viscous liquid
Pump discharge, condensate
Pump discharge, boiler feed
Pump discharge, general service
Pump discharge, viscous liquid
Header, general service under
2.0 kg/sq.cm.(g)
Header, general service
2.0 kg/sq.cm.(g) & up
Note :
10 - 15
mm &
above
15 - 20
10
- 0.9
- 1.2
- 1.2
- 1.0
0.7
0.9
1.5
0.5
2.2
2.4
2.4
1.4
2.4
The above velocity values are indicative and showing the maximum
limits of the flow velocity. Lower velocities may be selected if found
necessary to meet the allowable pressure drop across the pipes.
4.2.10.3.30.3 Drains at all low points and vents at all high points shall be provided.
4.2.10.3.30.4 All local instruments shall be located on pipelines so as to render them
observable from the nearest available platform.
4.2.10.3.30.5 All pipes of size NB 50 & below shall be schedule 80 thickness for all
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applications.
4.2.10.4
Materials
4.2.10.4.1
Pipe materials for various services and materials for fittings, flanges,
fasteners shall not be inferior to the specifications given below. All
piping except, for cooling water, raw water, safety and relief valve
exhausts, vents and air services shall be of seamless steel. For
cooling water, raw water and air services the piping could be of ERW.
4.2.10.4.2
Piping for services with metal temperatures equal to or greater

than
400 Deg.C and less than 510 Deg.C, 1 1/4% chromium,
1/2% molybdenum ferritic alloy steel seamless pipe as per ASTM A335 P-11 or P12. Piping for services with metal temperatures
higher than 510 Deg.C shall conform to the specifications of
ASTM A-335 P22 (2 chromium 1 molybdenum steel) or its
equivalent.
4.2.10.4.3
Piping for services at temperatures less than 400 Deg.C for steam,
boiler feed, condensate, drain piping etc., carbon steel piping as per
ASTM A-106 Grade B.
4.2.10.4.4
HP and LP chemical dosing system: Stainless Steel to SA 312 TP 304

specifications.
4.2.10.4.5
Other Services: Carbon Steel Piping as per ASTM A-106 Grade B.
4.2.10.4.6
For the safety valve exhaust piping, where the exhaust steam
temperature is less than 400 Deg.C, the piping material shall be IS
1239 Black Heavy Class for size upto NB 150 and as per IS 3589 for
size NB 200 and above.
4.2.10.4.7
For cooling water and raw water applications the piping material shall
be IS 1239 Black Heavy Class for size upto NB 150 and as per IS 3589
for size NB 200 and above.
4.2.10.4.8
For Service air applications the piping shall be GI pipes IS 1239.
4.2.10.4.9
For instrument air applications: IS 1239 GI pipes.
4.2.10.4.10
For piping system where IS1239 or 3589 pipes are used, the fittings
shall be as per A 234 as per ASME B 16.9 and ASME B16.11. All
flanges shall be as per ASME 16.5.
4.2.10.4.11
All materials shall be certified by proper material test certificates. All

material test certificates shall carry proper heat number or other
acceptable references to enable identification of the certificate with
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the material it purpose to certify. The heat number shall also be indicated on the material certified.
4.2.10.5
Fabrication and erection
4.2.10.5.1
Pipelines NB 50 mm and above size are deemed prefabricated.

SUPPLIER shall prepare necessary fabrication isometric drawings.
SUPPLIER's fabrication drawings shall take into account the
requirements of these specifications as also all applicable codes and
standards including statutory regulations such as Indian Boiler
Regulations. Fabrication and erection of piping systems NB 50 mm
and above size shall be as per SUPPLIERs fabrication drawings. In
case of systems requiring statutory clearance, fabrication and erection
shall commence only after the necessary clearance have been
obtained from the statutory authorities. SUPPLIER's fabrication
drawings including isometrics, if required, shall carry all details of
fabrication, welding etc. as may be required for obtaining the
necessary statutory clearances.
4.2.10.5.2
Piping NB 50 mm and above size shall be fully fabricated at

SUPPLIER's Works which shall be adequately equipped with the
required machinery, templates, gauges, tools and tackles etc.
Suppliers shall provide the details of the facilities available at their
works for fabrication of pipe work. The extent of fabrication at works
shall be such as to restrict field welding to circumferential line joints
alone. Further, the number of circumferential line joints to be
performed in the field shall be held to a minimum, limited by transport
considerations and erection constraints.
4.2.10.5.3
Pipelines having size NB 40 mm and below are deemed field run and
are hence fabricated in site. For bends, only socket weld elbows to
be used.
4.2.10.5.4
All welded attachments on pipelines shall be of same material as the

parent pipeline and shall be subjected to the same fabrication and
welding procedures as the associated piping.
4.2.10.5.5
The use of companion flanges to connect two pieces of pipe and the
use of odd or short pieces of pipe in making up long runs is prohibited
except as noted on OWNER's piping drawings.
4.2.10.5.6
Where welded pipe or fittings are used, longitudinal welds in adjoining

sections shall be staggered to a minimum of 90 degrees during
fabrication. All piping shall be fabricated true to lines and elevations
as indicated on the piping drawings.
4.2.10.5.7
Bends in seam welded pipe shall be oriented so that the seam is

positioned along the neutral axis.
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4.2.10.5.8
No welding shall be carried out on lined pipes.
4.2.10.5.9
Gas cutting for bolt holes including for U-clamp supports shall be
prohibited.
4.2.10.5.10
Cutting of standard elbows to odd angles as required per layouts, is

included in SUPPLIERS's scope.
4.2.10.5.11
Neither butt nor branch joints shall be closer than twice the pipe
diameter to any other joint in the same pipe except where "weldolet"
type fittings are used in which case the branch weld must be made to
the "weldolet".
4.2.10.5.12
All pipe bends, where the pipe diameter is NB 65 and above, shall
have a radius of five nominal pipe diameters unless otherwise
specified on the OWNER's piping drawings. The pipe bends shall be
true to angle and radius and shall maintain a true circular cross
section of pipe without deformity or undue stretching. Crimping of
pipes to form bends is not acceptable. Only cold bending which does
not require stress relieving operation may be carried out at site. Any
bending requiring preheating has to be done only at shop. Cold
bending shall be done using pipe bending machine (manual or
electric). Bends shall be free from wrinkles and bulges.
4.2.10.5.13
All welded branch connections shall be of suitable structural adequacy

by virtue of the intrinsic weld connection, reinforcing plates or rings or
material inherent in the branch. It is the SUPPLIERs responsibility to
provide reinforcement wherever necessary for branch connections.
Welded branch connections are not an acceptable alternative where
tees have been specified.
4.2.10.5.14
All threads on piping components shall be taper pipe threads as per

applicable standards. The nipples shall be fabricated by the
SUPPLIER at site as required.
4.2.10.5.15
The first circumferential weld joint after a pipe bend shall be after a
minimum straight length of two times the pipe diameter or 500 mm,
whichever is less.
4.2.10.5.16
No external support shall be welded on valves and specialities except

as provided by the Manufacturer.
4.2.10.5.17
Welding ends for butt-welding shall be as per Standard V-bevel with

an included angle of 75 degrees.
4.2.10.5.18
The SUPPLIER shall check the bench marks provided by the

OWNER. It shall be the SUPPLIER's responsibility to establish all
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layouts and levels using his own surveying instruments. The
SUPPLIER shall protect the bench mark and shall not remove or
disturb the bench mark without the approval of the OWNER.
4.2.10.5.19
All pipe flanges and contact surfaces shall be concentric with the axis
of the piping. All flanges and fittings shall be accurately machined
and drilled true to the template.
4.2.10.5.20
No welding / gas cutting shall be done locally to valves with soft

seating components in order to prevent distortion of the soft seats.
4.2.10.5.21
All stub and other attachment to be welded on the piping system shall
be carried out in the shop or in pre-fabrication yard and only in situ
butt welding alone will be carried out.
4.2.10.5.22
Welding and Non-destructive examination
4.2.10.5.23
a.
Welding, non-destructive examination of welded joints and

repair of weld defect areas shall conform to Clause
No.4.2.10.9, "Welding Specification for Fusion Welded Piping
Systems".
b.
Final welding of joints shall be undertaken only after the set

up of piping is fully checked with respect to layout drawings.
c.
At equipment terminal points, welding shall be carried out

after taking into account specific requirement and/or
recommendations of the equipment supplier.
Cleaning, flushing & blow-out

a.
All piping including valves and specialities shall be cleaned by

the SUPPLIER before and during erection to remove grease,
dirt, dust, scale and welding slag.
b.
Before erection all fabricated pipe work, assemblies, subassemblies, fittings and components etc. shall be thoroughly
cleaned internally and externally by blast cleaning or by power
driven wire brushes. The brushes shall be of the same or
similar material as the metal being cleaned.
c.
After erection, all steam, water and condensate lines shall be

mass flushed with water. The cleaning velocities in water and
condensate lines shall be 1.2 to 1.5 times the operating
velocities in the pipelines. Use may be made of standby
pumps wherever available for the purpose.
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4.2.10.5.24
d.
All compressed air pipework shall be cleaned by blowing

compressed air.
e.
All fuel oil, tight oil and lubricating oil lines shall be cleaned by
pickling. Alternately, these lines can be cleaned by steam
blowing subject to the timely availability of steam for this
purpose.
f.
All auxiliary steamlines shall be steam blown to effectively

remove scale and slag.
g.
For purposes of steam blowing, OWNER will make available

low pressure steam as required. It is SUPPLIER's responsibility
to install necessary temporary pipework for blowing and
remove the same after blowing and render all other assistance
to OWNER for carrying out the blowing operation.
h.
Electrical tracers of fuel oil lines shall be installed only after

steam blow out and cleaning of the FO lines. However, in the
event for any reason steam blow out has to be done after
installation of electrical tracing, then due care must be
exercised regarding steam temperature to be used for blow
out.
Inspection and testing

a.
On completion of erection, the inside of all pipes, valves,

fittings etc, shall be clean and free from loose scale and
foreign matter before subjecting the line to any test /
inspection.
b.
All piping systems shall be tested hydrostatically pneumatically

by the SUPPLIER after erection, at pressures given in the
applicable codes listed in data sheet or as given in the line
designation schedule. The test pressures shall be maintained
until all welded / flanged joints are inspected for leakage or
atleast for ten minutes.
c.
Mechanical equipment and pressure relieving devices should

be blanked-off or removed from the line during pressure
testing and control valves should be set in the open position
for the duration of the test.
d.
Orifice plates should not be erected until hydrostatic testing

and cleaning operations are completed.
e.
Lines having check valves should have the source of test
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pressure located on the upstream side.
f.
Expansion joints, instruments, filters and similar equipment for

which the maximum permissible cold test pressure is lower
than the hydrostatic test pressure applied to the system, shall
be removed or blanked off from the line before testing. The
SUPPLIER shall consult the OWNER / CONSULTANT for specific
guidance.
g.
Test pressure readings may be taken at the lowest point of the

system being tested provided the effect of static head is taken
into consideration.
h.
When conditions require a test pressure to be maintained for a

period of time, during which the testing medium in the system
might be subject to thermal expansion, provision may be
made for the relief of excess pressure thereto.
i.
After hydrostatic test any leaky joints shall be cut out and
repaired or completely replaced and test repeated until the
test has been satisfactorily passed. If any valve is found to be
leaking part the bonnet joint or steam gland packing,
SUPPLIER shall replace the gasket or gland packing and retest
the system to the satisfaction of OWNER.
j.
After completion of hydrostatic test, safety valves, orifice

plates etc., withheld for the hydrostatic tests, shall be installed
in an approved manner. Orifice plates shall however be
installed after completion of cleaning operations.
k.
Clean water at a temperature of not less than dew point or

10C whichever neither higher, nor exceeding 50C should be
used for hydrostatic test.
l.
The rate of pressure increase must not exceed 7 bars per
minute.
m. No one should be allowed near piping/equipment under test
when the test pressure is near the yield strength or when test
pressure over 35 bars are being applied. The pressure should
be lowered by 10% before inspection for the leaks.
n.
When draining the fluid, the pipelines should be vented slowly

to avoid excessive vacuum.
o.
A block valve is required on the line from the test pump to the
pipeline/equipment under test.
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4.2.10.5.25
p.
Only calibrated test gauges should be mounted in the upright

position. Pump discharge gauge must be visible to the pump
operator for the duration of the hydro test.
q.
The following test certificates shall be submitted to the

OWNER / CONSULTANT for review:
Material
a.
Chemical Composition
b.
Mechanical properties such as tensile, flattening, bending,

impact etc. as called for in the respective material specification
standards.
c.
Heat treatment in the case of pipes used for steam service.
d.
Dimensions.
e.
Hydrostatic Tests.
f.
IBR approved Certificates.
g.
NDT Reports.
h.
Reports on Visual Examination.
4.2.10.6
Hangers and supports
4.2.10.6.1
All equipment covered under this specification shall comply with all
currently applicable statutes, regulations and safety codes in the
locality where the equipment will be installed.
4.2.10.6.2
The SUPPLIER shall design, fabricate and furnish erection

drawings for all hangers, anchors, guides, clamps, stops and
supports, auxiliary structures, etc. required for the proper
installation and support of the piping.
4.2.10.6.3
It is desirable that supports should as far as practicable, be

arranged adjacent to the pipe joint.
4.2.10.6.4
Constant load hangers / spring hangers shall be provided wherever

necessary for critical piping systems such as main steam piping and
boiler feed delivery piping. The variation between hot and cold
loads, if variable spring hangers are used, shall not exceed 25%
of the rated load.
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4.2.10.6.5
Lugs and additional structural members should be suitably welded

to the pipes wherever necessary for hangers and restraints.
4.2.10.6.6
All bare pipes on racks and sleepers shall be clamped at intervals of

atleast 2 M.
4.2.10.6.7
Pipe clamps shall have a minimum thickness of 6 mm.
4.2.10.6.8
All rigid hangers shall provide a means for vertical adjustments

after erection.
4.2.10.6.9
All components of hangers which move relative to the pipe during

expansion shall be connected to the pipe clamps or lugs in such a
way that these parts are outside insulation.
4.2.10.6.10
Vertical pipes near tanks should be supported from pad plates

already provided on the tank shell.
4.2.10.6.11
All vertical lines shall be properly supported on the vertical run and
additionally provided with adequate number of lateral restraints
where the length of vertical run exceeds 5 M.
Except for small bore lines, pipes should not be supported from
brick walls.
4.2.10.6.12
4.2.10.6.13
In selecting position and type of hangers, SUPPLIER shall

endeavor to layout the work such that pipe load stress imposed on
the supporting steel are kept to minimum.
4.2.10.7
Valves
4.2.10.7.1
General Technical Requirement
All valves shall be suitable for the service conditions i.e. flow,
temperature and pressure, at which they are required to operate.
Valves performing similar duties and of same size, rating, material
and type shall be interchangeable with one another.
All rising stem valves shall be provided with back seat to permit
repacking (of glands) with valves in operation. All valves shall
preferably be of outside screw and yoke type.
All gate valves shall be of full-way type, when in the full open
position, the bore of the valve shall not be constricted by any part
of the gate.
All globe valves of size NB 50 and below shall be of integral type.
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Reconditioning of seating surface shall be possible without

removing the valve body from the line.
All valves shall be closed by rotating the hand wheel in the

clockwise direction when looking at the face of the hand wheel.
All valves shall have indicators or direction clearly marked on the

hand-wheel so that the valves opening / closing can be readily
determined.
Manually operated valves shall be provided with gear operator of

proven quality conforming to some Internationally accepted
Standard and Make if the torque required to operate the valve
exceed 13.8Kg.M.
Integral bypass valve shall be provided for valves of size NB 250

and above with pressure class rating 300, 400 and 600. Integral
bypass valve shall be forged gate or globe valve socket welded to
ASME B 16.11. The material of integral bypass valve shall be SA
105. The pipe used for mounting the integral bypass valve shall be
seamless to SA 106 Gr.B and minimum schedule 80 thickness.
Integral bypass valve shall be provided for valves of size NB 100

and above with pressure class rating 900 and above. Integral
bypass valve shall be forged gate or globe valve socket welded to
ASME B 16.11. The material of integral bypass valve shall be A
182 F22. The pipe used for mounting the integral bypass valve
shall be seamless to A 335 Gr.P22 and minimum schedule 80
thickness.
Bypass valves shall be motor operated, if the main valve is motor

operated.
When globe valves are provided as integral bypass valve, the

direction of flow of fluid must be marked on the body of the main
valve by stamping or embossing.
Integral bypass valve shall be supplied in the condition of As

welded with the main valve. The size of the valve shall be
minimum NB 25.
All globe valves shall be of vertical stem type. The construction of

globe valves shall facilitate for easy disassembly of the internals
(stem and disc).
The body, seat shall be inclined at such an angle from the vertical
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RAJASTHAN
so as to facilitate closing and to prevent chattering for check
valves.
Direction of flow shall be marked on the body of globe valve and

check valve.
Valves to be installed outside shall be required to have the stem

properly protected against atmospheric corrosion. All valve end
connections shall suitably be protected to prevent damage and
entry of dirt till erected.
The valves as well as all accessories shall be designed for easy

disassembly and maintenance. End to end dimensions shall be in
accordance to ASME B 16.10 or as per respective codes.
All valves under the purview of IBR shall be provided with IBR
certificate.
No asbestos or cadmium based material shall be used.

All sampling and root valves furnished shall be of integral body
bonnet type.
Y type globe valves are to be provided in drain and vent root

valves for more than or equal to class rating 900.
4.2.10.7.2
The materials, design and construction of all types of valves shall be

subject to the approval of the OWNER.
4.2.10.7.3
All gate valves with pressure seal bonnet and used for steam application
shall be provided with bonnet relief nipples, which will be connected to
the piping upstream or downstream of the valve depending on the
application.
4.2.10.7.4
The valves used in the vacuum service shall be gland sealed valves.
4.2.11
SPECIFICATION FOR GENERATOR
4.2.11.1
General
4.2.11.1.1
The generator shall be of closed air circuit water cooled (CACW) type
housed in IP 54 enclosure and driven by Steam turbine. The
necessary coupling bolts shall also form part of the supply. The
generator cooler shall be bottom mounted.
4.2.11.1.2
The nominal output of the unit shall be delivered at power factor from
0.8 PF. Generator shall be suitable for over loading of 110% for one
hour in every 12 hours and 150% for 30 seconds. Generator shall be
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able to operate at full load with a variation of 10% in voltage and
5% in frequency, with a continued voltage and frequency variation
of 10%. Excitation System shall have a control accuracy of 0.5%.
4.2.11.1.3
Generation voltage of the Unit shall be 11 kV, 3 Phase R, Y, B in

clockwise rotation.
4.2.11.1.4
The rating and specification of all the required accessories should be

suitable for 11 kV rated voltage.
4.2.11.1.5
The generator shall be suitable for operation over a range of voltage

variation as mentioned at 4.2.11.1.2 and operate satisfactorily under
system conditions stated above. The generator shall withstand on the
sudden application of maximum load or sudden loss of maximum load
and during momentary short circuits or sustained ground faults.
4.2.11.1.6
The generator shall be star connected and the main and neutral leads
shall be brought out of the stator frame for insertion of current
transformer for protection, metering and surge protection apparatus.
The generator shall be suitable for grounding through grounding
resistor. The SUPPLIER shall submit his proposal scheme to explain
housing arrangements of various current transformers.
4.2.11.1.7
The short circuit ratio (SCR) shall not be less than 0.5.
4.2.11.1.8
The generator shall be capable of withstanding without damage a

stator current of 150 % for a period of 30 seconds.
4.2.11.1.9
The generator shall be capable of withstanding without damage a

three phase, a line-to-line, a line-to-earth or two line-to-earth short
circuit for a period of three seconds, when operating at the rated
speed and with an excitation corresponding to a 5 % over voltage at
no load.
4.2.11.1.10
The maximum line charging capacity at rated voltage that can be

obtained without negative excitation and with stable operation shall
not be less than 35% of rated kVA.
4.2.11.1.11
The saturated rated direct axis sub transient reactance of generator

should not be less than 14% and not more than 18%.
4.2.11.1.12
The moment of inertia of the generator shall be so selected that it

meets the requirement of over speed.
4.2.11.1.13
The machine shall be capable of operating continuously on an

unbalanced system such that, with none of the phase current
exceeding the rated current, the ratio of the negative sequence
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component of current (I2) to the rated current (IN) does not exceed
0.1 and under fault conditions shall be capable of operation with the
product of (I2/IN)2 and time (t) in seconds not exceeding 15. In other
words, the machine should be designed so as to set the negative
sequence relay at 10% of the FLC especially while operating in
parallel with grid and system harmonics. (As per IEC in case of direct
cooled rotor winding maximum value of I2/In shall be 8% for
generator capacity less than 350MVA. Offered value is I2 = 10%).
4.2.11.1.14
In the design of generator, each part shall be so proportioned that the

maximum unit stresses therein resulting from any continuous
operating conditions specified shall not exceed one third of the yield
point or one fifth of the ultimate strength of the material whichever is
less.
4.2.11.1.15
The design of the generator structure and housing in which resonance

might become objectionable shall be so proportioned as to avoid the
possibility of resonance with higher rated frequency or multiple and
within the frequency variation.
4.2.11.1.16
The synchronous generator shall be designed and constructed so as

to facilitate easy repair / replacement of generator stator bars and
rotor pole winding at site without the necessity of going back to works
for repairs. Suitable provision shall be made in the base frame of the
Generator to facilitate easy removal of the rotor body by sliding it on
the bed plate.
4.2.11.1.17
The equipment offered shall be suitable for manual and auto control
from the machine control panels located in the control room.
4.2.11.1.18
The machine shall be suitable for low resistance earthing of the

neutral through neutral grounding resistor to limit the maximum earth
fault current to 100 A. The SUPPLIER shall indicate maximum
allowable duration for clearing fault inside generator under this
condition, to ensure that no damage occurs to the stator laminations.
4.2.11.2
Over Speed
4.2.11.2.1
The generator shall be designed so as to be capable of running at

over speed of the turbine, and all parts of the generator and other
equipment shall fully and safely withstand stresses resulting from over
speed operation. The rotor shall be tested at 1.2 times the rated
speed for two (2) minutes.
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4.2.11.3
Insulation
4.2.11.3.1
The offer shall give a full description of the windings offered both as
to the conductor and insulation. Detailed drawings shall be submitted
showing the arrangement of conductors and the thickness and nature
of all materials used both for insulation and mechanical protection in
the slots of the stator. The insulation, after completion of winding,
shall be VPI treated. The SUPPLIER shall furnish detailed write-ups
on treatment methods and procedures. The SUPPLIER shall also
furnish sufficient details on replacing,
servicing / repairing of
the generator, etc., in case of damage of the windings for VPI treated
windings, giving time factor involved.
4.2.11.3.2
Insulation of minimum `F ' class as specified in IEC specification of

the latest issue shall be used. The quality of the insulation must be
such that it is non-hygroscopic and no deterioration will take place
when subjected to the maximum, specified operating temperatures
nor must it be permanently injured when exposed to this feature as
the machine is to operate in a most tropical climate.
4.2.11.3.3
The end turns and coil connections shall have not less than full
insulation, equivalent to, and of the same construction as the coil
insulation in the stator slots. The coil and end turns shall be
impregnated with high grade insulating varnish. Provision shall be
made for tightly wedging the coils in the slots with the wedges which
shall not shrink or buckle. Care shall be exercised that the blocking of
air passages shall not occur.
4.2.11.3.4
The insulation and taping of the coils shall be such as to prevent

permanent injury from exposure to dampness to provide adequate
corona shielding, to withstand high temperatures without injury, to
prevent the entering of magnetic particles and to prevent formation of
zones.
4.2.11.4
Temperature Rise
4.2.11.4.1
Even though insulation of Class-F must be used, when operating

continuously at the maximum continuous rating at its rated 0.8 PF at
any working voltages (10%) and any frequency (5%) in the range
stipulated, the temperature rise shall not exceed Class-B limit at full
load. The SUPPLIER shall furnish temperature limit curve, for the
specified voltage & frequency range.
The bearing metal temperatures shall be detected by means of duplex
RTDs which shall be hooked upto the temperature scanner of the
control panel in the control room.
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4.2.11.4.2
Measurement of temperature shall be made as specified in IEC. The

maximum temperature of inlet air shall be taken as 43 Deg. C and the
maximum cooling water inlet temperature as 35 Deg. C. Temperature
rises shall be within the Class 'B' insulation Temperature rise limits.
4.2.11.4.3
The machine shall further be capable of operating continuously at full

load at 0.8 power factor at 11 kV at frequency 5% below normal,
satisfactorily and without undue heating.
4.2.11.4.4
The machine shall be capable of generating more kW than the rated

kW during operation of the machine from 0.8 lagging power factor to
unity PF but within the kVA rating of the machine.
4.2.11.5
Efficiency And Output Guarantees
4.2.11.5.1
The guaranteed overall efficiency of the generator at rated terminal

voltage and power factor at 75 Deg. C winding temperature, for the
percentage rated output of 100%, 75%, 50% and 25% shall be as
furnished. The efficiencies shall be determined by summation of
losses method as specified in the latest edition of IEC Publication No.
60034.2 or IS:4889 or equivalent standards. A tolerance will be
permitted in the determination of efficiencies as per IEC 60034.2.
4.2.11.5.2
The generator shall be guaranteed to be capable of giving its rated

output under the conditions described earlier without exceeding the
temperature rise as specified and without tolerance.
If the
temperatures are not within the specified limits, the vendor shall do
the necessary modifications to bring the temperature within the
prescribed limits before acceptance by the OWNER.
4.2.11.5.3
Guaranteed maximum temperature rise, for the stator and rotor

windings of the machine, above inlet temperature of the cooling air not
exceeding 45 Deg. C, when operating under rated load conditions shall
be as follows:
a)
Stator winding by embedded temperature detectors
85 C
b)
Rotor winding by resistance
90 C
4.2.11.6
4.2.11.6.1
Cooling
Generator shall be provided with adequate cooling systems based on
air circulation principle; complete with fans etc., depending on the
capacity of the units. The air passages in the stator, rotor fans,
coolers, etc., shall be designed to give a smooth and quick flow of air.
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The SUPPLIER should submit drawings in detail to show the cooling
system he proposes for the generator.
4.2.11.6.2
The SUPPLIER shall submit a detailed description of the cooling

system taking note of the class of insulation and maximum permissible
temperature, size of the unit. Justification for the adequacy shall be
given in the description of the cooling system.
4.2.11.6.3
Duplex type RTDs of minimum two numbers each shall be provided in

the cold and hot air passages.
4.2.11.6.4
The coolers shall be constructed out of admiralty brass and shall be

located clear off the stator on the bottom of the generator. Any leakage from the cooler shall be drained safely and properly and there shall
not be any chance of the cooling water finding its way to the
stator / rotor windings. Suitable moisture detector device shall be used
to detect and warn accidental leakage of water into the cooling air
stream. The coolers shall be designed for the shutoff head of the
cooling water pumps which will be about 5 Kg/Sq. cm(g) and tested for
two times the design pressure. The Cooler shall have isolating valves on
either side of the coolers (Upstream insolating v/v shall gate v/v and
down stream v/v shall be glove v/v) in cooling water line.
4.2.11.6.5
The cooler shall have ten percent plugging margin and shall be
sectionalised and designed to be suitable for shutting off section by
section for cleaning. The design shall be such that the generator can
deliver 100% of rated output with one section out of service.
4.2.11.7
Construction
4.2.11.7.1
All parts of generator shall be designed and constructed to safely

withstand maximum stresses during operation, over speed, short
circuit conditions, out of phase synchronizing. The pedestal of each
generator will be supported on the concrete foundation. All necessary
accessories like shims, dowel etc., shall be included in the scope. All
sole plates shall be interchangeable and suitably machined and
prepared for use at site with minimum amount of work.
4.2.11.7.2
The SUPPLIER shall give full particulars of the extent to which the
generator will be assembled for purpose of shipment and the work to
be done at site.
4.2.11.7.3
Pedestal bearings shall be provided for alternator for ease of

maintenance and shall be insulated from ground to prevent shaft
currents.
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4.2.11.7.4
After primer, the generator enclosure shall be given two coats of

epoxy paint, shade RAL 6024, Munsell Green.
4.2.11.8
Stator
The stator frame shall be a single piece to consist of a cylindrical
casing of welded plate construction, reinforced internally in the radial
and axial direction by stationary web plates making the entire frame
perfectly rigid. Light non magnetic alloy end shields shall be bolted to
the ends of the frame. Stator core shall be made up of segmental,
annealed punchings of high quality silicon steel to give minimum
electrical losses. The stator winding shall be of the double layer lap
type with Class 'F' insulation.
4.2.11.9
Rotor
4.2.11.9.1
The rotor construction shall be of cylindrical type. The generator rotor

shall be forged from a single piece ingot of special alloy steel carefully
heat treated to obtain excellent mechanical and magnetic properties.
A comprehensive series of ultrasonic examinations on the rotor body
shall be done to ensure that absolutely no inadmissible internal
failures are present and that the material meets the quality standards.
Rotors of four pole machines shall be made up of stacked laminations,
mounted on the shaft.
4.2.11.9.2
The design and construction of the rotor shall be in accordance with

the best modern practice and shall be fully described in the offer. The
factor of safety on yield point of material shall not be less than 1.5.
4.2.11.9.3
The insulation between turns of field winding shall consist of special

epoxy impregnated insulation and glass laminates shall be used for
the insulation to ground.
4.2.11.9.4
The rotor spider shall be of steel constructions. To facilitate

synchronization a shorted damper consisting of several round copper
bars in each pole head shall be provided.
4.2.11.9.5
The field poles shall be provided with adequate damper windings to

ensure stability under fault conditions and to meet (I22 x t) value of
15.
4.2.11.9.6
The rotor shall have pedestal bearings with oil cooling system so that
the end shields could be removed without disturbing the bearings for
inspection of the rotor/stator coils.
4.2.11.9.7
The assembly shall be dynamically balanced at shop at rated speed

and maximum speed.
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4.2.11.10
Earth Terminal
Two Nos. of Earth terminals shall be provided. The earth terminals
shall be designed to terminate Galvanized Iron conductors.
4.2.11.11
Speed Regulation
The moment of inertia of the alternator together with that of the
turbine shall be sufficient to ensure stability and the speed regulation
specified in the section covering turbine for full load rejection. The fly
wheel effect shall be incorporated in the alternator and turbines as
integral part and not added in the shape of separate weights, rings or
other means.
4.2.11.12
Shaft
4.2.11.12.1
The generator shaft shall be made of best quality forged alloy steel,
properly treated. The shaft shall be of ample size to operate at all
speed, including maximum over speed without vibration or distortion
and shall be able to withstand short circuit, heavy momentary
overloading and other stresses without damage. To prevent the flow
of harmful shaft currents damaging the bearings, suitable shaft
earthing shall be provided.
4.2.11.12.2
A complete set of test reports covering metallurgical strength,

crystallographic and ultrasonic tests performed in each shaft during
various stages of its manufacturing shall be furnished as also the
complete specifications of the shaft material forging and its design
parameters such as stresses and critical speed.
4.2.11.12.3
The generator shaft shall have a suitably shaped flange for coupling
to the turbine. The coupling flange shall be forged integral with the
shaft and the shaft coupling shall comply with the requirements of IEC
for shaft coupling. All coupling bolts, nut and nut guards for coupling
shall be included in the scope. The alignment limit for the shaft shall
be as per the latest NEMA / DIN standards.
4.2.11.13
Space heaters & RTDs
4.2.11.13.1
Suitably rated heaters shall be installed within the enclosure of the

generator. Location and the maximum temperature of the heaters
shall be such that no damage can be caused to any insulation.
Heaters shall be suitable for operation on a single phase 230 V AC
supply. A suitable double pole switch shall be mounted on or adjacent
to the stator frame for the manual switching of the heaters.
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4.2.11.13.2
Duplex type RTDs shall be provided in the following locations, which

shall be hooked up to the temperature scanners:
a)
b)
c)
d)
e)
Coil sides
Stator core
Bearings
Cold & Hot air circuits
Exciter Field
4.2.11.14
Excitation System
4.2.11.14.1
A brushless exciter shall be used and it shall be mounted on the out

board end of the generator frame.
A digital excitation regulation
system (with twin redundant auto and a manual back-up channel)
shall be provided to control the excitation of the synchronous
generator by varying the current applied to the field of the main
exciter. The digital auto excitation regulator shall be fed from
Permanent Magnet Generator (PMG) which shall be coupled at the
end of the generator shaft. Alternative arrangement shall be made
available for supply to the excitation regulator, to enable operation of
the set even during failure of PMG supply.
4.2.11.14.2
The excitation regulation system shall be of the state-of-the-art

microprocessor technology, high speed, fully tropicalised, automatic
excitation regulator. It should be complete with necessary cable
entries, adjusting rheostats, auto / manual control facilities, on / off
and raise / lower selector switches. The following minimum displays
shall be made available in the operator pad / digital display unit:
a)
b)
c)
d)
4.2.11.14.3
4
4
2
2
2
Nos. per phase.

Nos.
nos. each for DE and NDE
Nos. per stream.
Nos.
Exciter Field Current

Exciter Field Voltage
Generator Voltage
Generator Power Factor
The excitation system shall be provided with the following minimum

features:
a)
b)
c)
d)
shutdown
e)
f)
g)
h)
Generator voltage control

Auto power factor control
Field current control
Excitation buildup during startup and field suppression
Limiter for the under excited range & delayed limiter for
overexcited range
PT fuse failure detection and auto changeover
Diode failure supervision
Stator current limitation for lagging & leading loads
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i)
j)
k)
4.2.11.14.4
Rotor current limiter

Load angle limiter
Volts / Hz limiter
The system offered shall have the following facilities:

a)
f)
g)
Two independent auto cum manual channels. Each channel

will have its own thyristor / power bridge arrangement.
Back-up manual mode for testing / emergency operations
Follow-on mode for each operation to have bumpless transfer
between auto channel and manual channel
Audible annunciation for internal faults and for channel
changeover with accept provisions
RS485 Communication port with MODBUS protocol for
configuration / setting option from PC / DCS
Digital display & keypad, for front panel operation
All necessary software for interfacing the system with PC /
h)
Self diagnostic facility
b)
c)
d)
e)
DCS
4.2.11.14.5
AVR panel shall have a height of 2200 mm, including base channel of
100 mm.
4.2.11.15
Accessory Equipment
4.2.11.15.1
Main power terminal boxes shall be fully phase segregated and

suitable for the envisaged type of connection arrangement.
4.2.11.15.2
The generator shall be provided with stator temperature sensors

installed in the stator winding with leads and shall be brought out to
the terminal boxes. RTDs shall be provided for hooking up to the
temperature scanner in the control panel. Space heaters for anticondensation shall also be provided. Necessary vibration transducer,
displacement transducers with transmitters shall be provided which
shall be hooked up to the control panel in the control room.
4.2.11.15.3
The SUPPLIER may propose to accommodate auxiliary equipment like

current transformers, potential transformers, lightning arrestors and
surge capacitors in the generator terminal boxes, if available as their
standard practice. Requirements of such equipment shall be in
accordance with IS / IEC standards and the specifications furnished
elsewhere in this document.
4.2.11.15.4
Terminal cubicles, if used for single core cable connections, shall be

provided with non-magnetic type gland plates.
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4.2.11.16
Protective Devices
4.2.11.16.1
The protective devices as listed under the topic Protection, Metering

and Control cubicles and the schematic diagram shall be offered.
4.2.11.16.2
The SUPPLIER shall note the system conditions like voltage,

frequency variations, SC level at the location of the proposed
generating units and offer suitable generating equipment with
necessary accessories required for satisfactory working of the
generating units.
4.2.11.17
4.2.11.17.1
4.2.11.17.2
Tests
The generator shall be completely assembled at works and type tests
as specified below shall be conducted on the assembled unit and
auxiliaries as per the latest edition of IS / IEC. Detailed test reports
shall be furnished.
Tests
The following tests shall be carried out on the machine:
a)
Measurement of DC resistance of stator and rotor windings.
b)
Insulation resistance of stator winding (before and after high

voltage tests), rotor winding, bearings and embedded
temperature detectors.
c)
High voltage test of stator and rotor windings at industrial

frequency.
d)
Phase sequence.
e)
Determination of open-circuit characteristics.
f)
Determination of short-circuit characteristics.
g)
Over speed at 120% for 2 minutes and vibration there of.
h)
Pressure test on coolers for close - circuit cooling.
i)
Determination of efficiency by separation of losses methods.
j)
Vibration.
k)
Impedance test of the rotor winding.
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l)
Stator winding capacitance and tan delta measurement.
m)
Measurement of Shaft Voltage
n)
Polarization Index
o)
Wave form recording.
p)
Shaft vibration measurement
q)
Momentary over current test for 150% of rated current for 30

Secs.
r)
Harmonics
s)
Voltage balance test
t)
Air gap
u)
Noise test
v)
Temperature rise test at iron loss, copper loss with equivalent

method including exciter.
In addition to the routine test, the following type tests shall also be
carried out, if the generator manufacturer had not carried out the
type tests on similar machine (kW rating & speed):
4.2.11.17.3
a)
Mechanical run test for temperature rise.
b)
Temperature rise test of windings.
c)
Instantaneous Three (3) phase short circuit test at rated speed

and 30% voltage.
d)
Determination of reactances and time constants.
Tests on Exciters
a)
High voltage test
b)
Measurement of resistances
c)
Measurement of insulation resistance
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4.2.11.17.4
Tests at Site
Site tests for generator shall include the following:
Mechanical run and vibration measurement.
Measurement of stator and rotor winding insulation resistance.
Over speed test
Measurement of shaft voltage
Measurement of stator and rotor winding resistance
Phase sequence test before excitation (with residual voltage) and
after excitation
Open circuit and short circuit test
Load acceptance and rejection test at selected loads from no load to
full load.
Overall response of machine and excitation system
Adjustment of excitation regulator parameters
Synchronising test
Dynamic checking of all protective functions
Checking and commissioning of various other auxiliary equipment.
Function of RTD and its circuits
Pressure tests on coolers
Tests on other equipment like CTs, PTs, LAs, shall comply with the
routine tests etc., as per relevant standards.
Test reports for all the type tests on the generator, CTs, PTs, & LAs
carried out on similar equipment already supplied shall be furnished
for approval.
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4.2.12
SPECIFICATION
FOR
CONTROL CUBICLES.
4.2.12.1
Scope
PROTECTION,
METERING,
This specification covers the requirements of protection, metering,

synchronising and control cubicles and the associated equipment
mounted therein.
4.2.12.2
Codes and Standards
4.2.12.2.1
The design, manufacture and performance of equipment covered by

this specification shall conform to the relevant Indian Standards and
Codes. Where Indian Standards are not available, they shall conform
to relevant British, IEC and American Standards.
4.2.12.2.2
The equipment shall conform to following standards in particular.

IS:1248
Direct acting electrical indicating instruments.
IS:2705
Auxiliary current transformers.
IS:3156
Auxiliary potential transformers.
IS:3202
Code of practice for climate proofing of

electrical equipment.
IS:3231
Electrical relays for power system protection.
IS:5578
IS:11353
4.2.12.3
& -
Marking and arrangement of switchgear, busbars, main connection and aux. wiring.
IEC:44
Instrument Transformers
IEC:185
Current Transformers
IEC:186
Potential Transformers
IEC:255
Electrical Relays
IEC:1036
Static Meters
Scope of Work
The scope of design, manufacture, testing and supply of equipment
covered under this specification shall include but not necessarily be
limited to the following:
4.2.12.3.1
Design,
specifications.
engineering
and
fabrication
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of
cubicles
as
per
the

RAJASTHAN
4.2.12.3.2
Supply and mounting of all the equipment and auxiliary equipment

like auxiliary relays, test switches, test blocks, plugs, etc., necessary
for satisfactory functioning of the control and protection system.
4.2.12.3.3
The protection system shall be provided with communication ports /

auxiliary contacts to integrate the system with the PURCHASERs
DCS /ECS for the purpose of Data Acquisition.
4.2.12.3.4
All internal wiring between all equipment upto the terminal blocks and
the interpanel wiring.
4.2.12.3.5
Preparation and furnishing of all data / drawings / documents as per

the requirement and specifications.
4.2.12.3.6
Testing at works of the cubicles and the mounted equipment.
4.2.12.4
Design Requirement
4.2.12.4.1
Constructional Features
4.2.12.4.1.1
The cubicles shall be of 'Simplex' type, with height of 2200 mm,

including 100 mm base channel.
4.2.12.4.1.2
Cubicles shall be sheet steel enclosed dust and vermin proof type.
Cubicles shall be floor mounting, free standing, formed on a
framework of standard sections. The enclosure shall be of cold rolled
sheet of minimum 3 mm for front and back and 2.5 mm thick for rest.
The supporting structure shall be so designed to form a rigid
structure.
4.2.12.4.1.3
All doors and openings shall be provided with neoprene gaskets.
4.2.12.4.1.4
The cubicles shall be suitable to be installed on a base frame supplied

in one piece along with foundation bolts. Amply dimensioned oblong
holes shall be provided at the bottom of all the cubicles for their
installation on base frame, in addition the cubicles shall have an
additional base channel at the bottom with smooth surface. Anti
vibration type mounting shall be provided.
4.2.12.4.1.5
A suitable removable undrilled gland plate shall be provided for cable

entry from bottom.
4.2.12.4.1.6
The degree of protection of the cubicles shall be IP 42.
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4.2.12.4.2
Mounting
4.2.12.4.2.1
All instrument and control gears and relays shall be mounted on the
front. All equipment shall be flush or semi-flush type.
4.2.12.4.2.2
Checking and removal of components shall be possible without

disturbing the adjacent equipment. It shall be possible to set all the
measuring relays insitu. All mounted equipment inside the cubicles
shall have identification tags of self sticking engraved tapes; in
addition identification numbers shall be painted on cubicle wall to give
permanent identification mark. The mounting of terminal blocks and
any other auxiliary equipment such as transducers, interposing CTs
etc. shall be done in such a way so as to be readily accessible but
without impeding the access to internal wiring and components.
4.2.12.4.2.3
The centre line of switches, push buttons and indicating lamps shall
be not less than 750 mm from the bottom of the cubicle. The centre
line of relays and meters shall not be less than 450 mm from bottom
of the cubicle. All switches, push buttons, indicating lamps, relays,
etc. shall be neatly arranged in a matching manner.
4.2.12.4.2.4
The cubicle shall be matched with other cubicles in dimension, colour

and mimic.
4.2.12.4.3
Type
All the cubicles shall be of simplex type and shall consist of vertical
front panels with mounted equipment and rear wiring access. Doors
shall have handles with locking facility.
4.2.12.4.4
Wiring
4.2.12.4.4.1
All wiring shall be done with PVC insulated, 1.1 kV grade, single-core
multi strands (minimum 3 strands) annealed copper conductors
suitable for temperature and humidity specified. The cross section of
the wires for voltage, current and control circuits shall be 2.5 Sq. mm
and that for the alarm circuits shall be 1.5 sq. mm. The wires shall be
vermin proof and shall be laid in plastic gutters.
4.2.12.4.4.2
Each wire shall be identified at both ends with wire numbers by

means of PVC ferrules. Colour coding for the wires shall be as per
IS:375. Each cable shall be identified with aluminium tags.
4.2.12.4.4.3
The terminal boards shall be set at 45 Deg. to the side panels for easy
access. Minimum 20% spare terminals shall be provided on the
cubicles.
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4.2.12.4.4.4
The terminals shall be suitable to receive crimped wires to give

positive connection. All terminals shall be properly shrouded against
accidental contact. Sufficient terminals shall be provided so that not
more than one wire is connected to each terminal.
4.2.12.4.4.5
The terminal blocks shall 1.1KV, 10 amps rated, one piece moulded
complete with insulated barriers, stud type terminals, washers, nuts
and lock nuts and identification strips.
4.2.12.4.4.6
Terminal blocks for the CT and PT secondary leads shall be provided

with test links and isolation facilities. Also CT secondary leads shall be
provided with short circuiting and earthing links.
4.2.12.4.5
Painting
4.2.12.4.5.1
All metal surface shall be thoroughly cleaned and degreased to

remove mill scale, rust, grease and dirt. Fabricated structure shall be
pickled and then rinsed to remove any trace of acid. The under
surface shall be prepared by applying a coat of phosphate paint and a
coat of yellow zinc chromate primer. The under surface shall be made
free from all imperfections before undertaking finishing coat.
4.2.12.4.5.2
After preparation of the under surface, the relay and control panel
shall be spray painted with two coats of final paint. Colour shade of
final paint shall be pebble grey, shade RAL 7032 with glossy finish and
shall be duly approved by the PURCHASER before final painting is
done. The finished panel shall be dried in stoving oven in dust free
atmosphere. Panel finish shall be free from imperfections like pin
holes, orange peels, run off paint etc. The vendor shall furnish
painting procedure details for approval by the PURCHASER /
CONSULTANT.
4.2.12.4.5.3
All unpainted steel parts shall be cadmium plated or suitably treated

to prevent rust corrosion. If these parts are moving element then
these shall be greased.
4.2.12.4.6
Cubicle Illumination
4.2.12.4.6.1
Compact fluorescent lamps working on 240 V AC, operated by door

switches shall be provided for internal cubicle illumination, in each
panel.
4.2.12.4.6.2
A 240V, 1-Phase, 5 Amp., 3 Pin Socket shall be provided in the panel

corridor or interior of each cubicle with on-off switch for connection of
hand lamps. This socket shall be metal clad type with a spring loaded
flap.
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4.2.12.4.7
Earthing
4.2.12.4.7.1
A continuous 25 mm x 3 mm copper (tinned) or equivalent aluminium

/ GI earth bus shall be provided running along the full lengths of the
cubicles. Suitable arrangement shall be provided at the two ends for
connection to the plant earthing system.
4.2.12.4.7.2
Each cubicle and the equipment mounted on each cubicle shall be

securely connected to the earth bus. For this purpose, the earth wire
shall be looped from equipment to equipment and both ends of the
earth wire shall be connected to the earth bus.
4.2.12.4.8
Space Heaters
Panel space heaters shall operate off 240 V AC and shall be supplied
complete with on-off switch, fuse and thermostat. A common
thermostat shall be provided for the entire panel. The thermostat
shall maintain the internal temperature above the ambient
temperature to prevent moisture condensation.
4.2.12.4.9
Mimic
4.2.12.4.9.1
Mimic diagram shall be provided on cubicles. Mimic diagram shall be

screwed on to the cubicles and shall be made of anodised aluminium
or plastic of approved fast colour. The mimic shall be 10 mm wide for
horizontal run and 5 mm wide for vertical run.
4.2.12.4.9.2
Semaphore indicators used for isolator positions, they shall be so

mounted in the mimic that isolator (or breaker) closed position shall
complete the continuity of the mimic. The mimic diagram shall
incorporate red and green lamps for isolator position indication and
controlling switches with indicating lamps for breakers.
4.2.12.4.9.3
Alternatively, automatic semaphore indicators for isolators and built in

hand operated semaphore and position indicating lamps for breaker
control switches may be provided.
4.2.12.4.9.4
a)
The lamps will remain steady where the hand operated

semaphore position correspond with the breaker position.
b)
The lamps shall flicker with a time delayed alarm if the

semaphore position does not correspond with the breaker
position.
The colours for various voltages in the mimic diagram shall be as

below.
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Voltage Level
Mimic Colour
Shade as per IS:5
EHV
Signal Red
537
11 kV
Canary Yellow
309
4.2.12.4.10 Ten (10) nos. of illuminated push buttons with covers along
with master trip relay (86) with a minimum of 2NO + 2NC
(Model VAJH13 or equivalent) shall be wired up to TBs for
load shedding purpose.
4.2.12.4.11
Equipment Specifications
4.2.12.4.11.1
Transducers
Transducers with output of (4-20) mA shall be arranged by the
BIDDER, wherever required. Transducers for voltage, current,
frequency, Megawatt, MVA, MVAR and power factor as indicated in
the tender single line diagram shall also be provided.
4.2.12.4.11.2
Indicating Lamps
These shall be switchboard type of low power consumption, LED
cluster type lamps and shall be supplied complete with necessary
resistors. Lamps shall be provided with screwed translucent covers
to diffuse light. The lamp covers shall preferably be unbreakable,
moulded, heat resistant material and shall be provided with
chromium plated bezels.
4.2.12.4.11.3
Control Switches
4.2.12.4.11.3.1
All control switches shall be rotary, back connected type

having cam operation contact mechanism. Phosphor bronze
contacts shall be used on switches.
4.2.12.4.11.3.2
The handle of control switches used for circuit breaker

operation shall turn clockwise for closing and anti-clockwise
for tripping and shall be spring return to neutral from close /
trip with lost motion device. Each switch shall be provided
with external red and green indicating lamps.
4.2.12.4.11.3.3
The no. of poles in any selector switch shall be

restricted to eight (8) numbers, by providing
multiplication contactors / relays to meet scheme
requirement.
4.2.12.4.11.4
Control MCBs
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Control MCBs shall generally be mounted on the top half of the

cubicles. All MCBs shall be provided with suitable identification
labels.
4.2.12.4.11.5
Annunciation
Following audible alarm / annunciations, with distinct tones shall be
provided for
a)
b)
c)
Protective relay operated - Alarm

Protective relay operated - Trip
DC failure with AC as auxiliary supply
The scheme shall include necessary acknowledge &

buttons.
reset push
The annunciator shall have first-in facility.

4.2.12.4.11.6
Relays
4.2.12.4.11.6.1
All relays shall be switchboard pattern, back connected draw out

type suitable for flush mounting and fitted with dust tight
covers.
4.2.12.4.11.6.2
A set of test block and test lead for necessary secondary

injection tests shall be included. All relays in draw out cases
shall have suitable spring loaded contacts for inserting test
block.
4.2.12.4.11.6.3
The rating of the auxiliary contacts shall not be less than

5 amp at 240 V AC and 15 amp for 110 V DC.
4.2.12.4.11.6.4
Relay terminals to be of stud type / self-locking plug-in type.
4.2.12.4.11.6.5
The detailed list of protective relays for each cubicle is listed

elsewhere. The relays shall be supplied with the necessary
accessories to make the system complete.
4.2.12.4.11.7
Clock, Name and Identity Plates
4.2.12.4.11.7.1
One No. digital clock with minimum 50 mm height digital

display shall be fitted in an attractive position on the complete
cubicle assembly. The clock shall have a hand operated device
for adjustment of clock hands from front.
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4.2.12.4.11.7.2
All instruments, relays and other electrical devices mounted on

the cubicle shall be provided with plates bearing the
manufacturer's name, serial number and the electrical rating
data.
4.2.12.4.11.7.3
Reverse engraved name plate at least 10 mm wide bearing

suitable identification marks shall be fixed in the interior of the
switchboard, at the test blocks, at the MCB blocks and at the
cable terminals. Similar plates shall be fixed to the exterior of
the switchboard in appropriate places to indicate the functions
of control switches, push buttons, lamp and other equipment
not incorporated in the mimic diagram.
4.2.12.4.11.7.4
Name plates bearing respective circuit designation of 50 mm

width etched in 40 mm high letters shall be mounted on the top
of the front side and back side of each cubicles shall be
supplied and fixed in such a way that these can be removed
and refitted when desired.
4.2.12.4.11.7.5
Each equipment shall have a rust proof metal tag permanently

attached to it with the tag number.
4.2.12.4.11.8
Auxiliary PT and CTs
4.2.12.4.11.8.1
Necessary auxiliary potential transformers for open delta

potential polarisation and auxiliary current transformers,
wherever required, shall be included in supply.
4.2.12.4.11.8.2
Auxiliary CTs required for summation of two or more feeders

and auxiliary PTs required for galvanic isolation of different
synchronising inputs shall be included.
4.2.12.4.11.8.3
The instrument transformers shall have the following accuracy

class
Potential Transformer
Measurement
Protection
4.2.12.4.11.8
0.2
3P
Current Transformer
0.2S
5P20 & PS
Synchronization
Panel mounted synchronising equipment complete with double
voltage & frequency meters, synchroscope, synchronising check
and guard relays, no voltage relays, synchronising cut off
switch, lamps, breaker selection switches for all the breakers to
be synchronised, auto synchroniser with output for governor &
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AVR controls etc. shall be provided. The TG shall be considered
for 15 nos. breaker synchronisation including back
synchronisation with the grid, PLC based synchronization
scheme is to be offered.
4.2.12.4.11.9
Trivector / power measurement metering
4.2.12.4.11.9.1
Two (2) numbers of integrating meters of the Trivector or

equivalent types capable of indicating all phase instantaneous
parameters and recording kWH, kVARH and kVAH directly shall
be provided. They shall be capable of record / display of
harmonic data upto 51st harmonics.
4.2.12.4.11.9.2
These should be suitable for 3 phase, 4 wire 50 Hz circuits with

unbalanced loading and with two sets of elements connected to
current and potential transformers of specified ratio.
4.2.12.4.11.9.3
The meters shall be of digital type, class 0.2 or better with

communication port, RS485 interface - MODBUS RTU protocol,
for hooking up to PC and plant DCS. Necessary softwares for
downloading of stored parameters and analysis shall also be
supplied. Each of these meter shall be provided with a minimum
of three analog out puts in addition to soft signal at modbus.
4.2.12.4.11.9.4
Meters for frequency, power factor and MW should be of digital

type.
4.2.12.4.11.10
Temperature scanners
Microprocessor based temperature scanner shall be provided to
process the signals from RTDs of the generator windings /
bearings / cooling air paths. The scanner shall have scrolling
display with output relays for High-Alarm and High-Trip signals,
individually for all channels. It shall be possible to set the
parameters through membrane type keypad. Resolution for the
complete range shall be not less than 0.1 C with accuracy of
better than 1%. The scanner shall be provided with RS 485
communication port, suitable for MODBUS RTU protocol.
4.2.12.4.12
Details of Protective Relays
4.2.12.4.12.1
Protection of the generator shall be achieved through

microprocessor based, composite protective digital relays, with
one as primary and the other as back-up. Both the relays shall
include the following minimum protective functions:
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4.2.12.4.12.1.1
Generator
-
4.2.12.4.12.1.2
Generator transformer protection

-
4.2.12.4.12.1.3
Accidental energisation protection

Over & Under voltage (1st and 2nd stage)
Under & Over frequency(1st , 2nd & 3rd stage)
Field failure
Reverse Power
Low forward power
Voltage restrained over current
Generator differential
Stator standby earth fault protection (95% and 100%)
Local breaker back-up / struck-up
Negative sequence
Voltage balance / PT fuse failure
Over fluxing Protection
Pole slipping protection
IDMT overcurrent (1st and 2nd stage)
Instantaneous overcurrent
PT fuse supervision
Restricted earth fault protection
Thermal Overload
Rotor earth Fault
Differential protection
Restricted earth fault protection
Directional overcurrent and earth fault
Over fluxing
Oil and winding temperature
Oil Level
Buchloz relay
Alarm and trip for all above
Overall
- Overall differential protection
4.2.12.4.12.2
The SUPPLIER shall make available a set of output contact,

duly configured for one stage of the following voltage /
frequency function:
-
Over voltage
Over frequency
Under voltage
Under frequency
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4.2.12.4.12.3
Both the generator and generator transformer protection relays

shall have the following minimum features:
-
4.2.12.4.12.4
Additional discrete relays shall be provided for the following

main functions, even if the same is available in the composite
relays:
-
4.2.12.4.12.5
Communication port, RJ45 interface IEC61850

protocol, for hooking-up to plant DCS, for down loading
& parameter settings
Necessary software, for processing of data.
Event recording facility, for a minimum of 32 events.
Disturbance recording & analysis facility
All the event, disturbance and the fault records shall be
stored in the internal memory of the generator
protection relays and shall be capable of being
downloaded when required.
Self diagnostic facility
Rotor Earth Fault protection

95% Stator earth fault relay to cover 95% of winding
protection with
necessary current and voltage
operated relays.
100% stator earth fault protection with third harmonic
over voltage principle may be provided based on the
system and generator suitability along with minimum
setting available in the relay for the above function
Static / microprocessor based reverse power relay, with
settable range of 0.5% connected from Class 0.2 core
CT
Additional discrete relays shall also be provided for the

following auxiliary functions:
-
Master trip relays

Trip circuit supervision relays for each trip coil of the
tandem circuit
breaker and all master trip relays
DC supply failure relay
Auxiliary relays, if required
Rotor earth fault relay
Check synchronization relay
Guard relay
No volt relay
Dead bus relay
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4.2.12.4.12.6
Discrete relay for overall differential protection shall be

envisaged. This relay shall be of numerical type suitable for
three winding transformer (three sets of CT inputs).
4.2.12.4.12.7
Discrete relay for grid islanding purpose shall be envisaged.

This shall consist of the following relays:
-
Vector surge relay

Master trip relay
Trip circuit supervision relays
Generator and generator transformer shall provided with

following signal through kWT for plant DCS:
-
Current
Power factor
MW
MVAR
MVA
Frequency
Voltage
In addition, following for governor:

-
MW
MVAR
4.2.12.4.12.8
A common PC, loaded with necessary software and interface

units to receive signals from RS 485 and RS 232 communication
ports shall be supplied, along with A4 LaserJet Colour printer. PC
shall be with minimum configuration of Intel I7 processor with
CPU speed 2.933 GHz, FSB 2933 MHz, Cache 18 MB, 8GB RAM
DDR3 / 500 GB SATA @ / 15000 RPM / No-FDD/DVD-RW/ 32 X
combo / 21 TFT monitor with 4 USB and 1 serial ports, LAN
network interface, Keyboard, Mouse, 1 parallel port. The PC and
Printer shall be supplied with latest configuration as available in
the market. The PC shall also be loaded with complete Software
required for interfacing, downloading, uploading, programming
with relays and meters.
4.2.12.4.12.9
Connection configuration of the protective relays shall be as

shown in the enclosed Electrical Schematic Diagram.
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4.2.13
SPECIFICATION FOR SEGREGATED PHASE BUSDUCT,

NGTR / LAVT CUBICLES AND SEALED TVM CUBICLE
4.2.13.1
Segregated Phase Bus ducts
4.2.13.1.1
Standards
The equipment covered under this specification shall unless
otherwise stated be designed, constructed and tested in
accordance with latest revisions of relevant Indian Standards.
IS:2099
HV Porcelain Bushing
IS:2544
Porcelain Post Insulator
IS:2629
Hot Dip Galvanising
IS:5082
Bus conductor material
IS:6005
Phosphate treatment of Iron and Steel
4.2.13.1.2
Design Particulars
Continuous Current Rating
2000Amp
Rated Voltage Class
12 kV
System Voltage
11 kV, Resistance Earthed
BIL (kV Peak)
75
dry :
28
Short time rating for 3 sec (kA rms)
40
Dynamic Rating (kA Peak)
100
One minute power frequency

withstand voltage (kV rms)
Maximum hot spot temperature of :

busbar at rated current
85 Deg. C
Maximum hot spot temperature of :

enclosure at rated current
70 Deg. C
Busbar Material
Copper
Enclosure
Aluminium Alloy
Porcelain
Insulators :
Type
Voltage (Rated / One min. power :

frequency)
(kV rms)
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Impulse withstand voltage
(kV Peak)
75 kV
Earthing
Generator neutral
through resistance
4.2.13.1.3
earthed
Definition
A segregated phase busduct is one in which phase conductor
with its associated connections, joints, accessories and
insulating supports are enclosed in an earthed metal housing
with either metal or insulation barrier between the phases. If
the BIDDER offers insulated barriers, the type, composition,
electrical withstand characteristics and thickness of the
insulating material used shall be indicated by the BIDDER in
his bid and shall be subject to the PURCHASER's approval.
The 11 kV busduct shall connect the generator to generator
transformer to 11 kV generator tandem circuit breaker panel,
generator & NGTR Cubicle with tap off to LAVT Cubicle with
necessary bends, joints, wall through busducts, phase cross
over chambers, disconnecting links and tap-off busducts. The
fault level along with the distance of busduct to be considered
shall be as follows:
Busduct
STC
Generator to generator transformer
40 kA for 3 Sec
Generator Transformer to CB panel

Tap Off for LAVT Panel
40 KA for 3 Sec
40 kA for 3 Sec
Generator to Star Point formation
40 kA for 3 Sec
Star Point to NGTR Panel
40 kA for 3 Sec
4.2.13.1.4
Dedicated CTs and PTs of rating furnished in the tender single

line diagram shall be provided in the busduct for open access
metering. Suitable provision for sealing of this chamber and the
junction boxes shall be made available. CT for future use as
spare shall also be envisaged as indicated in the tender
single line diagram.
4.2.13.1.5
General Requirements
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4.2.13.1.5.1
Bus Enclosure
This enclosure shall be made of aluminium alloy of minimum 3
mm thickness.
4.2.13.1.5.2
Mechanical Strength
The design of the busduct enclosure shall be such that it will
withstand the internal or external pressures resulting from the
following:
a) Normal operating conditions
b) Momentary short circuit current (peak)
c) Rigours of adverse weather conditions, and
d) Combination of the above.
The housings shall be of sturdy construction to have inherent
strength to withstand the above forces.
4.2.13.1.5.3
Construction
The entire bus duct shall be designed for indoor installation with
a dust and vermin proof construction. Busduct shall have degree
of protection better than equal to IP 54 for indoor and IP55 for
outdoor.
4.2.13.1.5.4
Painting
The inside of the bus enclosure shall be treated with a matt paint
of dark colour, preferably black to facilitate efficient heat
dissipation. The bare enclosure with above painting shall be
designed so as not to exceed the temperature specified
elsewhere when the conductor is carrying rated current. The
BIDDER shall submit supporting test certificates.
The outside of the enclosure shall be given a finish of epoxy paint
with shade flint / pebble grey RAL 7032.
4.2.13.1.5.5
Temperature Rise
Under normal operating conditions, the hot spot temperature of
the conductor shall not exceed 80 Deg.C i.e. temperature rise of
conductor shall not exceed 35 Deg.C over an ambient
temperature specified in the design basis. The bus duct shall be
of natural cooling type.
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4.2.13.1.5.6
Bellow Joints
Joints consisting of rubber bellows shall be provided on the bus
enclosure at following points:
a) At terminations at Generator
b) At terminations at switchgear cubicles
4.2.13.1.5.7
Flexible Expansion Joints

Flexible expansion joints for the enclosure shall be provided
wherever deemed necessary by the manufacturer.
The
flexible joints shall take care of expansion and contraction due
to temperature variations and fault conditions.
4.2.13.1.5.8
Bonding
Necessary bonding shall be provided at the above expansion
joints if made of insulating material.
4.2.13.1.5.9
Terminal Enclosures and Flanges

Three-phase terminal enclosures shall be provided with
flanged ends with drilling dimensions to suit the flanges at
equipment terminals.
The flanges shall be provided with gaskets, nuts, bolts, etc.
It shall be the responsibility of the manufacturer of the
busduct to coordinate with various equipment (by others) to
which his busduct has to be terminated to ensure proper
alignment of the busduct with this equipment.
4.2.13.5.10
Inspection Covers
Provision shall be made for periodic inspection of insulators by
means of inspection covers. The inspection covers shall be
provided with quick acting stainless steel clamps and shall
have gaskets.
4.2.13.5.11
Drain Plugs and Vents

Filter type drain plugs shall be installed at low points along the
run of the busduct to drain out automatically any moisture
condensing within the bus enclosure. The drain plugs shall be
fitted with porous filter elements which will permit the escape
of moisture but prevent the ingress of dust. The filter
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elements shall be easily removable for cleaning purposes.
4.2.13.5.12
Gaskets
The gasket material and thickness shall be so selected as to
satisfy the operating conditions imposed by temperature,
weathering durability etc. Care shall be exercised to ensure
that covers fit easily, that the required compression of the
gaskets can be obtained without damage to the inspection
covers by bolts and that covers do not bend after this
compression has been applied. Over-compression of the
gaskets shall be avoided.
The material of the gaskets shall preferably be neoprene
closed cell sponge rubber or equivalent.
Flange gaskets shall be provided at the equipment terminal
connections.
4.2.13.5.13
Miscellaneous Hardware
The busduct shall not have any through bolts. All nuts and
bolts shall be mild steel hot dip galvanised. MS spring washers
shall be provided for making satisfactory joints. Clamps, splice
plates, etc. shall be provided wherever necessary.
4.2.13.5.14
Earthing
Necessary earthing arrangement as applicable shall be provided with clamps to receive the station earthing bus. All
accessories and hardware required for the earthing
arrangement shall be provided.
4.2.13.6
Bus Conductor
4.2.13.6.1
Material
The material of the conductor shall be of high grade Copper.
4.2.13.6.2
Rating
The bus conductor shall be designed to carry the rated current
under normal site operating conditions without exceeding a
hot spot temperature of 85 Deg. C. Also the temperature
of the bus shall not be exceed 250 Deg. C while carrying
the specified short circuit current for three seconds when a
fault occurs at the operating temperature.
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4.2.13.6.3
Shape
The section of the bus conductors used shall be rectangular,
tubular, hollow square, hollow rectangular, double channel or
hollow hexagonal/octagonal type.
4.2.13.6.4
Mechanical Strength
The bus conductors and insulated supports shall withstand
without permanent deformation, deterioration of conductor
material and reduction in the BIL value of the busduct, the
stresses consistent with the momentary short circuit current.
4.2.13.6.5
Painting
The bus conductor may be given a coat of matt black paint to
facilitate heat dissipation. The bare conductor with above
painting shall be designed to carry the normal rated current
without exceeding temperature rise as specified.
The
manufacturer shall submit supporting test certificate.
4.2.13.6.6
Losses
The losses in the conductor shall be limited to such a value that
the temperature rise of the conductor does not exceed the
specified values. The losses should be such that an optimal
operating cost is obtained.
4.2.13.6.7
Joints
Adjacent sections of the bus conductors shall be bolted or
welded to provide an efficient, electrically continuous and
mechanically strong connection.
Welded Rigid Joints
Joints shall be highest quality done as per the recognised
methods of welding practice. Suitable aluminium or copper
connectors shall be provided wherever the bus sections change.
Welded Expansion Joints
Flexible aluminium or copper connectors welded to the main
busbars shall be provided wherever deemed necessary.
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Bolted Rigid Joints
The connectors shall be of the same material as the conductor
and these shall be silver plated to ensure an efficient connection.
The bolting schedule and contact pressures shall conform to
accepted codes of practice.
Bolted Flexible Joints
Flexible braided copper connections shall be provided at the
equipment terminal connections. Bimetallic connectors shall be
provided between the busbar and the copper flexible if the bus
conductor is of aluminium alloy. The joints shall be capable of
25mm settlement of equipment mounting pads. The joints shall
be suitably designed to take care of the vibration at the
terminals as well as the expansion and contraction of the
busbars.
Bolted Expansion Joints
Expansion joints made of aluminium or copper strips shall be
provided wherever deemed necessary by the vendor, to take
care of expansion and contraction of the busbars under normal
operating conditions.
All the above joints shall be tested for temperature rise to prove
the adequacy of the design. The maximum temperature rise at
the joints shall be less than the specified temperature rise for
the busbars.
4.2.13.6.8
Clamps and Hardware

The busbar clamps and insulators shall be designed to withstand
the forces due to momentary short circuit current. They shall
permit free longitudinal movement of the busbars during
expansion and contraction. The material of the clamps shall be
aluminium alloy. Suitable copper or aluminium spacers shall be
provided wherever necessary.
All bolts, nuts and lock washers used in the bus assembly shall be
of high tensile steel, plated for corrosion resistance.
Suitable splice plates and bimetallic connectors shall be provided
wherever necessary.
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4.2.13.6.9
Disconnecting Links
Disconnecting links with rating same as that of the main busbars
shall be provided in the run of the bus duct to facilitate
disconnection of the bus bars during testing and maintenance.
The separation of the busbar sections with the bolted links
removed shall be sufficient to withstand the rated voltage of the
busduct. Details of disconnecting links shall be furnished by the
manufacturer. The minimum number of disconnecting links shall
be provided as shown in the enclosed drawings
4.2.13.6.10
Shorting Links
Shorting jumpers, for the purpose of drying out the equipment
before commissioning or for carrying out short circuit test on the
equipment, rated for the main bus current shall be supplied for
shorting the busduct at a location, adjacent to the disconnecting
links.
The shorting links shall have drilling dimensions matching those
of the main bus disconnecting links.
Suitable supporting
structures and support insulators for the shorting links if
necessary shall also be offered.
4.2.13.6.11
Phase Barriers
4.2.13.6.12
The phase barriers shall be of the material shall be same as that

of the busduct enclosure material.
4.2.13.6.13
Insulated phase barriers, when specified, shall be made of nonhygroscopic insulating material such as fibre glass.
4.2.13.7
Bus Support Insulators
4.2.13.7.1
Within the busduct the bus shall be mounted and supported on

insulators. The insulators shall be mounted on resilient pads
provided in the bus enclosure.
4.2.13.7.2
Material
The insulators shall be of porcelain.
4.2.13.7.3
Mechanical Strength
The insulators shall possess sufficient mechanical strength to
withstand the forces due to momentary short circuit currents of
magnitude detailed in this specification. The spacing of the bus
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insulators shall be decided giving due factor of safety.
4.2.13.7.3
Electrical Strength
As a consequence of current loading and variation in external
temperatures in the external sections of the busduct,
condensation of moisture may take place on the surface of the
insulators. Hence the insulators shall have a high creepage
distance and a withstand voltage rating sufficient to provide
specified insulation under highly humid conditions.
4.2.13.8
Wall Frame Assembly and Seal-off Bushings
4.2.13.8.1
Seal off Bushings

The busduct shall be equipped wherever necessary with baffle
or seal off bushings to prevent interchange of air at different
temperatures. The seal off bushings shall be flanged type.
4.2.13.8.2
Material
The insulator for wall frame assembly and seal off bushings
shall be of porcelain. Also the bushings shall be designed for
thermal expansion / contraction due to temperature differential
for outdoor / indoor use.
4.2.13.8.3
Mechanical Strength
The insulator shall withstand the maximum short circuit forces
under fault conditions specified in this specification. The
insulator material shall not deteriorate under normal operating
temperatures or due to temperature rise under fault conditions.
4.2.13.8.4
Electrical Strength
The electrical properties of the insulator shall be in conformity
with this specification.
4.2.13.8.5
Phase Clearances
The minimum phase to phase and phase to earth clearances of
busbars within the enclosures shall be as follows:
Phase to Phase
Phase to Earth
:
:
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4.2.13.9
Busduct Supports
4.2.13.9.1
Material
The supporting structure shall be fabricated from standard steel
sections and shall be hot dip galvanised after fabrication.
4.2.13.9.2
Mechanical Strength
The supporting structures shall be designed to withstand the dead
weight of the busduct and also the short circuit forces under
maximum fault conditions and also the wind load and forces due to
seismic accelerations as per relevant Indian Standards.
Calculations shall be furnished to substantiate the above and shall
be subject to the PURCHASER / CONSULTANT's approval.
4.2.13.9.3
Accessories and Hardware

The supporting structures including supporting members, brackets,
hangers, longitudinal beams, channels, nuts, bolts, insulating pads,
insulating washers and all other hardware which are necessary for
erection and support of the entire busduct installation. All the
accessories and hardware of ferrous material shall be hot dip
galvanised.
4.2.13.9.4
Earthing
Each supporting structure shall be securely connected at two points
to the station earthing bus. All necessary hardware, such as
clamps, connectors etc. required for this purpose shall be furnished
by the vendor.
4.2.13.9.5
Markings
All components of the busduct along with the supporting structure
shall be distinctly marked for erection in accordance with the
erection drawings to be prepared and furnished by the vendor.
These marks shall be made in a manner as not to be obliterated
and erased in transit or to damage the galvanising of the busduct
or the supporting structure.
4.2.13.10
Miscellaneous
4.2.13.12.3.5
Studs, nuts, bolts and tapped holes shall conform to the relevant
standards. Only hexagonal nuts shall be used. All bolt holes shall
be spot faced for nuts.
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4.2.13.10.2
Castings and forgings shall conform to respective material

specifications and shall be free from flaws. They shall be machined
true as per good workshop practice. Welding shall be performed in
accordance with relevant standards.
4.2.13.10.3
All threaded pipe connections and fittings, pipe flanges and tube
fittings shall comply with relevant standards.
4.2.13.11
Design Requirements of Busduct
4.2.13.11.1
The bid shall contain design calculation in support of the following

parameters of the busduct design:
a)
Sizing of the busbars vis-a-vis thermal capability to

withstand rated continuous current and three seconds
short time current.
b)
Spacing of the insulators vis-a-vis mechanical strength

to withstand forces due to momentary short circuit
current.
c)
Heat loss and temperature rise calculations for

conductor and enclosure.
4.2.13.12
Space Heaters & Silica gel breathers
4.2.13.12.1
The busduct shall be provided with space heaters of adequate

capacity to maintain the internal temperature above the dew
point to prevent moisture condensation within the busduct. The
space heaters shall be rated for 240V single phase, 50 Hz AC
supply. The space heater shall be automatically controlled by
differential thermometers.
4.2.13.12.2
Adequate number of silica gel breathers shall be provided in the

busduct.
4.2.13.12.3
Tests and Test Reports
4.2.13.12.3.1
The following type and routine tests certificates shall be

conducted on representative section of the bus assembly. The
bus assembly tested shall include bolted connections and flexible
connections. The tests shall be conducted as per standards
indicated in this specification.
4.2.13.12.3.2
Type Tests
a)
One minute power frequency withstand voltage test.
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b)
c)
d)
e)
f)
4.2.13.12.3.5
Impulse voltage withstand test.

Temperature rise test of bare black matt painted conductors
and enclosures.
Dynamic withstand test.
Water tightness test.
Air tightness test.
Routine Tests
The following routine test shall be conducted at the vendors
shop:
a)
b)
c)
4.2.13.12.3.5
One minute power frequency withstand voltage test.

Water tightness test.
Air tightness test.
Test Report for Components

Manufacturer's type and routine test certificates shall be
submitted for tests conducted as per relevant standards for the
following components:
a)
Insulators
b)
Seal-off bushings
c)
Bolted and flexible joints
d)
Busbars
e)
Enclosure material
f)
Galvanising of support structures
4.2.13.13
NGTR Cubicle
4.2.13.13.1
Standards
The transformer and resistors covered by this specification shall
conform to the following and other relevant Indian Standards.
Wherever Indian Standards are not available, they shall conform to
relevant British or IEC Standards.
IS:3043
BS:162
IEEE-32
Code practices for earthing.

Electric power switchgear and associated apparatus
(applicable to Class-B apparatus in BS:162)
Requirements, terminology and testing procedures for
Neutral grounding devices.
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IEC 129
Alternating
IEC 185
Current Dis-connectors
Switches
Current Transformers
IEC 529
Classification of Degree of Protection
and
Earthing
Wherever the stipulation in this specification are in conflict with any

of the above standards, the requirement under this specification
shall be binding.
4.2.13.13.2
General Specifications
The values and ratings of transformer and resistors shall be
designed to limit the earth fault current to 5 to 10 A depending on
the capacitance of the system. The rating of transformer and
resistor shall be designed to ensure the resistive component of
fault current should not be lesser than residual capacitance current
to avoid transient over voltage during earth fault. The resistive
component should be at least more than 3 to 5 times of residual
capacitance current. The BIDDER shall furnish the detailed
calculation and basis for the rating selection of transformer and
resistor for the specified rating.
4.2.13.13.3
Transformer and Resistors
4.2.13.13.3.1
The distribution transformer shall be of dry type and single

phase. The neutral current shall be limited to 100A during earth
fault. The duty of the transformer shall be continuous during
normal operating condition and for 30 seconds during earth fault
condition. The transformer shall be designed with following
capabilities:
- No saturation shall occur at all conditions.
- To be suitable for withstanding over voltage caused due to
sudden load loss, field forcing condition and flux doubling
conditions.
- The knee point voltage of the transformer primary shall be at
least 1.3 times of line to line voltage of generator.
4.2.13.13.3.2
The resistor shall be of stainless steel edge wound type made up

of unbreakable, corrosion proof, jointless grids. It shall be
suitable for use in monsoon tropical climate.
4.2.13.13.3.3
Resistors shall be designed for continuous duty during normal

operating condition and for 30 seconds during earth fault
condition with temperature rise not exceeding 325 Deg.C over
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an ambient temperature of 50 Deg.C when the resistor is
housed in a covered space.
4.2.13.13.3.4
Grids shall be mounted on steel rods insulated by special heat

resistant micanite paper tubes. Grid washers shall be of natural
mica. Porcelain insulators shall be used to insulate the resistor
element from body of the enclosure.
4.2.13.13.4
Isolator, Current
Contactor
4.2.13.13.4.1
Manual link or manual isolator with vacuum contactor of

adequate rating, with sufficient auxiliary contacts shall be
provided in the NGTR cubicle.
4.2.13.13.4.2
Current and potential transformers, as required for ground fault

protection shall also be provided.
4.2.13.13.4.3
These devices shall be rated for voltage class in accordance with

the recommendations of IEEE-32.
4.2.13.13.5
Enclosure
4.2.13.13.5.1
The resistors shall be housed in a metal clad enclosure suitable

for indoor installation, with minimum IP52 enclosure.
4.2.13.13.5.2
The enclosure shall have an arrangement for fixing it on

concrete foundations / floor and its thickness shall be not less
than 3 mm.
4.2.13.13.5.3
The terminals for neutral and earthing connection shall be

housed in a separate vermin proof, weather proof compartment.
Transformer,
Potential
Transformer
and
It shall be possible to periodically clean the resistors after lifting

the top cover.
It shall be possible to earth the cabinet or enclosure at two
places and for this suitable size of studs shall be provided on the
sides.
4.2.13.13.6
Terminals
4.2.13.13.6.1
The connection between generator neutral and NGT shall be

done by means of bus duct / internal busbar connection,
depending on the envisaged connection configuration.
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4.2.13.13.6.2
Suitable washers shall be provided between grid and terminals

to maintain good contact.
4.2.13.13.6.3
The two ends of the resistor shall be brought out to

weatherproof bushing type terminals of adequate rating. Bolted
type link shall be provided for isolating the resistor.
4.2.13.13.6.4
Bushing terminals shall be provided for neutral and earth

connections and they shall be housed in a metal clad enclosure.
4.2.13.13.7
Space Heater
4.2.13.13.7.1
Suitable space heater along with thermostat shall be provided

inside the resistor cabinet to prevent condensation of moisture.
This shall be rated to operate from 240 V, 50 Hz supply. The
terminals of the space heaters shall be brought out in a separate
terminal box.
4.2.13.13.7.2
The cable used for space heater shall be aluminium conductor

PVC insulated armoured cable. The entire arrangement shall be
complete with double pole switch, MCBs and thermostat.
4.2.13.13.8
Cooling
The NGT shall be natural air cooled and any type of forced
cooling shall not be used. However, if required, louvers can be
provided in the enclosure. But wherever the louvers are being
offered it shall be completely guarded on inside with a fine wire
mesh (holes less than 0.5mm) to make it vermin proof.
4.2.13.13.9
Name plate Marking

The equipment shall have a nameplate located conspicuously
giving particulars, such as make, name of the equipment, rating
and other relevant details.
4.2.13.13.10
Painting
All surfaces to be painted shall be thoroughly cleaned, descaled,
made free from rust and given a priming and final coat of the
paint, shade RAL 7032.
4.2.13.13.11
Inspection & Test

Inspection shall be carried out by the PURCHASER /
PURCHASERs representative and the following tests shall be
conducted:
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Measurement of resistance value at room temperature

by Kelvin
Double Bridge.
One minute power frequency high voltage withstand
test shall be as
per applicable voltage.
4.2.13.13.12
Heat Run Test

The test shall be conducted by passing the rated current for
rated time on the complete assembly or by any method
mutually agreed upon.
4.2.13.13.13
Test Certificates
Test certificates of the equipments shall be furnished at the
time of inspection.
4.2.13.14
LAVT Cubicle
4.2.13.14.1
Standards
IEC:71
Co-ordination of Insulation
IEC:99
Lightning Arrestors
IEC:18
Potential Transformers
IEC:52
Classification of Degree of Protection
4.2.13.14.2
Design Requirements
4.2.13.14.2.1
The cubicle shall house Potential transformers required for

metering, protection, synchronisation and excitation system
sensing..
4.2.13.14.2.2
Surge capacitors and Lighting arrestors required for surge

protection of the generator shall be housed in this cubicle.
4.2.13.14.2.3
The surge capacitors shall conform to the latest IS:2834 and

shall be rated 0.25 F. The capacitors shall be suitable for
indoor mounting and shall be provided with built in discharge
resistor.
4.2.13.14.2.4
The lightning arrestors shall be heavy duty indoor station class

gapless metal oxide type suitable for repeated operation to
limit voltage surges on alternating current power circuits and
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to interrupt power follow current. The arrestors shall conform
to IEC 99-4. The nominal discharge current of lightning
arrestor shall not be less than 5 kA.
4.2.13.14.2.5
The SUPPLIER to submit design back-up details for selection

of PT, LA and SC ratings.
4.2.13.14.3
Construction Features
4.2.13.14.3.1
The cubicle shall be simplex type.
4.2.13.14.3.2
The cubicle shall be sheet steel enclosed dust and vermin proof
type. The cubicle shall be floor mounting, free standing and
suitable for busduct entry. The enclosure shall be of cold sheet
of 3 mm thick for front and back and 2.5 mm thick for rest. Type
of enclosure shall be IP 52.
4.2.13.14.3.3
The doors and openings shall be provided with neoprene gaskets.
4.2.13.14.3.4
Cubicles shall be suitable for top busduct entry.
4.2.13.14.3.5
All mounted equipment inside the cubicle shall have identification

tags of self sticking PVC tapes, in addition identification number
shall be painted on cubicle wall to give permanent identification
mark.
4.2.13.14.3.6
All wiring shall be done by PVC insulated 1100 V grade 2.5 mm

stranded copper cable. Each wire shall be identified at both ends
by means of PVC ferrules.
4.2.13.14.3.7
Minimum 20% spare terminals shall be provided more than one

wire shall not be connected in any terminal. All terminals shall be
stud type.
4.2.13.14.3.8
All busbars shall be sleeved type with colour coding at each end.
4.2.13.14.3.9
The PTs shall be of fully drawout type and both the primary and
secondary shall get isolated and earthed through scrapping earth.
4.2.13.14.3.10
PTs primary shall be with uniform insulation.
4.2.13.14.3.11
The PTs shall be protected with HRC fuses on primary. MCBs

shall be made available on secondary side for circuit protection.
4.2.13.14.4
Painting
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After preparation of the under surfaces, with two coats of primer

suitable for epoxy paint the cubicle shall be spray painted with
two coats of final epoxy paint. Colour shade RAL 7032, with
glossy finish. All unpainted steel parts shall be cadmium plated
or suitably treated to prevent rust corrosion.
4.2.13.14.5
Earthing
A continuous earth bus running along the full length of cubicle
shall be provided. Suitable arrangements shall be provided at
each end for connection to main earthing grid.
4.2.13.14.6
Space Heater
Anti condensation space heater shall be provided along with
thermostat to keep the cubicle temperature above ambient.
4.2.13.14.7
Test
The PTs shall be fully tested for 35 kV as per IS:3156. Lightning
arrestors and surge capacitors to be tested as per relevant IS
standards.
Following tests shall be carried out:
a)
b)
c)
d)
Checking of correctness of wiring of circuit

High voltage test.
I.R value test.
Routine tests.
4.2.13.15
Sealed TVM Cubicle
4.2.13.15.1
The trivector meter shall be of digital type, class 0.2S with ABT
feature. The meter shall be suitable for 3 Phase, 4 wire system.
The meter shall also be provided with RS 485 communication
port with MODBUS RTU protocol and software.
4.2.13.15.2
The TVM shall be base mounted type and shall be provided

with the arrangement of sealing. The cubicle shall be provided
with a door and view glass. This cubicle shall also be suitable
for wall mounting.
Current and Potential Transformers
4.2.13.16
4.2.13.16.1
Current and potential transformers, for protection, metering &

controls shall be provided, in generator terminals, NGTR / LAVT
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cubicles, 11 kV switchgears and busducts, depending on the
envisaged system.
4.2.13.16.2
Standards
IS:2705 & IEC:185
- Current Transformers
IS:3156 & IEC:186
- Potential Transformers
4.2.13.16.3
The current transformer will be epoxy cast, bar primary, dry

type unit confirming to IS / IEC. The current transformer shall
be designed to withstand the thermal and magnetic stresses
resulting from the maximum short circuit current. The accuracy
class for metering shall be 0.2 and protection shall be 5P20 &
PS. The accuracy class for the dedicated CT for open access
metering shall be 0.2S. For class PS core CTs, the knee point
voltage shall match with the requirements of the connected
relays. Care shall be taken to ensure that the matching CTs are
properly matched for knee point voltage & magnetising current
requirements; and preferably sourced from same manufacturer.
All CTs shall be provided with not more than two cores and
shall be suitable for 120% rated current, continuously.
4.2.13.16.4
The potential transformers will be single phase, epoxy cast, dry

type units. Potential transformer will be protected on primary
by HRC fuses and secondary side by MCBs. The accuracy class
for the dedicated PT for open access metering shall be 0.2. The
accuracy class for Metering 0.2 and protection 3P. Voltage
factor for the PTs shall be 1.2 times continuous and 1.9 times
for 8 hours.
4.2.13.16.5
As the PTs are intended to be in service in unearthed system

and to avoid ferro resonance effect, the BIDDER shall
envisage a suitable method to mitigate the above effect. A
detailed write-up on the proposed method shall be furnished for
CONSULTANTs review.
4.2.14
SPECIFICATION FOR DC STARTER PANEL, DCDB AND

ELECTRIC MOTORS
4.2.14.1
Panel Construction
4.2.14.1.1
The distribution board and starter panel shall generally conform

to the following standards:
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IEC-439 & IS:8623
IEC-947 & IS:13947
IEC-269 & IS:9224

IEC-144 & IS:2147
Specifications of Low Voltage Switchgear &

Control gear Assemblies
Specification
of
Low-Voltage
IS:13947
Switchgear & Control gear
Low voltage fuses
Degree of protection of enclosure for low
voltage switchgears and control gear
IE rules, guidelines, regulation of CEIG

4.2.14.1.2
The panels shall be dust, damp & vermin proof construction,

sheet steel clad totally enclosed, compartmentalized, floor
mounted, self standing type with access from front & back by
means of hinged doors. The panels shall have bottom entry
provisions and shall be natural cooled.
4.2.14.1.3
The panels shall be fabricated with 2.0 / 2.5 mm thick sheet

steel and structural steel. It shall be free-standing with suitable
louvers for ventilation and must be suitable for use in tropical
climate. Hinged doors shall be provided at the front and back
where required.
4.2.14.1.4
Inter panel sheet steel barriers shall be provided. The sheet

steel used for fabrication shall be thoroughly cleaned and
degreased to remove mill scale, rust, grease and dirt.
Fabricated structures shall be pickled and then rinsed to remove
any trace of acid.
4.2.14.1.5
All metal surfaces shall be chemically cleaned, degreased and

pickled in acid to produce a smooth surface, free of scale,
grease and rusts. After cleaning, phosphating and passivation
treatment, the surface shall be given two (2) coats of zinc rich
epoxy primer. The assembly shall be finished with two coats of
epoxy paint in pebble / flint grey shade RAL 7032.
4.2.14.1.6
Reverse engraved name plates shall be provided for the panels

and all module sections.
4.2.14.1.7
All fuses shall be provided inside the panel. All fuses shall be
link type. Diazed fuses will not be acceptable. Terminal blocks
shall be `Elmex' type.
4.2.14.1.8
All potential free metallic parts shall be earthed with soft drawn
copper conductor. The main earth connection shall be brought
out to two terminals for connection to station earthing system.
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4.2.14.1.9
All live parts shall be properly shrouded. This shall ensure

complete safety to personnel intending routine maintenance by
opening the panel doors. Busbars shall be colour coded. All the
equipment inside the panel shall have suitable name plates.
4.2.14.2
EOP & JOP Starter Panel
4.2.14.2.1
DC starter panel for control of EOP & JOP DC motor shall be

provided, as part of the DC distribution board. A spare feeder
with complete starter modules shall be provided in the DCDB.
4.2.14.2.2
DC starter shall have switch fuse unit for short circuit protection.
Overload relay shall be provided for alarm purpose. The starter
shall also have field failure protection for the motor.
4.2.14.2.3
DC contactor used in the starter panel shall be provided with

adequately rated magnetic blow out coil for effective arc
quenching.
4.2.14.2.4
DC resistance in suitable steps, but not less than three (3), shall
be provided.
4.2.14.2.5
For interfacing with PURCHASERs DCS, the following signals

shall be hooked-up to a marshalling compartment in the
distribution board :
-
4.2.14.3
EOP & JOP starter ON / OFF status

EOP & JOP motor over load relay operated
EOP & JOP motor field failure relay operated
Start & Stop command from DCS
DC Distribution Board
4.2.14.3.1
Two (2) numbers of DCDB with each of the DCDB sized to cater
100% of the TG loads shall be provided. Bus coupler for
interconnection shall also be envisaged. The DCDB shall be
connected to its own dedicated battery bank.
4.2.14.3.2
The DC distribution boards and for each TG set shall have the
following feeders, in addition to the feeders to meet BIDDERs
requirements:
a)
b)
4.2.14.3.3
Two (2) numbers 63A FSU feeders

Ten (10) numbers 32A FSU feeders
The distribution board shall have the following meters / relays /

transducers:
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Ammeter and Voltmeter at the incomer

Ammeter for all outgoing feeders
Current and Voltage transducers at the incomer
Current transducer for EOP starter
Bus under voltage and over voltage relay
4.2.14.3.4
For interfacing with PURCHASERs DCS, the following signals

shall be hooked-up to a marshalling compartment in the
distribution board
-
ON and OFF status of incomer and all outgoing feeders

Bus under voltage and over voltage signals
(4-20) mA signals from all transducers
4.2.14.4
AC Electric Motors
4.2.14.4.1
All the auxiliaries shall be suitable for 415 V (3 Phase 3 Wire

system), without neutral.
4.2.14.4.2
All the motors shall be of squirrel cage type.
4.2.14.4.3
Starting Methods of Motors shall be as below unless otherwise

specified elsewhere in this document:
-
Motors shall be suitable for DOL starting unless otherwise

specified elsewhere in this document.
All VFD application motors shall be capable of starting with

DOL as bypass starting arrangement.
4.2.14.4.4
System fault levels to be considered for design of the equipment

shall be 65 kA for one second at 415V system.
4.2.14.4.5
The Rated voltage shall be 415V, three phase for motors of rating
0.37 kW and above. It shall be 230V, single phase for motors of
rating below 0.37 kW.
4.2.14.4.6
All AC motors driving various auxiliaries of the unit shall be

designed to operate in humid atmosphere with a maximum
ambient temperature as indicated in project information. The
motors shall be of squirrel cage induction machines with a degree
of protection IP54 for indoor application and shall conform to
IS:325 / IEC-60034. Motors for outdoor application shall be IP55
degree of protection with sheet steel canopy.
152 of 373

RAJASTHAN
4.2.14.4.7
The motor windings shall be provided with Class F insulation. The

motors shall be suitable for 10 % voltage variation (on rated
voltage) and 50 Hz 5% frequency variation (subject to combined
variation of 10%) with maximum temperature rise limited to limits
of Class-B insulation.
4.2.14.4.8
All the continuous duty motors shall be of energy efficient (IE2

range type for motor rating upto 55 kW and IE3 range type for
motor rating 75 kW & above), with efficiency figure at 100% load
is not less than the efficiency value as indicated in the Table for
Motor Efficiency. Motor efficiency between 60% to 100% load
shall be constant.
4.2.14.4.9
Motors of rating 30 kW and above shall be provided with space

heaters.
4.2.14.4.10
Terminal box to be rotatable by 4 x 90 Deg. Higher rated motors

shall be provided with extension terminal box to receive the
aluminium cables of following sizes to avoid cramping of the cable
in the terminal box:
a.
90-110 kW :
2-3Cx185 Sq.mm
b.
132-180 kW :
2-3Cx300 Sq.mm
c.
200-280 kW :
4-3Cx185 Sq.mm
d.
300-440 kW :
4-3Cx300 Sq.mm
e.
425-600 kW :
6-3Cx300 Sq.mm
f.
625-720 kW :
8-3Cx300 Sq.mm
4.2.14.4.11
The terminal boxes shall be capable of withstanding the maximum

system fault current for a duration of at least 0.25 second.
Terminal boxes mounting shall be tapered and not on top.
4.2.14.4.12
Motors shall be suitable for being switched on to a solid main even

at phase opposition at a maximum residual voltage of 50% i.e. the
motor shall be capable of withstanding 150% of the rated voltage.
4.2.14.4.13
Motors shall be capable to start and run-up at a minimum of 80%

of rated voltage at its terminals with the driven mechanism /
equipment connected.
4.2.14.4.14
Motors shall be capable of operating satisfactorily at full load

for 5 minutes without injurious heating with 75% of the rated
voltage at its terminals.
4.2.14.4.15
Brake away torque, pull-up torque and pull-out torque shall be

properly coordinated with the speed torque characteristics of the
driven equipment, and the BIDDER shall submit the characteristic
curves interposing motor & driven equipment curves.
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RAJASTHAN
4.2.14.4.16
Hot withstand time of the motor shall be at least 10 seconds longer

than the starting time under rated load conditions, for the motors
where the starting time is more than 30 second. For motors with
lesser starting time, a margin of 5 seconds shall be ensured. The
starting time of the motors shall be mentioned in the document.
4.2.14.4.17
Starting current of the motor shall be less than or equal to 600 %

of the rated current.
4.2.14.4.18
Continuous duty motors shall be capable of three equally spread

starts per hour under normal condition or two starts in quick
succession from cold or one hot start, under rated load conditions.
4.2.14.4.19
All bearing to bee of lubricated anti-friction type. No forced

lubrication acceptable.
4.2.14.4.20
Motor to be of Totally Enclosed Fan Cooled (TEFC) design. Cooling

fans shall be shaft mounted type only (No additional cooling motor
shall be provided).
4.2.14.4.21
Specific requirements of LV general duty motors

-
Rated voltage shall be 415V.
Motors shall be provided with RTDs/BTDs as indicated in the

table
below:
SL
Motor Rating
RTDs
BTDs
1.
30 90 kW
One (1) per phase
2.
110 kW
Above
Not Required
Two (2) Nos.
(Drive End 1 No. and
Non-Drive End 1 No.)
4.2.14.4.22
and
One (1) per phase
Specific requirements of motors intended for VFD application:

-
Rated voltage shall be 415V.
Should be suitable for the selected IGBT based variable

frequency drive, and shall match with the drive in respects of
over voltage / spikes generated by the drives.
The windings shall be VPI treated and two coat enameled.

These motors shall be sized to operate satisfactorily under the
lowest speed conditions. Operating speed requirement shall be
as below:
154 of 373

RAJASTHAN
Fans
Pumps
Fuel feeders
50% to 100%
50% to 100%
10% to 100%
The motor windings shall be provided with Class H insulation

with maximum temperature rise limited to limits of Class-B
less 10 Deg C insulation.
NDE bearings of motors of rating 110 kW and above shall be

insulated to prevent circulation of shaft currents.
Manufacturer shall furnish details of bearing insulation.
The BIDDER shall submit detailed calculations for checking

adequacy of the motor selected under extreme speed
conditions, furnishing the selection chart of the motor
manufacturer for VFD application.
All variable frequency drive motors shall be provided with

embedded Thermistors / RTDs / BTDs for motors as indicated
in the table below:
Sl
Motor Rating
1.
3.7 22 kW
2.
30 90 kW
3.
110
kW
Above
4.2.14.4.23
:
:
:
Thermistors
RTD
BTD
One
(1)
per
Not Required
Not Required
phase
One
(1)
per
Not Required
Not Required
phase
Two (2) Nos.
(Drive End 1
and
One
(1)
per
Not Required
No. and Nonphase
Drive End 1
No.)
Inspection & Testing:

The following minimum tests shall be carried out on the motor to
ensure its Successful operation as per the specification.
TESTS
Up to
22 kW
Measurement of resistance of windings of

stator and rotor
No load test to measure input power,
current, speed and to determine no load
losses and efficiency at full load
155 of 373
30 kW to
55 kW
75 kW &
above

RAJASTHAN
Locked rotor readings of voltage, current
and power input at a suitable reduced
voltage
Reduced voltage running up test to check
the ability of the motor to run up to its
rated speed at no load.
Open circuit voltage ratio of stator and
rotor windings (applicable for slip ring
motors)
High voltage test
Insulation resistance test
()
()
Vibration test
()
Noise level test
()
Momentary overload test
()
Full load test to determine the efficiency,

()
power factor, and slip
Over speed test
()
()
Test for degree of protection
()
()
Test on insulation system
()
()
Temperature rise test at limiting values of

voltage and frequency variation.
() Test report of identical motor (frame, speed & kW) for having carried
out with in five years.
- The tests shall be carried out in the motor.
4.2.14.4.24
lso the efficiency calculations by using the values of locked rotor test
and full load test for all the motors of above 22kW shall be submitted.
4.2.14.4.25
All the routine and type tests shall witnessed and verified by
PURCHASER/CONSULTANT.
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RAJASTHAN
4.2.14.4.26
TABLE FOR MOTOR EFFICIENCY
RATING
in KW
2 POLE
3000 RPM
4 POLE
1500 RPM
6 POLE
1000 RPM
8 POLE
750 RPM
0.37
0.55
0.75
1.1
1.5
2.2
3.7
5.5
7.5
9.3
11
15
18.5
22
30
37
45
55
75
90
110
125
132
160
200
250
300
350
440
450
500
Above
70.2
74.0
77.0
82.8
84.1
85.6
87.5
88.6
89.5
90.0
90.5
91.3
91.8
92.2
92.9
93.3
93.7
94.0
94.6
95.0
95.0
95.3
95.3
95.5
96.0
96.0
96.0
96.2
96.5
96.7
73.0
78.0
82.5
83.8
85.0
86.4
88.3
89.2
90.1
90.5
91.0
91.8
92.2
92.6
93.2
93.6
93.9
94.2
94.7
95.0
95.2
95.5
95.5
95.8
96.2
96.2
96.3
96.5
96.8
97.0
69.4
72.0
74.6
77.3
79.6
82.2
85.1
86.8
88.1
89.3
89.7
90.5
91.3
91.8
92.6
93.0
93.4
93.8
94.2
94.5
94.6
94.8
94.9
95.2
95.2
96.0
96.0
96.2
96.5
96.5
66.8
71.1
73.8
76.2
77.9
80.5
83.0
85.1
86.4
87.3
88.1
89.0
89.8
90.2
91.5
91.9
92.4
92.8
93.5
93.9
94.3
94.6
94.7
94.9
95.3
95.5
95.5
95.7
96.0
96.1
97.0
97.2
96.6
96.2
&
NOTE :
-
All efficiency figures are subject to IS Tolerance

Wherever ratings other than those mentioned in the above
table are used, the efficiency figure will be interpolated.
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RAJASTHAN
4.2.14.5
DC Motors
4.2.14.5.1
Constructional features
-
Industrial type, heavy duty, continuously rated, totally enclosed,

generally designed and manufactured as per IEC:60034/1,
BS:2613, IS:4722.
Stator Yoke and Poles as well as armature shall be preferably of

fully laminated construction with low loss silicon steel sheet
Frame made of cast steel or thick rolled steel plates.
Shaft forged from special high tensile steel with tapered ends.
Brush holder to maintain constant brush pressure regardless of

brush wear and to ensure spark less commutation at top speeds
and over-load.
Machine feet cast integral with the body as integral foot

mounting construction.
Degree of protection for motor, bearing housing and terminal box

shall be IP54.
4.2.14.5.2
Bearings and bearing Lubrication

-
Motors with shaft heights upto 225 mm, shall be life time
greased.
Motors with shaft heights 250 mm and above, shall be equipped

with regreasing devices and grease quantity controllers.
4.2.14.5.3
Terminal Box
-
To be dimensioned adequately for receiving aluminium cable.
To be provided on the right hand side as viewed from the drive

end.
Shall be rotatable by 4 x 90 Deg.
4.2.14.5.4
Cooling
-
TEFC
158 of 373

RAJASTHAN
4.2.14.5.5
Quality of operation
- Same as specified for low voltage squirrel cage induction motors
4.2.14.5.6
4.2.15
Electrical design
-
Operation from DC starter panel
Operation shall be unaffected by voltage or current ripples.
Overload Capacity : Minimum 160% frequently repeated

momentary load for 15 seconds.
Over speed : Capable of withstanding and over speed of 20%

above rated maximum field weakening speed.
Insulation: Shall be provided with class F insulation throughout

the stator and rotor windings but designed for temperature rise
(as measured by resistance method) corresponding to that of
class B insulation.
SPECIFICATION FOR FEED WATER HEATERS

HP heater #1 & #2
4.2.15.1
Process Parameters
4.2.15.1.1
Feed water flow (tube side)
: As per HMBD
4.2.15.1.2
Feed water inlet temperature
: As per HMBD
4.2.15.1.3
Heater
Required Feed water outlet temperature
: 190 Deg.C ( For HP

#1)
235 Deg.C
Heater
#2)
: As per HMBD
4.2.15.1.4
Feed water inlet operating pressure
4.2.15.1.5
Extraction Steam Parameters
4.2.15.1.5.1
Steam Pressure
: As per HMBD
4.2.15.1.5.2
Steam Temperature
: As per HMBD
159 of 373
(For
HP

RAJASTHAN
4.2.15.2
Design Parameters
4.2.15.2.1
Tube side design pressure
: The same shall be cold

shutoff head of the
BFP
4.2.15.2.2
Shell design pressure
: Supplier to specify
4.2.15.2.3
Design temperature for shell side
4.2.15.2.4
Design temperature for tube side
4.2.15.2.5
Allowable pressure drop on tube side
: 0.8 kg/cm2
LP heater
4.2.15.3
Process Parameters
4.2.15.3.1
Turbine condensate (tube side)
: As per HMBD
4.2.15.3.2
Turbine condensate inlet temperature
: As per HMBD
4.2.15.3.3
Turbine condensate outlet temperature
: As per HMBD
4.2.15.3.4
Turbine condensate inlet operating pressure : As per HMBD
4.2.15.3.5
Extraction Steam Parameters
4.2.15.3.5.1
Steam Pressure
: As per HMBD
4.2.15.3.5.2
Steam Temperature
: As per HMBD
4.2.15.4
Design Parameters
4.2.15.4.1
Tube design pressure
: cold shut off pressure of

CEP
4.2.15.4.2
Shell design pressure
4.2.15.4.3
Design temperature for shell side
4.2.15.4.4
Design temperature for tube side
4.2.15.4.5
Allowable pressure drop on tube side
: 0.8 kg/cm2
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RAJASTHAN
4.2.15.5
Other Requirements
4.2.15.5.1
Orientation of feed water Heater
: Horizontal
4.2.15.5.2
Location
: TG Hall.
4.2.15.5.3
Drain cooler section required
4.2.15.5.4
Maximum tube velocity
: 3.0 Mtrs/Sec
4.2.15.5.5
Heat Load (Design)
: Shall be designed with

5% margin over and
above the maximum
expected heat duty
4.2.15.6
Material of Construction
4.2.15.6.1
Tube material
HP heater
: Stainless Steel to ASME

SA 213 Gr.TP 304
LP heater
: Stainless Steel to ASME

SA 688 Gr.TP 304
4.2.15.6.2
Tube plate material
: Carbon Steel to ASME SA

516 Gr.70 or equivalent
4.2.15.6.3
Shell material

4.2.15.6.4
Channel / channel cover

4.2.15.6.5
Flange material

4.2.15.6.6
Nozzle material

181 Gr. 1
4.2.15.6.7
Materials of baffles,tube
support plates, tie rods
: Commercial Quality Steel

and spacers
4.2.15.6.8
Stud and stud bolts/nuts
: SA 193 Gr.B7 or
equivalent
SA 194 Cl.2H or
equivalent
161 of 373

RAJASTHAN
4.2.15.7
Accessories
The Heater shall be supplied with the following minimum accessories.
Shell Relief Valve, Channel Relief Valve, Shell Vent Valve, Channel
Vent Valve, Shell Drain Valve, Channel Drain Valve, Supports /
Brackets, Tube Bundle Shield, Lifting Lugs, Thermal Insulation Clips,
Alignment Dowels, Jack Screws, Name Plate, Earthing Cleats.
4.2.15.8
Design & Construction Requirements
4.2.15.8.1
General
4.2.15.8.1.1
The capability, size and design conditions for the feed water heater
shall be as specified.
4.2.15.8.1.2
The design shall have provision for complete drainage of both shell
and tube sides. Adequate drains in size and number on low points of
heater shells and water inlet channels for proper drainage and/or
supply of solutions during chemical cleaning process shall be included.
The minimum size of nozzle shall be 50mm. Pneumatically operated
level control valve with 100 % bypass same as main valve on the
condensate line of both the heaters. Also a set of special tools and
tackles shall be provided by the EPC contractor.
4.2.15.8.1.3
All connections to feed water heater 65 mm NB size and larger, shall

be welding-nozzle type with ends shop beveled, except where flanged
joints are specified for removal of shell connection or removal of tube
bundle. Connections 50 mm NB and smaller, shall be socket welded
or screwed.
4.2.15.8.1.4
Heaters shall be provided with startup vent connections which will be

separate from the vent connections required for continuous
operation.
4.2.15.8.1.5
The heater shall be designed for full vacuum conditions, on the steam
side.
4.2.15.8.1.6
Heaters shall be provided with name plates which shall include all
information required by the applicable regulations and codes. The
necessary information shall be on a metal name plate permanently
affixed to the heater and set off the surface by brackets so as to be
readily visible after the equipment is insulated.
4.2.15.8.1.7
The feed water heater shall be furnished with instrument connections

for alarm, indication and control of drain level as specified.
162 of 373

RAJASTHAN
4.2.15.8.1.8
Corrosion allowance on all cast iron, carbon steel and low alloy steel
parts shall not be less than 3.2 mm (0.125 in). A minimum corrosion
allowance of 1.6 mm (0.0625 in) shall be added to the thickness of
ferrous tubes. Where flanges like weld neck flanges are used, the
corrosion allowance shall be applied to the inside flange diameter and
the flange thickness shall be calculated with the inside diameter under
corroded conditions. No corrosion allowance shall be required to be
added to the thickness of non-ferrous tubes, external and internal
bolting material, baffles and supports.
4.2.15.8.1.9
The feed water heater shall be provided with relief valves on the shell
and tube side.
4.2.15.8.2
Heater Shells
4.2.15.8.2.1
The shell shall be of longitudinally welded or seamless type. Of the

two, seamless shell is preferred. While offering seamless shell, the
minimum wall thickness (nominal wall thickness less the tolerance )
less corrosion allowance shall be considered as available for design.
4.2.15.8.2.2
The shell cover shall be of forged or built-up welded construction.

The shell cover shall have a 2:1 elliptical, torispherical or spherical
head. The shell cover shall be welded on to the shell in case of Utube bundles. The thickness of the flat channel cover shall be
measured at the groove made for receiving the pass partition wall.
The channel cover shall be of either rolled plate or of forged
construction. The pass partition plates shall be tightly welded in
place and shall be structurally adequate to withstand normal plant
operations such as start-up restarts, shutdowns and trip outs.
Channels shall be so constructed that the tube side of the feed water
heater shall be self draining through the tubes.
4.2.15.8.2.3
Jack screws of proper size and number shall be provided for breaking
the channel cover joint and shell cover joint. The jack screws shall
have the same material specification as the bolting material.
4.2.15.8.2.4
Suitable forged bolts or drilled lugs shall be provided for channel

cover, shell cover, tube sheets, floating head cover for use in
assembling and dismantling the unit. All bolt holes shall be spot
finished for nuts.
4.2.15.8.2.5
Suitable insulation clips shall be welded to the shells in an appropriate

manner for the application of insulation at site.
4.2.15.8.2.6
One piece, metal jacketed or solid metal gaskets shall be used.

Mating surfaces shall not be exposed to fluid.
163 of 373

RAJASTHAN
4.2.15.8.3
Tubes
4.2.15.8.3.1
Tube MOC shall be as mentioned above. The tube bundle shall be

removable. The annular clearances between the tubes and the shell
must be kept to a minimum to prevent the shell side fluid bypassing
the bundle and to obtain full penetration of steam through the tube
bundle for efficient heat transfer.
The tube to tubesheet joint shall be seal welded and fully rolled.
Tubes shall be expanded into the tube sheet for a length of tubesheet
thickness minus 1/8 th inch (3.2 mm). Tube sheet shall be machined
with two grooves for additional longitudinal load resistances. The
tube rolling procedure shall be submitted for the OWNER's review
and acceptance prior to the use.
4.2.15.8.3.2
U tubes when used, shall consist of one continuous bent tube. U

tubes welded at bends shall not be acceptable. Bends shall not have
cracks, kinks or deformations. The minimum wall thickness required
at any points, including bends, shall be in accordance with the
specified codes. Due allowance shall be made for thinning of tubes
during bending. Hot bending to form U tubes shall not be allowed.
4.2.15.8.3.3
All tubes and U-bends, shall conform to the requirements of latest

revisions of the codes and standards.
4.2.15.8.3.4
Stainless Steel
4.2.15.8.3.4.1
The stainless steel tubes shall meet the requirements of the

following paragraphs:
4.2.15.8.3.4.1.1
Minimum tube wall thickness of stainless steel tubes shall be

determined by standards and codes, but in no case shall be
tube wall be less than 20 BWG average wall before bending.
Straight tubes may be 22 BWG average wall.
4.2.15.8.3.4.1.2
Tubes shall comply with the requirements of the latest revision

of the specification indicated. In addition the following shall
also apply.
a.
The stainless steel tubes including bends shall be in

the heat treated condition. The bends shall be solution
annealed after bending. Electric resistance heating is
acceptable for heat treating the bends.
b.
Finished tubes shall be annealed and pickled or passivated in a manner acceptable to the codes and
standards.
164 of 373

RAJASTHAN
c.
4.2.15.8.3.4.2
Lubricants, if used during the manufacturing processes

(drawing, bending etc.) shall be chloride free (5 ppm
maximum), completely water soluble and shall be
removed entirely before heat treatment, welding and
at completion of fabrication (before testing).
Tests
Tests performed on stainless steel tubes shall be as follows:
4.2.15.8.3.4.2.1
Hydrostatic and non-destructive electric tests (eddy current

tests) shall be performed on each tube in accordance with
ASTM A-450 or approved equivalent standards.
4.2.15.8.3.4.2.2
Each lot of tubes shall have a flare test with atleast two tests
per lot. The flare test shall be in accordance with ASTM
Specification A-450 or any approved standard.
4.2.15.8.3.5
Adequate stainless steel impingement plates of 10mm (3/8")

minimum thickness shall be provided at all shell nozzles receiving
steam to protect tubes against impingement and erosion attack. The
impingement plate shall have double the area of the inlet nozzle and
will be located on the tube bundle. Perforated impingement plates
shall not be accepted.
4.2.15.8.3.6
The design of the feed water heater shall incorporate necessary vents
and baffles to avoid blanketing of the tube surface by stagnant
pockets of non-condensible gases.
4.2.15.8.4
Tube Sheets, Baffles and Support Plates
4.2.15.8.4.1
Tube sheets shall be designed for the full design pressure acting
independently on either side. The tube sheet shall have grooves for
receiving the pass partition wall and the web of the gasket. The
effective tube sheet thickness shall be as measured at the bottom
of the pass partition wall groove minus shell side corrosion
allowance. The tube sheet shall be of rolled plate or forged and faces
of the tube sheets shall be true before and after the tubes are rolled
in. Suitable threaded holes for eyebolts shall be provided on the tube
sheet to facilitate pulling and removal of the tube bundle.
4.2.15.8.4.2
The feed water heater shall be designed to prevent the superheated

steam at entry to the feed water heater from coming into contact
with the tube plate and plate joint.
4.2.15.8.4.3
Tube nests shall be suitably baffled to prevent vibration and to obtain

uniform distribution of steam and free drainage of the condensate of
165 of 373

RAJASTHAN
the tubes.
4.2.15.8.4.4
Baffles and support plates shall be of rolled plates. All baffles shall be
designed to eliminate, as far as practicable, dead fluid spaces
between adjacent passes. Baffles and support plates shall be
provided with
notches required for shutdown drainage or for
removal of condensate where necessary. The number of tie rods and
spacers used to retain the cross baffles and tube support plates shall
be as recommended by specified codes. Spacers may be welded to
baffles to stiffen the baffle assembly. Alternatively, the tie rods may
be secured to end baffles by nuts which will be screwed on to the tie
rod ends.
4.2.15.8.4.5
The complete assembly of tubes, tube support plates, baffles,

shrouds etc. shall snugly fit around the tubes and the shell interior to
avoid short circuiting of shell fluid and permit unrestricted differential
expansion.
4.2.15.8.5
Water Boxes
The water box or channel section of all heaters shall be of fabricated
or forged steel construction. The water boxes shall be sufficiently
deep and specially designed for efficient and smooth entry of water
into the tubes and uniform distribution of feed water to all the
tubes. Wherever required, stiffening sections shall be external to
the water box in order to reduce the turbulence in the waterways to
a minimum. Easy access to the interior of water box for inspection
and maintenance shall be provided. The water box shall be fitted
with relief valves and vent valves.
4.2.15.8.6
Flanges, Bolts, Nozzles and Pipes
4.2.15.8.6.1
All flanges shall have a minimum thickness as per code specified.

Forged and weld neck flanges shall be preferred. Main shell and
channel flange joints shall be of tongue and groove type.
4.2.15.8.6.2
The minimum entrance area shall not be less than the inside area of
the inlet nozzle. All pipes used for nozzles shall be seamless. The
nozzle wall thickness shall be calculated in accordance with codes
specified. Nozzle openings shall be flanged. All nozzle flanges shall
be capable of withstanding the maximum test pressure and shall have
raised face.
4.2.15.8.6.3
Nozzles shall project a minimum of 150 mm outside the insulation.
4.2.15.8.6.4
External Forces on Major Pipe Connections

The heater including its supports, shall be capable of withstanding
166 of 373

RAJASTHAN
safely the forces and moments transmitted from any of the
interconnecting piping.
Feed water heater channel (water or tube side) connecting nozzles to
the Feed water piping shall be capable of withstanding the forces and
moments transmitted from the piping on the basis that the piping
may be fully stressed under the rules of ASME B 31.1 Power Piping
Code except that the supplier may limit the forces and moments
individually or severally.
4.2.15.9
Fabrication Tolerances
4.2.15.9.1
Dimensional tolerances shall be as per TEMA standards. The shell

sections shall be sufficiently true to roundness so that the difference
between the maximum and minimum measured inside diameter at
any cross section along the length of the shell shall not exceed 3.2
mm.
4.2.15.9.2
The tolerances for the finished tube holes in tube sheets shall not
exceed the limits prescribed by TEMA. Care shall be exercised to
ensure 96% or more of tube holes are within prescribed limits to
avoid over or under expansion when mechanical means of expansion
of tubes are employed.
4.2.16
List of Motorized valves

The OWNER wishes to go in for automation of the plant
operation to the maximum extent possible. This calls for
motor operation for a few of the important valves.
Notwithstanding any thing mentioned to the contrary,
elsewhere in these specifications, the following gives the list of
minimum number of motor operated valves (For additional
scope for Motorized Valve also refer P & IDs).
- Vacuum breaker isolation valve (1 no/ TG)
- LP extraction line (1 no/ TG) with integral bypass (inching type)
- HP 1 and 2 extraction steam line (2 nos/ TG) with integral bypass
(inching type)
- Upstream isolation valve in pneumatically operated control valve
(main line)
The motorized valves open / close time shall be suitable for the
application. However, motor operated valves used in the HP heaters
isolation shall have a closing time of maximum 12 seconds.
167 of 373

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ULTRATECH CEMENT LIMITED, BIRLA WHITE

CEMENT - III, KHARIA KHANGAR, JODHPUR,

DETAILED TECHNICAL SPECIFICATION

This section of the technical specification defines minimum technical

The steam turbo generator will be installed in a separate powerhouse,

The turbine control shall be located in the control room, located

Design and Engineering

Highest possible thermal and energy efficiency.

State-of-the-art technology and well proven in actual operation

Rugged, conservatively designed, proven components and

Minimum outage for field maintenance and routine inspection.

Better operability at various load conditions.

Advanced instrumentation, control systems, shut-down and

Minimum requirement of operating and maintenance man-

ULTRATECH CEMENT LIMITED, BIRLA WHITE

Suitability for harsh tropical ambient conditions prevailing at

Simple design and ease of installation.

The SUPPLIER may incorporate additional features and improvements

The turbine shall be horizontal, single cylinder, bleed cum condensing

All casings and stator blade carriers shall be horizontally split or

ULTRATECH CEMENT LIMITED, BIRLA WHITE

The blading shall be designed to withstand all vibrations, thermal

Gland Sealing System

ULTRATECH CEMENT LIMITED, BIRLA WHITE

Lubrication and control oil system

ULTRATECH CEMENT LIMITED, BIRLA WHITE

The oil system shall include the following:

One hundred percent (100 %) capacity centrifugal type AC driven

2 x 100% (1AC+1DC) Jacking oil pump with all piping, valves,

Oil storage and settling tank with adequate reservoir capacity,

Flow and temperature indication for oil from every bearing.

LVDH for oil purification including interconnecting piping and valves.

Oil clarification system (ELC machine of 100 LPH capacity)

Emergency gravity lube system designed for lubrication up to

ULTRATECH CEMENT LIMITED, BIRLA WHITE

ULTRATECH CEMENT LIMITED, BIRLA WHITE

Oil purifier and ELC Machine

Emergency Oil Tank

ULTRATECH CEMENT LIMITED, BIRLA WHITE

Collecting/ Settling oil tank

Steam Turbine Governing System

The governor shall be configured to incorporate the following controls

ULTRATECH CEMENT LIMITED, BIRLA WHITE

Load set point shall remain unaffected for the variation of

The turbine inlet steam pressure shall be maintained at the set

External Forces and Moments

Thermal Insulation and Lagging

Capacity and Performance Requirement

Turbine Generator Rating

ULTRATECH CEMENT LIMITED, BIRLA WHITE

No load and Minimum load operation

Specific steam consumption

ULTRATECH CEMENT LIMITED, BIRLA WHITE

Over speed trip

Steam inlet pressure falling below pre-determined level.

ULTRATECH CEMENT LIMITED, BIRLA WHITE

Variation of steam pressure and turbine

ULTRATECH CEMENT LIMITED, BIRLA WHITE

Limit of lubricating oil temperature

All controls shall operate in a fail safe mode.

All coupling and gears shall be provided with adequate guards.

Piping shall be arranged in such a manner as to avoid tripping or