tender document for boiler unit for 15 mw …

TENDER DOCUMENT

For

BOILER UNIT

For

15 MW COGENERATION PLANT

STAR PAPER MILLS LIMITED B.D. Bajoria road, Saharanpur, Uttar Pradesh

VOLUME – II

TECHNICAL SPECIFICATION

MAY 2018

Snyder Energo Private Limited No. 301, VITC Model Export Park,

#488, 14th Cross, 4th Phase, Peenya Industrial area, Bangalore – 560 058, India

E-mail: [email protected]

STAR PAPER MILLS LIMITED


TECHNICAL SPECIFICATION FOR

BOILER

DOC. NO : 4 – 3678 – MECH – 001 (R2)

VOLUME - II

TECHNICAL SPECIFICATION

FOR BOILER

REVISION NO. R0 R1 R2

ISSUED FOR FOR TENDERING FOR TENDERING FOR TENDERING

PREPD.BY/DATE SRN / 29-Mar-18 SRN / 25-May-18 SRN / 12-Jun-18

CHKD. BY/DATE SGN / 05-Apr-18 SGN / 28-May-18 SGN / 13-Jun-18

APPD. BY/ DATE BRC / 12-Apr-18 BRC / 30-May-18 BRC / 13-Jun-18

Consultant: Snyder Energo Private Limited Bangalore




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SECTION

TITLE

NO. OF PAGES

Section-1 GENERAL INFORMATION 03

Section-2 PROJECT SPECIFIC INFORMATION 11

Section-3 SCOPE OF WORK, TERMINAL POINTS AND EXCLUSION

17

Section-4 MECHANICAL SYSTEM 47

Section-5 ELECTRICAL SYSTEM 23

Section-6 INSTRUMENTATION AND CONTROL SYSTEM

19

Section-7 TOOLS & TACKLES AND SPARES 04

Section-8 QUALITY ASSURANCE REQUIREMENT 07

Section-9 PAINTING SYSTEM 07

Section-10 ERECTION TESTING & COMMISSIONING 06

Section-11 PERFORMANCE GUARANTEES AND LIQUIDATED DAMAGES

04

Section-12 TECHNICAL DATA SHEET TO BE FILLED BY THE TENDERER

-

Section-13

DRAWINGS AND DOCUMENTS TO BE SUBMITTED

08

Section-14

LIST OF APPROVED SUB VENDORS FOR MAJOR BOUGHTOUT ITEMS

05

Section-15

SPECIFICATION DRAWINGS 01

Annexure UTILITY REQURIMENT 02

Consultant: Snyder Energo Private Limited Index i Bangalore




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GENERAL INFORMATION





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SECTION – 1

GENERAL INFORMATION

1.0 GENERAL

1.1 This specification covers the design, engineering, procurement, manufacture, inspection and testing at Tenderer's and/or his sub-vendor’s works, loading, packing, transportation and delivery at site including unloading from carriers at site, handling and storage at site, intra-site transport, erection/installation, painting, testing, commissioning, carrying out performance and guarantee tests at site and handing over of one (1) no. of Boiler unit, for Star Paper Mills Ltd., (SPML) at Saharanpur, Uttar Pradesh.

1.2 Boiler shall supply superheated steam at the main steam stop valve at 80 tph, 110 Ata and temperature of 540±5 Degree C for the Steam Turbine of 15 MW. The Boilers will be circulating fluidised bed combustion type, double-pass, balanced draft, and semi-outdoor type. The feed water temperature at the outlet of HP Heater shall be 155 degree C.

1.3 All the equipment/plant shall conform in all respects to high standards of engineering, design and workmanship and be capable of performing in continuous commercial operation up to the Tenderer’s guarantees in a manner acceptable to the Purchaser/Purchaser’s representative, who will interpret the meaning of specifications and drawings to ensure that all the work and materials are in full accordance therewith.

1.4 The extent of supply under this contract includes all items shown in the appropriate sketches/drawings not withstanding the fact that such items are not covered in specification or schedules. Similarly, the extent of supply also includes all items mentioned in the specification and/or schedule, not withstanding the fact that such items are not shown in the sketches/drawings.

1.5 All specialised equipment/services necessary for proper erection, commissioning and performance testing of all items of the plant covered under this contract shall be arranged by the Tenderer. The cost of the same shall be included in the contract price.

1.6 The precision instrument/equipment required for the performance testing of all items of the plant covered under this specification as per code requirement shall be furnished by Tenderer on returnable basis.

1.7 All necessary coordination with regard to sub-contracted equipment shall be carried out by the Tenderer. The Purchaser/Purchaser’s representative will communicate only with the Tenderer for all matters pertaining to this contract.

1.8 All equipment shall be new, reputed and of approved make. The makes of all bought-out equipment shall be as per the vendor list and subject to approval by the Purchaser after the award of Contract. In addition to the main equipment, all major auxiliary systems/equipment such as Fans, Motors, Feed water pumps, De-aerator, Soot blowers, instrumentation & control system, etc., shall also be of field proven quality.

1.9 All plant, equipment, systems and works covered under this specification shall comply with the latest editions including amendments of applicable codes, standards, statutes, regulations and safety rules. Special care shall be exercised in observing compliance to the rules and regulations governing the locality where the plant is to be installed. Tenderer’s obligations in this regard shall not be limited to only those codes and standards mentioned in these

Consultant: Snyder Energo Private Limited Section-1 1 of 3 Bangalore




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specifications. Nothing in these specifications shall be construed to relieve the Tenderer of his responsibility in this regard.

1.10 The Tenderer shall perform all the works specified or necessary to complete the works in accordance with this specification. Further, the Tenderer’s performance of the works under the Contract shall be in accordance with good engineering and construction practices, notwithstanding the fact that every item involved may not be specifically mentioned or the item mentioned may be inadequate for its intended purpose. Details and items, which are not specifically mentioned herein, shall also be adequately and properly performed by the Tenderer at no extra cost if such details and/or items are reasonably necessary to complete the intent of this specification or otherwise to complete the Boiler.

1.11 The total price quoted for this contract shall be firm lump-sum all-inclusive basis and shall cover all items and services necessary for the successful completion of the contract. Even if all components of a system included in this specification are not explicitly identified and/or listed herein, these shall be supplied under this contract to ensure completeness of the system and facilitate proper operation and easy maintenance of the plant.

2.0 CODES AND STANDARDS

2.1 In addition to the requirement spelt out in various Sections of this specification, including all requirements of the Indian Boiler Regulation/Act (1950 edition, with amendments up to the date of construction) and any other statutory regulations in force such as Indian Explosives Act, Indian Factories Act, Indian Petroleum Act, Indian Electric Rules etc., wherever applicable. The equipment to be provided under this section shall specifically conform to the latest editions of the following codes, standards, specifications and regulations.

2.2 The steel structures and foundations shall be designed for earthquake conditions as per IS-1893 (Zone shall be project and site specific) and wind loads (Project and site specific) as per IS-875.

2.3 Codes/Standards for integral piping and valve shall be ANSI B 16.34 and ANSI B 16.25 (valves), ANSI B 31.1 (for piping) and ANSI B 16.5 (flanges), ASTM-A-335, ASTM-A-106, SA 210 and SA 213 (High Pressure / temperature piping and tubing). Wherever definite design stipulations are not available in the IBR, the ASME Section- I shall be referred. However if the bidder do not manufacture equipment/components to ASME then the offered equipment would be acceptable provided the material selected is comparable or superior to ASME.

2.4 The equipment shall also conform to the latest edition of the codes and standards specified below or equivalent recognized international standards as applicable on the date of award of contract and not limited to the following:

i) PTC-4 : ASME performance test code for Boiler

ii) ASME Section IX : Welding Qualification

iii) Indian Boiler Regulations (IBR)

iv) Bureau of Indian Standards (BIS)

v) Heat Exchanger Institute (HEI)

vi) Instrument Society of America (ISA)

vii) American Society for Non-destructive testing





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viii) American Gear Manufacturer's Association (AGMA)

ix) National Fire Protection Association (NFPA)

x) Federal Occupational Safety and Health Regulations (OSHA)

xi) Steel Structures Painting Council (SSPC)

xii) ASME Steam Table

xiii) Indian Electricity Act

xiv) Indian Factories Act and Uttar pradesh State Factories Act





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PROJECT SPECIFIC INFORMATION





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SECTION – 2

PROJECT SPECIFIC INFORMATION

1.1 PROJECT

1. Purchaser STAR PAPER MILLS LIMITED, B.D. Bajoria Road, Saharanpur, Uttar Pradesh

2. Project 15 MW Cogeneration Plant

3. Purchaser’s Consultant SNYDER ENERGO PRIVATE LIMITED, No. 301, VITC Model Export Park, # 488, 14th Cross, 4th Phase, Peenya Industrial Area, Bangalore – 560 058, India.

1.2 LOCATION

The proposed project site is located at B.D. Bajoria Road, Saharanpur, Uttar Pradesh. The location details of the proposed project site are as indicated below:

Latitude 29° 56' 17.95" N

Longitude 77° 34' 17.14" E

Height above mean sea level 280.00 m

Seismic Zone Zone – IV

Nearest town Saharanpur

Nearest City Saharanpur

Nearest national highway NH-73

Nearest Railway station Saharanpur

Nearest airports Sarsawa

Nearest seaports Dahej Port

1.3 CLIMATIC DATA

Maximum dry bulb Temperature 43.0 (degree C)

Minimum dry bulb Temperature 37.8 (degree C)

Ambient Air Temperature 30-33 (degree C)





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Multiyear Max. Temperature 43.0 (degree C)

Multiyear Min. Temperature -1.0 (degree C)

Multiyear Annual Average Temperature 30.0 (degree C)

Mean maximum (Summer) 74.0 %

Mean Minimum humidity 54.0 %

Maximum humidity (Monsoon) 72.0 %

Minimum humidity (Monsoon) 30.0 %

Multiyear annual mean rain fall 230.0 mm

Annual rainfall (minimum) 200.0 mm

Basic wind speed 19.0 mph

1.4 FUEL

1.4.1 Source of Fuel

Imported coal from Indonesia or USA will be transported upto nearest port through ship and thereafter by road transport upto the plant site.

Indian Coal will be transported from Dhanbad, Jharkhand. The Indian Coal will be transported to plant through Rail transport. Petcock will be procured from Indian refineries and/or Authorised agencies and the same will be transported to plant through Road transport by trucks.

Lignite will be procured from Gujarat/Rajasthan mines through Govt. authorized agencies. The Lignite will be transported to plant through Rail transport.

In addition, the Agro fuels viz., Mill Bagasse, Charkhi Bagasse, Saw dust, Rice husk, Wood chips, etc., are also under consideration. The Agro fuels are available nearby region and the same will be transported to plant through trucks.

1.4.2 Coal Analysis

Proximate and ultimate analysis of coal / Agro fuels

i) Indian Coal*

Sl. No Particulars Units Average

Proximate analysis (As received basis)

i. Moisture % 21.0

ii. Ash % 42.3

iii. Fixed carbon % 26.2





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Sl. No Particulars Units Average

iv. Volatile matter % 10.5

Total % 100

Ultimate analysis (As received basis)

i. Carbon % 33.73

ii. Hydrogen % 2.35

iii. Sulphur % 0.42

iv. Nitrogen % 1.02

v. Oxygen (by difference) % 5.48

vi. Moisture % 15

vii. Ash % 42

Total % 100

Gross calorific value kcal/kg 3308

Grindability index HGI 55

ii) Indonesian Coal* Sl. No

Particulars Units Performance coal

Average Range

Proximate analysis (As received basis)

By weight

i. Moisture % 24.85 28 20 to 40

ii. Ash % 1.19 7.5 1 to 11

iii. Fixed carbon % 36.14 32 35 to 45

iv. Volatile matter % 37.82 32.5 30 to 43

Total % 100 100


i. Carbon % 52.15 51.65 49 to 54

ii. Hydrogen % 4.21 3.71 3.3 to 4.5

iii. Sulphur % 0.43 0.61 0.06 to 1.14

iv. Nitrogen % 0.52 0.81 0.6 to 1.06

v. Oxygen (by difference)

% 16.65 10.65 7.16 to 17.68

vi. Moisture % 24.85 26.97 13 to 27

vii. Ash % 1.19 5.60 0.67 to 7.41

Total % 100 100





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Sl. No

Particulars Units Performance coal

Average Range

Gross calorific value kcal/kg 4736.42 5006.76 4807 to 5373

Grindability index HGI 50 56 40

iii) Pet coke (R)

Sl. No

Particulars Units Value

Proximate analysis (Air Dried Basis)

By mass

i. Moisture % 0.66

ii. Ash % 0.26



Total % 100

Ultimate analysis (Air Dried Basis)

i. Carbon % 87.96

ii. Hydrogen % 3.03

iii. Sulphur % 5.60

iv. Nitrogen % 2.10


vi. Moisture % -

vii. Ash % 0.26

Total % 100

Gross calorific value (Air Dried Basis)

kcal/kg 8440

iv) Pet coke (I)

Sl. No



By mass

i. Moisture % 0.39

ii. Ash % 0.12



Total % 100

Ultimate analysis





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Sl. No


(Air Dried Basis)

i. Carbon % 87.62

ii. Hydrogen % 3.10

iii. Sulphur % 7.40

iv. Nitrogen % 1.25


vi. Moisture % -

vii. Ash % 0.12

Total % 100


iv) Lignite*

Sl. No



i. Carbon % 31.00

ii. Hydrogen % 2.20

iii. Sulphur % 0.80

iv. Nitrogen % 0.50

v. Oxygen % 11.0

vi. Moisture % 50

vii. Ash % 4.5

Total % 100


iv) Fire wood

Sl. No



By mass

i. Moisture % 36.93

ii. Ash % 0.79



Total % 100





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Sl. No



i. Carbon % 31.61

ii. Hydrogen % 4.44

iii. Sulphur % 0.44

iv. Nitrogen % 0.84


vi. Moisture % -

vii. Ash % 0.79

Total % 100


kcal/kg 3380

Note: 50% moisture to be considered in As received basis.

iv) Rice husk*

Sl. No



i. Carbon % 36.67

ii. Hydrogen % 3.00

iii. Sulphur % 0.08

iv. Nitrogen % 0.40

v. Oxygen % 31.05

vi. Moisture % 10.0

vii. Ash % 18.80

Total % 100


v) Saw dust*

Sl. No



i. Carbon % 31.82

ii. Hydrogen % 4.39

iii. Sulphur % 0.70

iv. Nitrogen % 0.23





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Sl. No


v. Oxygen % 25.24

vi. Moisture % 35.0

vii. Ash % 3.25

Total % 100


vi) Mill Bagasse*

Sl. No



i. Carbon % 23.50

ii. Hydrogen % 3.25

iii. Sulphur % 0.05

iv. Nitrogen % 0.10

v. Oxygen % 21.6

vi. Moisture % 50

vii. Ash % 1.5

Total % 100


kcal/kg 2300

vii) Charkhi Bagasse

Sl. No



By mass

i. Moisture % 31.97

ii. Ash % 4.01



Total % 100


i. Carbon % 26.40

ii. Hydrogen % 6.05

iii. Sulphur % 0.16





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Sl. No


iv. Nitrogen % 0.42


vi. Moisture % -

vii. Ash % 4.01

Total % 100


kcal/kg 3090

Note: 50% moisture to be considered in As received basis.

Note: (*) mark indicates these values to be validated by SPML.

1.4.3 Ash analysis

Sl. No

Characteristics Unit Value Value Value Value

Indian Coal

Pet coke (R)

Pet coke (I)

Fire wood

i. Alumina as Al2O3 % by mass 23.60 12.13 1.42 3.74

ii. Silica as SiO2 % by mass 64.15 47.40 54.82 13.04

iii. Iron as Fe2O3 % by mass 6.22 6.19 5.05 0.56

iv. Calcium as CaO % by mass 1.48 2.11 5.24 38.2

v. Magnesium as MgO % by mass 0.64 0.18 0.94 5.04

vi. Manganese as Mn3O4 % by mass 0.04 0.01 0.05 0.05

vii. Phosphorous as P2O5 % by mass 0.27 0.13 0.10 3.32

viii. Potassium as k2O % by mass 0.66 0.16 0.49 12.62

ix. Sodium as Na2O % by mass 0.25 3.38 13.03 1.97

x. Sulphur as SO3 % by mass 0.90 6.65 5.63 0.62

xi. Barium as BaO % by mass 0.7 0.21 0.33 0.05

xii. Vanadium as V2O5 % by mass BDL 21.29 12.52 BDL

xiii. Titanium as TiO2 % by mass 0.70 0.04 0.17 0.04 Loss of ignition % by mass - - - 20.33

xiv. Ash Fusion Temperature (In Oxidising atmosphere)

xv. Initial deformation temperature (IDT)

Deg. C 1230 1111 1245 1379

xvi. Softening temperature (ST)

Deg. C 1450 1167 1314 >1530

xvii. Hemispherical temperature (HT)

Deg. C >1530 1180 1339 >1530

xviii. Fluid temperature (FT) Deg. C > 1530 1197 1355 > 1530





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Sl. No

Characteristics Unit Value Value Value Value

Saw dust Rice husk

Mill Bagasse

Charkhi Bagasse

i. Alumina as Al2O3 % by mass 6.29 0.36 1.97 4.09

ii. Silica as SiO2 % by mass 74.64 86.59 76.27 32.21

iii. Iron as Fe2O3 % by mass 2.20 0.58 1.47 6.28

iv. Calcium as CaO % by mass 4.88 1.77 4.78 27.04

v. Magnesium as MgO % by mass 2.44 0.90 2.37 3.62

vi. Manganese as Mn3O4 % by mass 0.06 0.07 0.04 0.07

vii. Phosphorous as P2O5 % by mass 1.13 1.03 1.65 2.34

viii. Potassium as k2O % by mass 4.75 2.34 3.08 6.35

ix. Sodium as Na2O % by mass 2.27 4.71 2.28 2.10

x. Sulphur as SO3 % by mass 0.30 0.96 2.84 0.71

xi. Barium as BaO % by mass 0.08 0.01 0.03 0.05

xii. Vanadium as V2O5 % by mass BDL BDL BDL BDL

xiii. Titanium as TiO2 % by mass 0.19 0.01 0.06 0.11 Loss of ignition % by mass 0.05 0.46 2.96 14.83

xiv. Ash Fusion Temperature (In Oxidising atmosphere)

xv. Initial deformation temperature (IDT)

Deg. C 1204 1424 1044 1245

xvi. Softening temperature (ST)

Deg. C 1271 >1530 1451 1253

xvii. Hemispherical temperature (HT)

Deg. C 1364 >1530 1512 1263

xviii. Fluid temperature (FT) Deg. C 1462 >1530 1517 1274

1.4.4 Secondary liquid fuels

Light Diesel Oil shall be used for start-up, coal flame stabilization and low load operation of the boiler.

Sl. No. Particulars Unit (As per IS : 1460) Latest Rev

i. Flash point Deg. C 66 ii. Pour Point ( Winter) Deg. C 12 iii. Pour Point ( Summer) Deg. C 18 iv. Kinematic Viscosity at 38 deg C Centistokes 2.5 to 15.7 v. Sediment by weight Percent 0.1 ( Max) vi. Water content by volume Percent 0.25 ( Max) vii. Sulphur by weight Percent 1.8( Max) viii. Carbon Residue by weight Percent 1.5(Max) ix. Specific Gravity at 15 deg C 0.85 x. Acidity ( Inorganic) Nil

xii. Ash Content Percent 0.02 ( Max) xii. Gross Calorific Value Kcal/ Kg 10,000





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1.5 WATER SYSTEM

1.5.1 De-mineralised water for Power Cycle Make-up

The quality parameters of demineralised water to be used for make up to the deaerator and feed water tank shall be as below:

i) pH : 7 ± 0.3 (After pH correction) ii) Conductivity : 0.2 micro Siemens/cm at 25 degree C iii) Silica : < 0.02 m as SiO2

1.5.2 Auxiliary cooling water

i) Inlet temperature : 33 degree C

ii) Outlet temperature : 42 degree C

iii) Pressure : 4 kg/cm2 (a)

1.6 POWER SUPPLY

The power supplies for distribution and auxiliaries shall be as under:

Sl. No Parameter Description

i) In Plant generation 11.0 KV ±5%, 3ph, 50Hz ± 5%, high resistance grounded.

ii) Power Evacuation 11.0 KV ±5%, 3ph, 50Hz ± 5%, high resistance grounded.

iii) HT distribution 6.6kV ±10 %, 3ph, 3W, 50 Hz, + 5 % to –5%, resistance grounded system.

iv) LT distribution 415V ±10%, 3ph, 4W, 50Hz + 5% to –5%, solidly grounded system.

v) Motor rated 180 kW and above. 6.6kV ±10 %, 3 ph, 50Hz +5% to –5%.

vi) Motor rated above 200W and below 180 kW and all motorized actuators.

415V ±10%, 3 ph, 50Hz +5% to - 5%.

vii) For motors equal and below 200W; panel space heating , lighting and small power distribution

240V ±10%, 1ph, 50Hz + 5% to –5%, solidly grounded.

viii) DC Motors 110V DC, 2-wire ungrounded system.

ix) Control supply for relay panel/MV breakers/LV breakers and DC emergency lighting.

110V DC, 2-wire ungrounded system.

x) UPS for instrumentation & Control system

240V AC ±2 %, 1 ph, 50Hz ±0.5%.

xi) DC power for control & instrumentation (if required.)

+24V DC (20V-30V), - VE side grounded.





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xii) Control supply for 415V Motor

contactors/AC Control circuits [to be generated in MCC/ panel by vendor with control transformers]

110V AC ±10%, 50Hz + 5% to –5%.

xiii) Diesel Generator emergency supply

415V ±10%, 3ph, 3W, 50Hz +5% to –5%.

NOTE: a) All equipment except generator shall be suitable for 10% combined voltage and frequency variation [absolute sum]

b) Any other power supply requirement shall be derived by the vendor from the above available power supplies

xv) Design ambient temperature for electrical equipment and devices

50 degree C.

vi) Fault levels

11 kV 40 kA for 1 sec.

6.6 kV 25 kA for 1 sec.

415V 65 kA for 1 sec.

1.7 INSTRUMENT AIR (OIL FREE)

i) Pressure at the terminal point : 6 kg/cm2 (a)





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SCOPE OF WORK, TERMINAL POINTS AND EXCLUSIONS





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SECTION – 3

SCOPE OF WORK, TERMINAL POINTS AND EXCLUSIONS

1.0 BROAD SCOPE OF SUPPLY

1.1 The scope of the Tenderer shall include design, engineering, material selection, manufacturing, testing at works, supply to site, installation, commissioning, performance testing at site, and other related items of work for One (1) no. of Boiler and auxiliaries inclusive of all mechanical, electrical, instrumentation & control systems, civil design interface (excluding civil works) and structural works, necessary for putting into commercial operation a highly reliable, safe, efficient and environmentally compliant Boiler and auxiliaries for Cogeneration Plant at Saharanpur, Uttar Pradesh. Boiler ambient inlet air temperature for boiler design and efficiency calculation is 30 Deg. C.

1.2 The Tenderer shall perform all the works specified or necessary to complete the works in accordance with this specification. Further, Tenderer’s performance of the works under the contract shall be in accordance with good engineering and construction practices. Details and items which are not specifically mentioned herein, shall also be adequately and properly performed by the Tenderer at no extra cost, if such details and/or items are reasonably necessary to complete the intent of this specification or otherwise to complete the boiler unit.

1.3 The intent of this specification is to relieve the Purchaser of the necessity of engaging or supplying any labour, service, equipment or material to complete the boiler except in respect of the works to be furnished by the Purchaser as specifically itemized in exclusions.

1.4 MECHANICAL WORKS

1.4.1 Complete steam/water cooled furnace with cyclone separators, water wall, headers, drains, drain funnels, drain pipelines, up to and including blow down tanks and necessary stubs for chemical cleaning and wet lay up.

1.4.2 Steam drum complete with all internals like, cyclone steam separators, demister pads, manholes with cover, connections for chemical dosing system, safety valves, level gauges, level transmitters, etc.

1.4.3 Complete superheater system including headers, connecting pipes, vents, drains, De-superheater system, safety valves, electromatic relief valve (ERV) on super heater outlet line.

1.4.4 Economiser complete with connecting headers, pipes, non-return valve and motor operated isolating valve.

1.4.5 Tubular air heater complete with primary air, secondary air, fluidising air (if required) tubes, By-pass duct and connecting ducts for primary, secondary and fluidising air.

1.4.6 Light up and combustion stabilising oil burners along with high energy electrical igniters, including LDO unloading storage and pumping system.

1.4.7 Flame scanners with accessories and scanner cooling air system.

1.4.8 Silencers for start up vents, safety valves, ERV. All drain lines including steam traps discharge with drain funnels and pipelines from funnels up to nearest plant drainage system.





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1.4.9 Integral piping, valves & fittings, complete steam and water sampling lines coolers &

collectors, chemical feed line, intermittent & continuous blow-down lines, blow-down tanks.

1.4.10 Complete power cycle and feed water piping as well as all auxiliary system piping, with hangers and supports, valves, drains, vents, sampling points, instrument tapping, etc., as required for boiler, steam turbine and auxiliaries and connected systems.

1.4.11 Complete soot blower system with drains, steam piping & fittings, control valves, etc.

1.4.12 Refractory and insulating & cladding material along with required fixing material for the equipment proposed.

1.4.13 2 x 60 % Primary air fans (with VFD), 2 x 60 % Secondary air fans (with VFD) complete with drives, connecting ducts, control dampers, suction filter, suction silencer, Bird-screen & rain protection hood.

1.4.14 2 x 60% Induced draft fans (with VFD) complete with drives, isolation dampers, ducting from ESP to fan and fan to chimney including supports.

1.4.15 Coal bunkers complete with supporting structure, coal feeding system from coal/rice husk bunkers to furnace. Agro fuel silos complete with supporting structure, Agro fuel feeding system from silo to furnace

1.4.16 Limestone bunkers complete with supporting structure, limestone feeding system coal bunkers to furnace.

1.4.17 Bed material silo and supporting structure, hoist for bed material loading bed material into silo, material feeding system etc.

1.4.18 Complete steam generator supporting structural steel, foundation bolts, anchors, inserts etc. Boiler structure shall start from + 300 mm above finished ground level, including supply of grouting material and grouting.

1.4.19 Coloured sheeting for boiler structure, Silo/coal/limestone bunker structure and roofing of Boiler & bunkers.

1.4.20 Galleries, walkways, platforms, hand-rails, ladders pipe supports and hangers, interconnecting platforms etc. Provision for installation various transmitters and process devices separately procured by Purchaser.

1.4.21 Chemical dosing system (HP & LP) complete with tanks, stirrers, dosing pump, piping, valves etc.

1.4.22 Four numbers of PRDS (One for MP Header + One for LP Header + One for Ejector System + one for Gland Steam) complete with motorised isolation valve at inlet, control valve, manual isolation valve at outlet, etc.

Boiler External Piping – From CSDH to LP header through PRDS – I

Boiler External Piping – From CSDH to Ejector system through PRDS – 2

Boiler External Piping – From CSDH to Gland sealing system through PRDS – 3





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Boiler External Piping – From CSDH to MP header through PRDS – 4

1.4.23 Flue gas cleaning system (Electrostatic Precipitator) complete with supporting structure, discharge & collecting plates, rapping mechanism, casing, Inlet & outlet ducting , TR sets, etc.

1.4.24 1 x 100% De-aerator complete with all internals, connections for steam & water, DM water make-up control station, PRDS for pegging system, storage tank, supporting structure, etc.

1.4.25 2 x 100 % feed water pump sets (with VFD) including drives, base frame, coupling, coupling guard, lube oil system, etc.

1.4.26 Auxiliary steam required for commissioning activities shall be arranged by Tenderer.

1.4.27 Purchaser will provide service air and instrument air at one point near Boiler 1st column. Further distribution by the Tenderer. The Tenderer shall draw the service air and instrument air distribution piping from these terminal points complete with al accessories like valves, regulators, filters etc, to all the equipment, actuators, panels and instruments wherever required.

1.4.28 Auxiliary cooling water supply & return line and DM water will be provided at one point near Boiler 1st column. Further distribution by the Tenderer. Tenderer shall draw the cooling water/DM water from this point to various equipment requiring cooling like, feed water pump, fans etc. The cold water inlet pipe and warm water outlet pipe shall be terminated at one point where the terminal point is indicated.

1.4.29 Pipe supports and associated structural works, pipe racks, trestles, trenches, etc. as required.

1.4.30 All lifting and handling equipment to facilitate the handling of equipment such as ID, SA and PA fans, feed water pumps, Fluidising/ purging/ sealing blowers, etc.

1.4.31 All necessary equipment for testing, monitoring and control of pollution of air and water from/within the Boiler.

1.4.32 All equipment base plates, lifting lugs, foundation bolts, sleeves, nuts, inserts, embedded plates as required for efficient installation of all equipment, including supply of grouting material and grouting.

1.4.33 Nitrogen bottles (adequate number for refilling), storage, handling and distribution system for preservation purpose.

1.4.34 Painting for equipment, structure, piping, etc as required.

1.4.35 Supply and installation of thermal insulation for Boiler, ESP, piping, etc., as required

1.5 ELECTRICAL WORKS

1.5.1 All drive motors both AC and DC

1.5.2 Electrical system for ESP (ESP switchgear, Rectifier transformers, service transformers and control panels, etc)

1.5.3 Steam generator motor control centre and ESP motor control centre.





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1.5.4 Variable Frequency Drive panels with all accessories.

1.5.5 Motor Operated valves with integral starters.

1.5.6 Starter Panels for DC motors.

1.5.7 Power Supply distribution Boards.

1.5.8 Junction Boxes/Marshalling boxes.

1.5.9 Earthing system above ground

1.5.10 HT Power and Control Cables including all special cables from Purchaser’s HT switchgear to Tenderers HT motor.

1.5.11 Cabling accessories (Cable glands, lugs, Flexible / Heavy duty conduits, cable dressing material, GI cable trays with painted supports structures to install trays)

1.5.12 Local Panels/Local Push Button Stations.

1.5.13 Lightning protection for Steam generator and ESP.

1.5.14 LT Power, Control Cables including all special cables between 1) Purchaser’s emergency PMCC and tenderer’s Motors.(as per key SLD) 2) Boiler MCCs and tenderers equipment 3) Between both the equipment/ part of the equipment of Tenderer’s scope.

1.5.15 Tenderer shall do the basic engineering lighting installations drawings for Steam generator / ESP showing the location of light fitting at different floor levels, SLD, type of fittings, BOM etc and shall be submitted to Purchaser’s for their procurement and installation

1.6 CONTROL & INSTRUMENTATION SYSTEM

1.6.1 Fuel and Lime stone Feeder control system including both local and remote control cabinets.

1.6.2 Soot Blowing System including PLC (PLC to be located in the control room).

1.6.3 Boiler Controls listed below will be implemented in Purchaser’s DCS based on the inputs furnished by Tenderer.

i) Boiler Start-up Shut down sequence logic including Boiler protection

ii) Boiler Analog controls like,

- Drum level (3-element)

- Furnace draft

- Super heater steam temperature

- Combustion control (fuel feed, Air flow) etc

iii) Boiler auxiliaries control

iv) HP and LP Chemical Dosing control

v) Any other BOILER control as recommended by the Tenderer





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1.6.4 Local gauge panels for mounting gauges.

1.6.5 For all the above controls all the field sensors, transmitters, final control elements, valves, interface devices etc., as required for Purchaser’s DCS interface shall be provided by Tenderer.

1.6.6 For analog drives, Purchaser’s DCS will only provide 4-20 mA command and will accept only 4-20 mA feedbacks only. For Binary drives, Purchaser’s DCS will only provide potential free contacts and will accept only potential free feedbacks.

1.6.7 Submission of input and output list for the various analog and digital signals.

1.6.8 All other interfacing devices to suit the above Purchaser’s DCS requirements shall be supplied by Tenderer as required.

Tenderer’s scope for the same shall include the following:

i) Furnishing of Recommended Control schemes/Logic diagrams, in Purchaser’s Format in soft and hard copies.

ii) Furnish all the required set-points, controller parameters, characteristic curves, equations etc., as required to implement the recommended schemes/ logics.

iii) Approving the Purchaser’s DCS vendor’s control schemes and logic diagrams related to Tenderer’s equipment

iv) Witnessing the FAT at Purchaser’s DCS vendor’s factory.

v) Participate in commissioning and pre-commissioning activities.

1.6.9 Any implementation delay because of incomplete inputs or delay in inputs by Tenderer in the required format for implementation in Purchaser’s DCS will be to Tenderer’s account.

1.6.10 Tenderer shall envisage Sub –Group Control based automated sequence control for the Boiler start-up and shutdown and accordingly ensure compatibility of the associated field equipment.

1.6.11 Tenderer shall ensure that the TRU based controllers envisaged for Spiess valve or Ash recirculation valve ( as applicable for the offered boiler), VFD panels, Feeders etc., shall be suitably mounted in AC rooms and not in hot combustor zone

1.6.12 All primary sensors like flow elements, temperature sensors.

1.6.13 All field instruments – process switches, transmitters, local gauges etc.

1.6.14 All sensors related to Boiler Protection and Critical Controls, shall be triple and sensors for balance control loops shall be redundant.

1.6.15 All final control elements like control valves, de-superheaters, control dampers and actuators, de superheaters, etc.

1.6.16 One number SWAS for analysing the following steam and water samples.

- Saturated steam

- Feed water to Economiser





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- Blow down

- Main steam

- Deaerator

1.6.17 The following steam and water samples shall be terminated at ground level with a pressure reducer and root cooler for each.

- Saturated steam

- Feed water to Economiser

- Blow down

- Main steam

- Deaerator

1.6.18 On line emission monitoring instruments, analysers of extractive type (sampling type) for SO2/ O2, NOX, dust concentration.

1.6.19 All analytical instrumentation system for pH, conductivity, silica, Carbon Monoxide, two dissolved Oxygen, Flue gas oxygen and CO.

1.6.20 Fuel, Silo, Limestone bunkers and bed material silo level switches and transmitters.

1.6.21 All machinery monitoring instruments like bearing temperature, vibration monitoring system in X-Y directions of all HT motors and Drives.

1.6.22 All junction boxes, transmitter racks, cubicles, enclosures, local panels, marshalling panels, pneumatic and process hook up hardwares and other erection materials and accessories.

1.6.23 Erection, testing, calibration, commissioning of all the items supplied by the vendor. Co-ordination with DCS suppliers for the hook-up with DCS.

1.6.24 Hand held calibrator for smart transmitters.

1.6.25 Burner management system including Igniters, digital (microprocessor based) scanners, etc.

1.6.26 Smart transmitters (pressure, DP, flow, level, temperature).

1.6.27 Furnace temperature probes, Electromatic relief valve controller ,

1.6.28 Drum instrumentation including two numbers conductivity type, bi-colour Electronic Drum Level indicators, Level gauges, bi-colour indicator in firing floor etc.

1.6.29 Complete Earthing system (separate electronic and frame earth).

1.6.30 Painting of impulse tubes, transmitter racks etc.

1.6.31 Inspection, FAT, SAT as per Purchaser approved procedures. Test certificates as required.

1.6.32 PLC and microprocessor based control system for ESP and BFP is included in the scope of Tenderer.

1.6.33 Spares, Special maintenance and erection tools and tackles required for installation, operation and maintenance of C&I equipment & system.





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1.6.34 Cable work

i) The I&C cables from sensor to JB , JB to Purchaser’s DCS

ii) Compensating cable, special cable (flame scanner EWLI etc.,) pre- fabricated cable, Fibre optic cable etc., within the battery limits including the field cables.( ie., field JB to control room / Purchaser’s DCS)

iii) Cable between Tenderer PLCs to Purchaser’s DCS for both hardwired signals and serial link.

iv) Cable trays and cable accessories for all the cable in the scope.

1.6.35 Power Supply

Purchaser will provide only redundant bulk feeders of 110 V AC UPS. All power supply distribution cabinets and distribution system for all the Tenderer’s supplied control room mounted and field mounted equipment shall be provided by Tenderer, including cables.

1.7 CIVIL STRUCTURAL AND ARCHITECTURAL WORKS

Inputs required for the civil design is included in the scope. This shall include civil load data, foundation plan. Mechanical, electrical and instrumentation coordination drawings indicating the details like providing of cut outs, insert plates, embedment of foundation bolts and providing of sleeves etc. However all civil works are excluded from the Scope.

1.8 PROJECT MANAGEMENT / SERVICES

1.8.1 The Tenderer shall identify a separate and independent project management team headed by a Project Manager for the execution of this project.

1.8.2 The Tenderer shall provide effective management of the Contract, which shall be compatible with the Purchaser’s requirements as set out in this specification. The Tenderer shall allow access to his works and those of his sub-Tenderer at all reasonable times to permit the Purchaser/Consultants participation, if the Purchaser/Consultant considers it necessary in monitoring the Contract

1.8.3 Obtaining approval from statutory bodies such as Chief Inspector of Boilers, Chief Electrical Inspectorate to Government, Andhra Pradesh Pollution Control Board, Chief Controller of Explosives etc. as applicable.

1.8.4 Management Organisation

i) The Tenderer shall include an organisation chart illustrating how the management structure/lines of authority shall function during the Contract.

ii) The Tenderer shall submit the names, qualifications and experience of the proposed managerial and senior supervisory staff to be employed after award of contract.

iii) The Tenderer shall constitute a separate commissioning team in consultation with Purchaser/Consultant before taking up of testing, commissioning and tying/connecting with other system, etc.





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1.8.5 Engineering Services

i) The Tenderer shall render complete engineering services for the equipment and associated system covered in this specification including detailed engineering, design submission and documentation as required for a good design and installation ensuring efficiency, operability, availability, maintainability and reliability of the plant.

ii) As part of document submissions, the design basis reports shall be submitted for the bought out items, by the Tenderer for approval by the Purchaser/Consultant. The approved design basis reports shall form the basis for procurement and engineering work.

iii) At any stage during the performance of the Contract, if the system warrants improvements in the Contracted plant and consequent modification in the equipment/system designs the Tenderer shall make the necessary design modifications and carry out the improvements in the plant with the approval of Purchaser/Consultant at no extra cost to the Purchaser.

iv) During the course of review of detailed engineering, it may be essential in Purchaser’s opinion to obtain data and information on similar equipment and plants engineered by the Tenderer. In case, Purchaser so desires the Tenderer shall submit such analogous data and information to the Purchaser.

v) The Tenderer shall interact with the Purchaser’s other agencies and the Consultant and exchange with them such technical information as are necessary to obtain the most optimum and economical design and to avoid unnecessary duplication of efforts.

vi) The Tenderer shall furnish a comprehensive and detailed schedule of drawings and design documents, which shall be submitted by him after award of Contract indicating submission dates against each document. The list shall be subject to the approval of the Purchaser/Consultant.

vii) The documents shall be divided into two categories:

- For approval

- For information / reference only

viii) Documents submitted during bid stage, shall be revalidated or revised as required and submitted as certified document for approval/information of the Purchaser, after award of Contract. Such documents shall include but not limited to the following:

(a) System schematic drawings, pipeline and instrumentation diagrams

(b) Design basis reports

(c) Specification for major bought-out items

(d) Equipment data sheets and general arrangement drawings

(e) Materials for construction

(f) Layout drawings, foundation plan and civil load data

(g) Operation logic diagrams





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(h) Typical control circuits

(i) Protection schemes

(j) Project schedule

(k) Quality assurance plan

1.8.6 Operating Manuals and Maintenance Instructions

i) The Tenderer shall submit to the Purchaser/Consultant, instruction manuals in English language for all equipment covered under the Contract at least thirty (30) days before the first shipment of the respective equipment.

ii) The operating manuals and maintenance instructions in English language shall be in sufficient detail to enable the Purchaser to operate, maintain, dismantle, re-assemble, adjust or replace all equipment and components during the lifetime of the plant. The manuals shall be specifically prepared for the contracted plant.

iii) The operating manuals and maintenance instructions manual shall be submitted in the form of one (1) reproducible original and six (6) copies as well as two (2) copies in Compact Disks (CDs). One (1) hard copy and one (1) copy in CD shall be furnished to Consultant. The instruction manuals shall be subject to approval of the Purchaser.

iv) If after the commissioning and the initial operation of the plant, the instruction manuals require modifications / additions, the same shall be incorporated by the Tenderer and the updated final version of the manuals shall be submitted to the Purchaser.

v) The Tenderer shall submit six (6) sets of spare parts catalogues.

1.8.7 Plant Handbook and As-Built Documentation

i) Plant Handbook

The Tenderer shall submit to the Purchaser, a preliminary main plant handbook preferably in combination of A4 and A3 size sheets which shall contain all approved design basis and design calculations, the design and performance data of various plant, equipment and systems covering the scope of his supply including single line flow diagrams, within twenty four (24) months from Letter of Award (LOA). The final main plant handbook complete in all respects shall be submitted by the Tenderer three (3) months before start-up and commissioning activities. The main plant handbook shall be submitted in form of one (1) reproducible original and six (6) copies along with two (2) copies in Compact Disks (CDs).

ii) “As-built” Documentation

The Tenderer shall provide and keep up to date “As built drawings of all structures constructed and all equipment and accessories and miscellaneous metal works erected or installed. These drawings shall show all changes and revisions from the original drawings and specifications. These drawings shall be kept in Tenderer’s field office but shall be made available at all times for review of the Purchaser/Consultant. One reproducible print with six (6) copies of all “As-Built” drawings shall be progressively handed over to the Purchaser after taking over of the plant by purchaser.





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1.8.8 Sub-Contractors

i) The Tenderer shall submit to the Purchaser a list of all major items/works that he deems necessary to be sub-contracted for approval. The Tenderer shall not change Sub-Contractor without prior approval of the Purchaser.

ii) A copy of all orders (which may be un-priced) placed on Sub-Contractors shall be submitted to Purchaser. The Purchaser’s Contract reference and station name shall be added to all inter works and sub-orders.

iii) The Tenderer shall ensure that their Sub-Contractors follow the requirement of the specification and have adequate control over all aspects covered by the specification.

1.8.9 Progress Reports

i) During the design, engineering and manufacturing, supply, erection, testing and commissioning stages the Tenderer shall submit to the Purchaser/Consultant reports and information on the progress of works by him and by the Sub-Contractors of all plant and materials required for the execution of the works. The progress of work shall be linked to the Project Schedule.

ii) The detailed procedure and requirements for progress reporting shall be agreed with the Purchaser during the early phase of the works, as part of regular Contract/project status reporting.

iii) The Tenderer shall also submit to the Purchaser monthly progress reports and any other reports as required by Purchaser/Lenders/Statutory authorities.

1.8.10 Access for Progress Monitoring

The Purchaser or his nominated representatives shall be entitled to visit the premises where design and manufacturing of the plant is being carried out in order to monitor and verify progress with intimation to the Tenderer.

1.9 MISCELLANEOUS

1.9.1 Packing & forwarding, transportation (ocean and inland), custom/port clearance, reconciliation with custom authorities, receiving and unloading at site, assessment of lost/damaged items in transit and arranging insurance claims and replacement of lost/damaged items in transit.

1.9.2 Proper storage within the site and taking custody of all the materials till the plant is officially taken over by the Purchaser after complete erection, successful trial run and commissioning.

1.9.3 Transportation of materials to their respective places of erection and erection of the complete plant & equipment as supplied under this specification.

1.9.4 Trial run and commissioning of individual equipment/ sub-systems and the plant as a whole to the satisfaction of the Purchaser including supply of temporary equipment and services for chemical cleaning steam blowing, etc.





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1.9.5 Provision for preservation of individual equipment after trial run and commissioning (e.g.

nitrogen blanketing) as necessary till take over of the equipment.

1.9.6 Supply and application of the paints on all the equipment to be erected under this specification

1.9.7 Deployment of all skilled and unskilled manpower required for erection, supervision of erection, watch and ward, commissioning and other services to be rendered under this specification

1.9.8 Deployment of all erection tools & tackles, construction machinery, transportation vehicles and all other implements in adequate number, capacity and size

1.9.9 Supply of all consumables, e.g., welding electrodes, filler wires, gas cylinders (carbon-dioxide, nitrogen, oxygen, acetylene), cleaning agents, lubricants, grease and chemicals as well as materials required for temporary supports, scaffolding, etc. as necessary up to completion of trial operation.

1.9.10 Supply of necessary calibrated instruments for carrying out performance tests of plant and equipment.

1.9.11 Taking approval of all statutory authorities by paying the requisite fee as applicable e.g., Boiler Inspector, Factory Inspector, Inspector of Explosives, Electrical Inspectorate, etc. for respective portions of work under the jurisdiction of such statutes or laws

1.9.12 Quality assurance and Quality Control of all work executed at site

1.9.13 Complete construction (including supply of material and labour, construction of site office, canteen, construction stores, residential accommodation of Tenderer’s staff labour, etc.), fabrication, erection, chemical cleaning, steam blowing, trial run, commissioning and performance testing of equipment.

1.9.14 Supply of lubricants/consumables and all temporary provisions till Provisional Takeover.

1.9.15 Mandatory spare parts, as specified, for the BOILER.

1.9.16 Tools and tackles including all special tools and tackle, as required, for the BOILER.

1.9.17 Conduct of performance tests for the entire boiler unit and for the individual equipments as required.

1.9.18 Conducting of various site acceptance tests on electrical, instrumentation and control systems of generator, excitation system, bus ducts, field instruments etc.

1.9.19 Training of the plant Purchaser’s personnel on main plant operation and maintenance.

1.9.20 Following documents to be submitted prior to six months start of erection to the Purchaser/Purchaser’s representative for approval.

i) All field quality plan for erection of complete equipment/system.

ii) Erection manual, NDT manual and welding procedure manual for all piping.





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NOTE:

The above list of work is not exhaustive. Any additional works, whether or not specifically described in this document and incidental to complete the BOILER units in all respects shall be deemed to be in the scope of work of the Tenderer.

2.0 TERMINAL POINTS

MECHANICAL

2.1 Steam

2.1.1 Superheated Steam (Main steam to Turbine)

: Up to the inlet of Emergency stop valve of TG along with necessary drains, vents and heating lines as per TG Supplier requirement (ESV Mating flange with gasket and fasteners will be provided by TG Supplier as a loose supply)

2.1.2 MP Steam from CSDH to MP Steam header

: From CSDH to MP steam header through PRDS – IV

2.1.3 LP Steam from CSDH to LP Steam header

: From CSDH to LP steam header through PRDS – I & From LP steam header to Deaerator for pegging steam/continuous steam requirement

2.1.4 First Extraction steam for MP steam

: From TG – Turbine Extraction flange to MP steam header

2.1.5 Second Extraction steam for LP steam

: From TG – Turbine Extraction flange to LP steam header

2.1.7 Ejector Steam for TG : From CSDH to ejector steam inlet header through PRDS - II

2.1.8 Gland sealing steam for TG : From CSDH to Gland sealing system for TG through PRDS - III

2.1.9 MP process steam line : From MP Header to Paper plant steam header (Approx. 170m developed length shall be considered)

2.1.10 LP process steam line : From LP Header to Paper plant steam header (Approx. 170m developed length shall be considered)

2.1.11 HP heater steam line : From MP Header to HP heater inlet (HP heater will be free issue to Tenderer)

2.2 Water

2.2.1 TG Condensate : At the inlet of De-aerator.

2.2.2 HP Heater Normal drain : From HP heater to inlet of De-aerator

2.2.3 HP Heater operating vent : From HP heater to inlet of De-aerator

2.2.4 HP Heater operation vent : Upto inlet of HP flash tank

2.2.5 Auxiliary Cooling water : At one point near Boiler 1st column. Further distribution by the Tenderer.

(ETP water will be provided for Auxiliary cooling water requirement – Titanium tube shall





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be considered for Heat exchangers)

2.2.6 DM water for make-up, dosing and initial filling

: At one point near Boiler 1st column. Further distribution by the Tenderer.

2.2.7 Deaerator over flow : At the inlet of Blowdown / IBD tank

2.2.8 Service water : At one point near Boiler 1st column. Further distribution by the Tenderer.

2.2.9 Blow down / drains : At the inlet of nearest drain trench

2.2.10 Other drains : At the inlet of nearest power plant drain pit located in boiler area

2.3 Air/Flue gas :

2.3.1 Combustion Air : At the Inlet of suction filter of fan (the silencer, filter & bird mesh are included in Supplier scope)

2.3.2 Flue gas : At the inlet of chimney (Chimney connecting flanges, counter flange, expansion bellows near chimney and all fasteners for the connections are included in Tenderer scope)

2.3.3 Instrument Air : At one point near Boiler 1st column. Further distribution by the Tenderer.

2.3.4 Service Air : At one point near Boiler 1st column. Further distribution by the Tenderer.

2.4 Fuels / Lime stone / Bed material / Fuel oil (LDO)

:

2.4.1 Coal : At the inlet of Fuel Bunkers

2.4.2 Agro fuels : At the inlet of Silos

2.4.3 Limestone : At the inlet of Limestone bunker

2.4.4 Bed material : At the inlet of Bed material bunker (Electrical operated hoist to lift the bed material from ground level to bunker is in Tenderer scope)

2.4.5 LDO : At the inlet of Day oil tank.

2.4.6 Nitrogen : At the inlet of Boiler Drum. However, Tapping and necessary distribution system will be considered

2.4.7 Dosing Chemicals : At the inlet of dosing tank

2.5 Bed Ash/Fly Ash :

2.5.1 Bed Ash : At the outlet flange of bed ash cooler @ 3.0 Mtrs. above FGL. (pneumatically operated knife edge gate valve is included in Supplier scope)





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3.0 SCOPE OF SERVICES

SL. NO. DESCRIPTION FACILITIES BY

3.1 Complete Design and Engineering of all the equipment supplied (listed out under Scope of Supplies and within the Terminal points specified)

Tenderer

3.2 Submission of Foundation loading plan drawings for the equipment supplied within the terminal points specified

Tenderer

3.3 Transportation from Supplier’s and sub-vendors works to power project site

Tenderer

2.5.2 Fly ash : At the outlet of respective ash collecting hoppers @ 3.0 Mtrs. above FGL (manual operated knife edge gate valve is included in Supplier scope)

2.6 Vents

2.6.1 Safety valve exhaust, Start-up vent & turbine warm-up vents

: At the outlet of silencer (to be terminated at safe elevation)

2.6.2 Steam line drains (Main steam, Extraction steam, Bleed steam, Ejector steam & Gland steam etc.,)

: At the inlet of Flash tank / Condenser / Drain header / Drain Trench

2.6.3 Other vents : To atmosphere, at safe elevation outside / above roof

ELECTRICAL

2.7 HT Power : Outgoing of Purchaser’s 6.6 kV switchboard

2.8 LT power : At MCC incomer

2.9 ESP Transformer : Outgoing of Purchaser’s 6.6 kV switchboard

2.10 Equipment earthing : Respective earthing stubs

I & C

2.11 Power Supply : Purchaser’s main UPS ACDB

2.12 Earthing (panel and Electronic)

: Purchaser’s Earth pit

2.13 For I & C cables : Purchaser’s DCS Marshalling box

1) At all terminal points, whether at equipment or on pipelines, it is the Boiler Tenderer’s responsibility to supply all the necessary jointing materials and make the final connection at the terminal point.

2) At all flanged terminal points, the Boiler Tenderer shall supply the counter flanges together with necessary gaskets, nuts bolts etc.





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3.4 Unloading at site Tenderer

3.5 Open space for material storage, fabrication, assembly, labour accommodation with access road

Purchaser

3.6 Safety equipment for site offices and labours Tenderer

3.7 First aid Purchaser

3.8 Ambulance Purchaser

3.9 Construction of site office, labour accommodation and store room Tenderer

3.10 Local conveyance, boarding and lodging for Contractor representatives

Tenderer

3.11 Submission of relevant drawings and calculations of pressure parts to IBR authorities and obtaining approvals at site. All co-ordination with IBR at site

Tenderer (Only Registration fee by Purchaser)

3.12 CEIG approval for electrical equipment supplied.

Purchaser (Necessary technical documents will be

provided by Contractor for

getting approvals)

3.13 Chief controller of explosives (if any) Tenderer

(Only Registration fee by Purchaser)

3.14 Overall security at site

Purchaser (But equipment

security till handover is in Tenderer scope)

3.15 Security of Tenderer’s equipment and other materials Tenderer

3.16 Comprehensive insurance Purchaser

3.17 Workmen compensation insurance for Contractor’s workmen Tenderer

3.18 Lighting facilities at site during erection and commissioning Tenderer

3.19 Erection drawings / As built drawings and documents, protocols (4 Sets in Hard copy and 2 Set in Editable Soft copy)

Tenderer

3.20 O & M Manuals (5 Sets in Hard copy and 3 Set in Non-editable Soft copy)

Tenderer

3.21 Final painting at site Tenderer

3.22 Communication facilities (Telephone and Email) Tenderer

3.23 Providing erection tools, tackles, cranes, hoists, derricks, slings, scaffolding, rigging tools, welding sets, instruments, appliances,

Tenderer





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consumables required for unloading, transporting, storing, erection, inspection, testing and commissioning to accomplish the work

3.24 Stress relieving of welded joints if any Tenderer

3.25 Emergency medical facilities at site Purchaser

3.26 O&M staff for boiler start-up, commissioning & operation Purchaser

3.27 Bed material for initial filling Tenderer

3.28 Supply of Indonesian Coal, Indian Coal, Bed material requirement after initial filling

Tenderer

3.29 First fill of Lubricants Tenderer

3.30 All Equipment base plates, lifting lugs, foundation bolts, sleeves, nuts, inserts, embedded plates

Tenderer

3.31 Supply of Grouting material and grouting work Purchaser

3.32 Supervision for grouting work Tenderer

3.33 Training / Familiarization of Purchaser’s representatives at site upto PG test

Tenderer

3.34 DM water supply for hydrotest & Start-up Purchaser

3.35 Pre-commissioning check, trial run of all equipment calibration of instrument & control etc.

Tenderer

3.36 Boiler hydrotest, Refractory dry-out, Alkali boil-out, Trail run of all equipment & calibrating of instruments

Tenderer

3.37 Safety valve floating, steam blowing, Target plates and temporary piping for steam blowing

Tenderer

3.38 Performance test of boilers Tenderer

3.39 Providing instrument for above testing Tenderer

3.40 Commissioning spares, special tools and tackles Tenderer

4.0 EXCLUSIONS

4.1 Steam turbo-generator

4.2 Coal, Agro fuel and Limestone handling systems.

4.3 Multi-flue stack. (However, pollution monitoring, sampling type analysers are included in Tenderers scope)

4.4 Bottom ash and fly ash handling system.





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4.5 Air cooled condenser, condensate extraction pumps, steam duct from steam turbine exhaust

flange to ACC, condensate piping from CEP to de-aerator.

4.6 Auxiliary Cooling Tower.

4.7 Laboratory for testing fuels, ambient air quality, and other effluents.

4.8 Below ground earthing

4.9 Battery and Battery charger

4.10 Station transformer, Generator Transformer and Unit Auxiliary Transformer

4.11 DCS system

4.12 HT Switchgear

4.13 Plant intercommunication and area illumination

4.14 Raw water makeup Storage.

4.15 DM water plant

4.16 Fire fighting and Fire detection system.

4.17 Plant air and Instrument air compressors

4.18 Air conditioning system.

4.19 Furniture and furnishings unless specifically included

4.20 Green belt development.

4.21 Effluent treatment plant and Plant sewerage system.

4.22 Complete civil works, site developments, construction of roads, drainage etc.





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DOC. NO : 4 – 3678 – MECH – 001 (R2)

MECHANICAL SYSTEM





BOILER

DOC. NO : 4 – 3678 – MECH – 001 (R2)

SECTION – 4

MECHANICAL SYSTEM

1.0 GENERAL

1.1 Boilers and their auxiliaries shall be two pass type and shall be designed for semi-outdoor installation. The boilers shall be state of the art circulating fluidised bed combustion (CFBC) design. Tenderer shall note that design requirements described below for both the steam generating units are identical unless otherwise specifically mentioned.

1.2 The boiler shall be guaranteed for the following fuel combination.

- 100 % Indian coal

The Tenderer should also demonstrate the capability of the boiler to generate the rated capacity at rated steam parameters for the following fuel combination.

- 100% Indonesian Coal

- 100% Rice husk

- 70% Indian Coal/Indonesian coal + 30% Pet coke (R) / 30% Pet coke (I)

- 70% Indian Coal/Indonesian coal + 30% Lignite

- 70% Indian Coal/Indonesian coal + 30% Agro fuel (Fire wood/Saw dust/Mill Bagasse/ Charkhi Bagasse/Rice husk)

- Any other optimum fuel combustion based on the Tenderer’s experience.

- CFBC Boiler shall also provision to fire fines (from dust extraction system and coal fines), less than 1mm size. Tenderer needs to be confirmed the maximum percentage of firing capability of fines

1.3 Boiler shall be designed for continuous operation with one High Pressure Feed Water Heater out of service, when the feed water temperature at economiser is low. The economiser shall be suitably designed to take a thermal shock of sudden change in feed water temperature, under such conditions. The superheater temperature control system shall be designed to maintain the rated steam temperature with the HP heater out of service from 60% BMCR to 100% BMCR.

1.4 Tenderer shall design the combustion chamber for staged combustion for better combustor temperature control and also to limit the formation of nitrogen oxides (NOx).

1.5 No auxiliary boiler has been envisaged in this project. Auxiliary steam required for commission and start-up activities of units shall be arranged by the Tenderer. Tenderer shall furnish the details of the arrangement envisaged in their offer.

1.6 All heating surfaces shall be arranged to prevent accumulation of slag on the walls, tubes and hoppers





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DOC. NO : 4 – 3678 – MECH – 001 (R2)

2.0 COMBUSTION CHAMBER

2.1 The combustion chamber assembly shall be membrane type, designed for natural circulation of water/steam. The combustion chamber shall be a gas tight enclosure.

2.2 The areas where a reducing atmosphere, erosion are expected the same shall be refractory lined. Metal spray coating shall be provided, 600 mm above refractory transient zone in all four walls of combustor. The material of spray shall be proven and guaranteed for 2 years of continuous operation.

2.3 The Combustion chamber shall be designed to withstand the maximum shut-off pressure of the Primary Air fan or the set point of the furnace very high-pressure trip, whichever is higher.

2.4 The combustion temperature shall be uniform in the entire volume of the furnace and shall be in the range of 850-900 degree C. The particle velocity in the combustor shall be 5 m/sec to 6 m/sec at 100 % BMCR. The same shall not cause any explosion in any of the fuel path.

2.5 The circulation system shall ensure adequate circulation ratio during rapid start-ups and load changes to prevent overheating of the water wall tubes with maximum possible heat flux in the furnace. An allowance of at least 4-mm towards erosion shall be provided over and above the designed water wall thickness in severe erosion prone area and an allowance of 1-mm towards erosion shall be provided over and above the designed water wall thickness in other areas.

2.6 The primary air connection to the wind box shall be only through sideways. The wind box shall be designed with suitable guide vanes for uniform distribution of primary air to all the nozzles.

2.7 If Tenderer proposes fuel feed via return lines the same shall be a proven system already operating in other installations successfully for not less than two years (i.e. 16,000 hours). Tenderer shall ensure that under no operating conditions the gas volume produced by fuel/moisture will choke the solids return lines or cause explosion in the solids return lines. Also the same shall not cause any explosion in any of the fuel path.

2.8 The fluidising air grid shall ensure that a good solids classification occurs naturally in the combustor at different load conditions and shall allow for large particles to be removed from the furnace to avoid an over accumulation in the bottom of furnace.

2.9 The air grid nozzles shall be of proven design with a good operating history and the Tenderer shall furnish details to justify the same. Nozzles should be designed for easy maintenance and replacement. One view glass to be provided in Primary Air (PA) wind box for inspection purpose.

2.10 Heat transfer surfaces in furnace region shall be avoided as far as possible due to potential erosion problems. The placement of superheater sections in the combustor by provision of suitable vertical panels (wing walls) would be acceptable provided Tenderer has supplied such designs and such units are in successful commercial operation for a period of not less than three years (i.e. 24,000 hours). However, these sections shall preferably be placed away from potential erosion regions.

2.11 The following aspects also shall be considered in the design of in-furnace surfaces:





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DOC. NO : 4 – 3678 – MECH – 001 (R2)

(a) The surfaces shall not be affected by the firing of Light Diesel Oil during low loads and

during start-up.

(b) The surfaces shall not be affected by any localised solid fuel combustion which may be possible during low loads and during start-up.

(c) The arrangement shall require minimum inspection and maintenance.

(d) Vertical legs with suitable height for maintenance shall be provided inside the Boiler at each end of the horizontal coil in the flue gas path for easy maintenance.

2.12 Field welds of headers shall be avoided and that of pipes shall be minimised to the extent possible.

2.13 100% Radiographic Test shall be carried out for the weld joints embedded in the refractory.

2.14 An adequate number of observation ports (minimum two) at different suitable elevations shall be provided. The observation ports shall be designed to prevent infiltration of air into the unit. Purging air arrangement shall be provided for observation ports.

2.15 The furnace wall and buck stay construction shall be at-least designed to provide intrinsic strength against explosion/implosion forces developed due to furnace pressure excursions. The buck-stay structure shall be adequately designed to take care of corner expansion and strains and ensure water wall stability under dynamic conditions.

2.16 Furnace guides shall be provided on all four sides at centre and at least at three elevations covering the entire boiler height.

2.17 The P&ID for steam and water system is furnished in drawing no. 2-3678-100-008 enclosed in this specification.

3.0 CASING

3.1 A gas tight enclosure shall be designed for the entire boiler from the lower furnace to the ID fan suction, considering explosion/implosion forces developed due to furnace pressure excursions. Frames shall be furnished around all openings in the boiler, designed to allow for expansion between the welded wall or inner skin casing and an outer aluminium lagging. Wall box sealing shall be ensured by seal welding for all the inlet and outlet connections of tubes in boiler.

3.2 Self closing/self sealing type explosion diaphragm shall be provided on all four sides at null point with exhaust upwards to a safer height of 1-metre above boiler roof with provision to drain water from the ducting.

4.0 CYCLONES

4.1 The cyclones shall be designed to provide a high recycle rate in order to ensure a uniform temperature in the furnace. The inlet and outlet temperature difference in cyclone shall be as minimum as possible and in any case shall not exceed +10 degree C. The inlet and outlet connection of cyclones with upper combustor chamber and boiler convection pass shall be equipped with suitable high temperature ducting. The duct connecting the combustor outlet and cyclone inlet shall slope downwards.





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DOC. NO : 4 – 3678 – MECH – 001 (R2)

4.2 Access doors shall be provided in the duct connecting combustor and cyclone and also in

the duct connecting cyclone outlet and convective pass. Non metallic expansion joints shall be provided in the above sloping ducts and suitably designed to avoid accumulation of solid particles.

4.3 The cyclones offered by Tenderer should be water cooled membrane design and shall have successful commercial operation for a period of not less than two years (i.e. 16,000 hours). Inspection doors shall be suitably provided in Cyclones. The solid particles leaving the cyclone along with gas to the convective pass shall not be of size greater than100 microns.

4.4 If the cyclone is provided with refractory, the refractory shall be suitable to withstand the temperature applications and shall be adequately. The refractory shall be capable of withstanding thermal expansion and thermal shocks. The design shall ensure that there shall not any choking/slagging in cyclone bottom outlet and seal pot zones.

5.0 SIPHON SEAL/SEAL POT

5.1 The Tenderer shall provide proven siphon seal box/pot design. The siphon seal shall be designed to allow free solids flow from low pressure region (cyclone outlet) to the higher pressure condition (combustor/furnace) without air locks and moving parts.

5.2 Air purges at strategic locations on return leg in seal box shall be provided to assist solids flow to the combustor. Spare nozzles shall be provided in important areas so that if difficulties develop during the start-up period of the boiler, air purges can be used to assist the solid flow.

5.3 Other solid re-injection device is also acceptable provided Tenderer has already supplied such designs of similar capacity and same are in successful commercial operation for a period of not less than two years (i.e. 16,000 hours).

5.4 Separate 1 x 100 % capacity Seal pot blower for each seal pot shall be provided with one common stand by.

5.5 During periods of Monsoon, the surface moisture of fuel would be higher. If Tenderer proposes introduction of fuel at discharge duct of siphon seal/box, he shall clearly indicate in his Tender that under no operating conditions would the gas volume produced by fuel and moisture choke the solids flow from the siphon seal to the combustor or induce a back-flow, causing explosion.

6.0 FLUIDISED BED HEAT EXCHANGERS (FBHE)

6.1 FBHEs, shall be proven type. Tenderer shall indicate in his Tender the design features of the valve to prevent plugging of same, maintenance requirements, cooling requirements and document detailing the availability of the valves based on operating plant history.

6.2 FBHEs, shall be an unfired bubbling type fluidised bed heat exchangers and shall operate with low fluidising velocity not exceeding 1 m/s to avoid erosion problems and overheating of tubes. Moreover, vertical legs to be provided inside the FBHE at each end of the horizontal coil for easy maintenance. In FBHE panels which are embedded in refractory should have close pitch fins.

6.3 Each FBHE shall be provided with two full capacity (100%) centrifugal air fans or blowers to provide the necessary fluidising air with necessary controls/bypass dampers with a common standby with adjacent blower.





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DOC. NO : 4 – 3678 – MECH – 001 (R2)

6.4 FBHEs with water cooled walls shall preferably be top supported. If furnace and cyclones

are top supported and refractory lined FBHEs are bottom supported, the refractory lined connections shall have good flexibility.

6.5 Tenderer shall elaborate the design features/ access space provided to enable replacement of damaged tube of an immersed tube bundle without the need for disturbing the healthy tubes.

6.6 Adequate provisions shall be provided for the immersed tube bundle heat transfer sections to effectively counter erosion. The entire bend pipes in the manholes and openings in combustor, cyclones and FBHE’s shall be manufactured out of T 22 or equivalent. Adequate draining arrangements shall be ensured in all FBHE’s in order to drain the bed material during any emergency situation to ash cooler as well as to the floor. All bed material drains, isolation dampers, provided in Combustor, FBHE’s and Seal pot are to be easily approachable for both operation and maintenance of the same.

7.0 BOTTOM ASH REMOVAL SYSTEM

7.1 The combustor bottom ash removal system shall adequately control the bed inventory, classification, removal, cooling and transfer of the bottom ash, over the full operating load range of the boiler for the specified range of fuel with additives (lime stone). The bed pressure drop shall be monitored for the measure of ash inventory and the bottom-ash flow shall be adjusted to maintain the desired bed pressure drop. Bottom ash shall be cooled to about 150 degree C sufficiently for ash removal equipment to handle.

7.2 The following aspects shall be considered in the design of the bottom ash removal system :

i) The total ash shall be based on maximum ash generated firing worst coal (maximum ash & lowest GCV) to achieve 100% BMCR.

ii) Provision of redundancy with a view to achieve high availability.

iii) Tenderer shall indicate in his Tender the % of total ash for which the bottom ash system is designed and shall furnish the basis for the same.

7.3 At least two adequately sized ash drains shall be provided in the combustor to drain the bed ash. Two 100% capacity bottom ash cooler shall be provided (if same is Tenderer's standard practice) to remove the oversize ash particles. The gate of the drains shall be pneumatically operated.

7.4 Two (2 x 100%) full capacity ash cooling fans/blowers shall be provided and each fan shall be sized to meet the air requirements to cool the entire bottom ash. Alternatively, Tenderer may use the air from the fluidising fans with suitable controls.

7.5 If the ash cooler do not fully cool the ash adequately, separate fluidised bed ash coolers (FBAC) could also be used if the same is manufacturer's standard practice. In such a case two 100% capacity FBAC shall be provided. Cooling bundles shall cool the ash by transferring heat to a closed loop auxiliary cooling water system. Ash cooler bundles to be designed for easy maintenance and replacement.

7.6 The bottom ash shall be removed from each cooler by rotary air lock feeder with air sealing arrangements.

7.7 Bed ash from Ash coolers shall be finally discharged into bed ash handling system to transfer it the ash silos.





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7.8 In case of a separate bed material feeding system, Tenderer shall provide necessary material

handling system for filling the bed material.

8.0 FLY ASH REMOVAL SYSTEM

8.1 All points of natural ash deposition including that in the second pass below the air pre-heaters shall be provided with hoppers to effectively and efficiently collect the fly ash. The ash hoppers shall be of welded steel construction. The hoppers shall be suitably insulated on the exterior.

8.2 Each ash hopper shall be provided with a dust tight sealed hinged inspection door and an access door of approximately 450 mm x 450 mm size. The hoppers shall be provided with the required outlet connections.

8.3 The total ash shall be based on maximum ash generated firing worst coal to achieve 100% BMCR. Tenderer shall indicate in his Tender the % of total ash for which the fly ash system is designed and shall furnish the basis for the same.

8.4 If justified by combustible content Tenderer shall provide a fly ash reinjection system. In such a case, Tenderer shall provide the necessary vacuum/pneumatic conveying system for fly ash from the fly ash hoppers to a fly ash reinjection silo. The fly ash reinjection shall consist of a rotary valve that feeds the fly ash from the fly ash reinjection silo into the combustor pneumatically with the help of a rotary blower.

8.5 The ash hoppers shall be designed for an ash density of 1350 kg/m3 structurally and shall provide 8 hours ash storage firing worst coal combination with ash density of 600kg/m3. The hopper material thickness shall be 6.00 mm minimum. All bracing and stiffening shall be on external side of hopper. No internal bracing, stiffening, etc. shall be utilised. The ESP Hoppers outlet flanges shall be at a height of 3.0 m from ground level.

8.6 The hoppers shall be of pyramid shape with plate angle of at least 70 degree with the horizontal with an access door on each side of baffle. All ash hoppers shall be provided with heating elements on all sides of ESP hopper. Suitable fluidizing air arrangement shall be made to ensure free flow of ash to the fly ash transmitting vessel in ESP hoppers.

8.7 Any requirement at the terminal points by the Ash handling system package Tenderer during design/ detail engineering shall have to be accommodated without any commercial implications.

9.0 STEAM DRUM

9.1 The design of the drum internal shall be such as to guarantee the steam quality required for the steam turbine, over the entire load range. The drum dished ends at both ends shall be provided with properly sized hinged manhole doors at the centre.

9.2 All nozzles shall be of the long body type so that this will extend through the boiler lagging. The ends of nozzles smaller than 50 mm shall have plane ends for socket welding. The nozzles 50 mm and larger shall have bevelled ends for butt welding. All nozzles shall be of full penetration welds and shall be ground flush with the inner diameter of the drum.

9.3 The distribution and placement of furnace water wall tube inlets to the drum shall be designed to permit uniform heating of the drum metal during start-up, shutdown and load changes. The Tenderer shall specify in the tender, the maximum permissible drum metal





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DOC. NO : 4 – 3678 – MECH – 001 (R2)

temperature differential and the corresponding maximum permissible rate of pressure and temperature changes during start-up, shutdown and load changes.

9.4 However, the temperature difference between the inner skin and mid wall temperature shall not exceed +/-25 degree C. The circumferential and longitudinal ligament efficiencies shall be as per IBR. The details of such calculations shall be furnished.

9.5 The drum shall be equipped with suitable eliminators, screens and the other necessary internals to ensure that the amount of dissolved solids carried over in the saturated steam leaving the drum do not exceed 0.02 ppm for the entire load range.

9.6 Tenderer to furnish the sizing calculation for drum storage volume (excluding internals) with retention time considered during detailed engineering

9.7 If possible all the spray stations and FCV stations shall be arranged at the same elevation.

10.0 SUPERHEATER

10.1 The superheater (SH) shall be of proven design and shall be designed to maintain superheat steam temperatures at superheater outlet over the entire steam temperature control range (i.e. from 60% BMCR to 100% BMCR rating) under the following conditions:

i) With the boiler heat absorption surface condition varying from clean to normally expected and permissible fouling limits.

ii) With minimum possible use of de-superheating spray.

iii) With normally expected unbalance or stratification in flue gas flow.

iv) With all specified mode of fuel burning.

v) With one HP heater out of service

10.2 The superheater elements shall be arranged to ensure the uniform steam distribution and steam temperature variation of not greater than ±15 degree C across the width of the boiler at all operating conditions and loads.

10.3 The superheater surface shall be either convective or fluidised bed heat exchanger type or a combination of the above according to the practice of the manufacturer. Only proven configurations which are in successful commercial operations for a period of not less than 16,000 hrs would be acceptable. Inter-stage de-superheaters shall be installed at one or more points in superheater sections to ensure rapid temperature/control response.

10.4 The attemperators are to be of spray type fitted with an inner removable lining, so arranged that the lining could be removed readily without recourse to extensive cutting of the construction welds. Complete superheater temperature control system with necessary piping, block, control, isolation, drain, vent, check valves and instrumentation & controls shall be provided. Provision for backwash arrangement of attemperator nozzles shall be made.

10.5 The superheater supports or hangers exposed to hot gases within the setting shall be of a heat-resisting material suitable for long life under the service condition. If SH tubes are used as supports, same shall be with protective SS shield in high flue gas velocity areas.

10.6 The maximum tube metal temperature (skin temperature) to which the boiler tubes will be subjected, shall be below the oxidation limit as applicable to the material. The Tenderer’s





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DOC. NO : 4 – 3678 – MECH – 001 (R2)

can also opt for higher grade materials at no additional cost. However same shall be subject to the approval of the Purchaser.

10.7 All SH tubes shall have an allowance of at least 1 mm towards erosion over and above the designed wall thickness.

10.8 An additional space of minimum 5% shall be provided in the flue gas path for any future increase in heating surfaces of SH.

10.9 The maximum flue gas velocity in the convection zone shall be limited to 12 m/sec so as to limit erosion problems.

11.0 ECONOMISER

11.1 It shall be ensured that the economiser design pressure exceeds the boiler design pressure by an amount of at least equal to the pressure drop (friction and static) through the economiser at the 100% BMCR condition. Suitable SS shields shall be provided on tubes connecting to headers inside the flue gas path.

11.2 The economiser shall be of non-steaming type. The economiser tube banks shall be of in-line design. Anti vibration baffles/plates shall be properly located for gas distribution.

11.3 An additional space of minimum 5% for any future increase in heating surface of economizers shall be provided in the flue gas path.

11.4 All economiser tubes shall have an additional wall thickness of at least 1 mm as erosion allowance in addition to the corrosion allowance.

11.5 Orifices are to be provided at economiser inlet tubes. Diversion baffles/plates shall be provided along the gas stream in convective pass in the clear space between the casing and the coils wherever inlet and outlet connections are envisaged.

11.6 All pressure part tubes and headers shall be of seamless type. Welded tubes are not acceptable. Tenderer to indicate in his offer the fouling factors considered on water and gas side for economiser, evaporator, and superheater. Adequate number of access doors should be provided for inspection and maintenance purposes.

11.7 The first heating surface in the convective pass shall be positioned at sufficiently lower elevation where the flue gas attains uniform distribution and velocity after change of direction. All pressure part coil bends are to be covered with proper cassette baffles to protect from erosion.

11.8 All SH, Economiser coils shall be designed to have clear in-house spacing of height 1.6 meter between every loop of all coils for easy inspection and maintenance.

12.0 HEADERS

12.1 All headers in high temperature gas path shall be located outside the gas path. Inspection stubs of length 600mm and 88mm diameter size shall be provided in all the headers for suitable access for maintenance and inspection. No hand hole plate assembly design shall be used. Sufficient pitch shall be maintained for welding of loose tubes with header stubs. Inspection stubs are to be provided at easy approachable locations.





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12.2 Headers shall be made of seamless steel pipes only. The header vents, drains, pressure

gauges, thermo-wells, steam and safety valve connections shall be of weld-end type.

12.3 All headers shall be thoroughly cleaned and be free of scale by shot blasting on the inside. Further final superheater outlet headers shall be supported adequately at three nodal points.

13.0 BLOW DOWN SYSTEM

13.1 The blow down system shall consist of continuous blow-down (CBD) tank and intermittent blow-down (IBD) tank, all piping, headers, valves, supports and hangers, insulation, level control system and instrumentation etc.

13.2 The CBD level control system shall be complete with drain control valve. All piping, header, valves, supports and hangers, insulation etc., for emergency blow down from steam drum to IBD tank shall also be included. Local gauge glass for level indication to be included.

13.3 Safety relief valve shall be provided on CBD tank.

13.4 All the inlet connections to both the tanks shall have tangential entry. Anti erosion compensating wearing plates shall be provided at the inlet of each tank. The tanks shall be provided with manhole openings of suitable size with bolted and hinged doors. A manual drain at the lowest point for each tank to the nearest trench shall be provided.

13.5 A vent pipe of sufficient size to take care of the back pressure shall be provided for the IBD tank and the same shall be suitably supported and insulated and shall be taken out of bunker bay roof to safely exhaust the steam.

13.6 The CBD tank shall be designed to accept continuously the drain from the steam drum. The steam space of CBD shall be connected to the de-aerator with necessary valves, if it is feasible. Necessary sampling system shall be provided.

13.7 The CBD valve shall be a pressure reducing and erosion free type, having finer control design. Suitable quenching arrangement shall be provided for IBD tank. Local pressure and temperature gauges shall be provided for both the tanks.

14.0 AIR AND FLUE GAS SYSTEM

14.1 The air and flue gas system shall be designed to meet the requirements of 100% BMCR conditions and with the worst fuel combination as specified elsewhere in the specification.

14.2 The air and flue gas system for each of the boiler unit shall be balanced draft system and shall consist of

(i) 2 x 60% capacity PA fans with VFD,

(ii) 2 x 60% capacity SA Fans with VFD,

(iii) 2 x 60% capacity ID fans with VFD,

(iv) 2 x 60 % (air flowing capacity) steam coil air pre-heater for primary and secondary air streams,

(v) 1 x 100% tubular air pre-heater for preheating the Primary Air, Secondary Air and fluidizing air requirements of FBHE





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(vi) 2 x 100 % high pressure blowers for each FBHE fluidizing air,

(vii) 2 x 100 % high pressure blowers for sealing/ purge air requirements,

(viii) 2 x 100 % high pressure blowers for fluidizing the ash coolers,

(ix) 2 x 100 % blowers for ash classifier [if applicable] with 100 % isolation and appropriate handling.

14.3 Locking devices shall be provided to dampers to permit locking in both open and shut positions. All damper bearing shafts shall be bearing supported.

14.4 The general design requirements for the fans shall be as follows :

i) The rotor shall be over speed tested to at least 10% above the maximum operating speed and shall be dynamically balanced.

ii) The fan shaft is to be supported in bearings on either side independent of the casings. Overhung impellers will not be acceptable.

iii) All fans shall be designed for under frequency operation up to 47.5 Hz without any reduction in its performance. The first critical speed of the rotor shall be well above the operating speeds (by at least 15%).

iv) Forced oil lubrication system (if offered) for the fans and motors shall consist of 2 x 100% oil pumps, 2 x 100% oil coolers and filters, one (1) oil tank, associated valves, piping, one accumulator etc.

v) Each bearing is to be provided with oil level indicator and a screwed drain plug.

vi) The flow induced pulsation should be avoided by suitable design of fan and connecting duct work.

vii) Suitable design of shaft sealing shall be provided to prevent ingress of atmospheric air.

viii) Each bearing pedestal shall be provided with vibration sensors to facilitate on line monitoring from the control room.

ix) Each bearing housing shall be provided with adequate number of duplex RTD’s and temperature indicators for remote and local monitoring.

14.5 Silencer shall be provided at the inlet of fans sucking atmospheric air with weather hood and inlet screen. The suction shall be taken at least 10m above the ground. The silencer shall be adequately designed with GI sheets of 2 mm thickness.

14.6 An adequate number of interconnecting, isolating and control dampers with drives shall be provided on all cold air, hot air, seal air and flue gas ducting before and after equipment. The control dampers shall be pneumatically operated and isolation dampers shall be electrically operated along with manual operation provision.

14.7 The gas and air ducts shall be designed for wind loads as specified for the steam generating unit proper and their own weight including fly ash load which may get deposited at the duct bottom, insulation and lining.





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14.8 The top of the ducts shall be crowned to ensure proper drainage. The bottom portion of the

flue gas duct between air heater outlet and ESP inlet shall have wall thickness of minimum 8 mm to counter erosion. However the thickness of the other three sides of this duct shall be of minimum 6 mm thick.

14.9 The duct work shall be free to expand, but it shall be rigid against wind and seismic disturbances. Adequate provision shall be made for all expected expansion or contraction. Metallic / Non metallic expansion joints shall be used in air and flue gas systems.

14.10 All gas and air ducts shall be designed to ensure uniform distribution of gas and air flow to the various portions of the unit.

14.11 Access Doors shall be provided in all air and flue gas ducts particularly near all dampers for maintenance purposes. Each ID fan shall be provided with an access door before discharge damper.

14.12 Aerofoil shall be provided in the air ducts for the measurement of air flow of PA & SA fans at individual limbs and total air flow after air pre-heaters.

14.13 Electrical operated guillotine type isolation dampers along with drives shall be provided as required. The inlet dampers for ID fans shall be located in horizontal duct of main inlet duct to avoid fly ash build up when in closed position. All other regulation dampers shall be pneumatically operated and isolation dampers shall be motor operated.

14.14 The flue gas duct layout shall be designed considering the following aspects:

i) The change of direction of flue gas duct shall be gradual to avoid ash collection at the bottom of the duct and also to prevent erosion by local concentration of fly ash.

ii) The number of direction changes of the flue gas duct shall be minimal to minimise the ash collection points. Adequate number of baffles to be provided at all direction changing locations.

iii) However, the air pre-heater, economiser and duct hoppers shall have provision for removal of fly ash during maintenance period when the steam generation is out of operation. To facilitate such fly ash removal, a 100% gas tight isolation gate near the hopper bottom shall be provided. The hopper bottom shall be blanked with a blind chute suitable for unloading fly ash from all the above mentioned hoppers.

14.15 All the fans and blowers shall be provided with electrically operated hoists both on fan and motor side. The primary air discharge ducts of left and right shall be interconnected with isolation dampers. The similar interconnection shall be carried out in secondary air system.

14.16 The characteristic curves giving full information on the fan total pressure, efficiency versus flow rate shall be submitted. Further, the sizing of fans shall be based on 30% margin over calculated values of flow and 15% margin over calculated values of head separately at maximum duty conditions. For the design of primary and forced draft fans, inlet air temperature of 45 deg C shall be considered

15.0 TUBULAR AIR PRE-HEATER (TAPH)

15.1 Tenderer shall include 1 x 100 % capacity Tubular Air pre-heater and shall consist of separate blocks for each of the following





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a) Primary air

b) Secondary air

c) Fluidizing air ( For FBHE)

15.2 The air pre-heater tube banks shall be of in-line design. The arrangement of the air pre-heater shall be such that the tube elements can be easily replaced when necessary. Anti vibration baffles/plates shall be properly located for gas distribution. An additional space of minimum 5% for any future increase in heating surface of air pre-heater shall be provided in the flue gas path.

15.3 The TAPH shall be so designed as to avoid erosion at the tube inlets and deposit of dust in the tubes. The design of the air heater shall take care of problems of corrosion of low temperature end. Last rows of air heater tubes shall be Cor-Ten steel.

15.4 Suitable access for inspection, cleaning and maintenance shall be provided. All necessary openings and fittings shall be provided to enable samples of flue gas to be taken at both inlet and outlet of the heater.

15.5 Steam soot blowers complete with necessary pipe work, valves and fittings shall be provided to enable on-load. If soot blowers are not a standard practice provision shall be made for installation of soot blowers in the future if required.

15.6 The air heater shall be suitable to take care of high ash content of the coal.

15.7 Flue gas temperature leaving air heater shall not be less than sulphur condensation temperature at 100% MCR. An air heater air side bypass system for primary and secondary air shall be provided to avoid cold end corrosion during start-up and low load operation.

16.0 START-UP / SUPPORT OIL SYSTEM

16.1 One common LDO storage system shall be provided for both the boilers. The LDO storage system shall consist of one (day oil) LDO storage tank, unloading/forwarding pumps, strainers, valves and piping common to both the units. Proper hose with coupling shall be provided for connecting the unloading pump to the tanker.

16.2 The LDO burning system for boiler unit shall consist of high pressure filters, air atomised burners, LDO safety and burner shut off valves, pressure control valve, metering units, atomising air headers at burners, atomising air pressure control valves, piping and valves necessary for bypass and isolation, LDO burner header recirculation control valve, recirculation piping with valves up to the LDO tanks.

16.3 The LDO system shall be designed to cater to maximum of 30% BMCR requirement. Tenderer shall clearly indicate the boiler load below which LDO stabilisation for coal burning is required. However the turn down ratio with coal firing shall be 1:4. The LDO oil shall be air atomised.

16.4 Tenderer shall provide start-up burner(s) as necessary for boiler. Tenderer shall elaborate the measures adopted to prevent clinker formation on the refractory throat of start-up burner. The start-up burner shall be designed to ensure the flame stability against turbulence of bed materials and high-pressure primary air.

16.5 Adequate number of bed lances shall be provided to quicken the heating up of bed materials.





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16.6 The burners shall be remotely operated and the entire operation of purging steam and

heavy fuel oil sequencing, steam blow-off shall be automatic after the initial command. Adequate number of position indicating contacts for integration into burner management system (BMS) shall be provided. The burners shall be arranged for automatic advancement and retraction under interlock conditions.

16.7 The flexible hoses (armoured type) shall be provided for oil and steam connections.

16.8 The oil firing system shall include all connections and provision for instruments and devices required for supervision and interlocking with all associate auxiliaries during purging, start up operation and shut down.

16.9 Suitable igniters, of reputed make and well proven in design shall be provided by the Tenderer.

16.10 Adequate number of flame scanners shall be provided for oil firing. Normal cooling of flame scanner to be done by seal and purge air. One motor driven scanner air fans shall also be provided for the flame scanner cooling, oil gun cooling and igniter cooling.

17.0 COAL AND LIME STONE SYSTEM

17.1 One (1) Nos. of Twin fuel storage bunkers with total storage volume catering to sixteen (16) hours operation, with 100% Indian coal, shall be provided for boiler. Each bunker shall be of rectangular or cylindrical type with conical outlet. The conical portion shall have uniform angle on all sides. Each bunker shall be provided with stainless steel lining (3 mm thick) for the entire length of conical portion. Bunker plate thickness shall be minimum 12 mm with necessary stiffeners for stability to suit the design requirements. Coal bunkers shall ensure uniform mass flow without arching and rat holing.

Adequate Nos. of Biomass storage silos with total storage volume catering to 6mins storage, with 30% firing of Agro fuel firing, shall be provided for Boiler.

17.2 One (1) No. of limestone storage bunker of water volume catering to sixteen (16) hours operation, when firing 100% Indonesian coal, shall be provided for boiler. The bunker shall be of rectangular type provided with two (2) Nos. of conical outlets. Bunkers shall be provided with stainless lining (3 mm thick) for the conical portion. Motorised Isolation gates shall also be provided at the each bunker outlet in the feed pipe to the feeders.

17.3 One separate bed material silo of adequate capacity (equal to twice the bed material quantity required for initial start-up operation) along with pneumatic conveying system to the combustor shall be provided for boiler. The downstream of the bed material silo shall have rotary air lock feeder with air sealing arrangements from seal and purge air system for poking/cleaning. The downstream of the rotary air lock feeder shall have isolating gate valves for maintenance works with air poking arrangements using seal and purge air. The connection details at all terminal points shall suit the ash handling system vendor requirements which will be discussed during the detailed engineering stage. One no skip-hoist shall be provided for feeding bed material from ground to the silo.

17.4 Separate feeders shall be used for each location feeding the coal/limestone into furnace walls/ for each location on siphon seals. Drag chain type feeders shall be used to feed and control the Coal into the combustor

17.5 The feeders shall be designed with ample capacity range as well as reserve capacity to allow for variation in size, quality and moisture content of the reject. With one of the feeders out





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of service, the remaining feeders shall be able to meet the fuel, requirement of 100% BMCR with worst fuel combination. All surfaces in contact with coal shall be made of corrosion and erosion resistant stainless steel unless specified otherwise elsewhere in the specification.

17.6 The casing of the feeder shall be air tight and designed to withstand an explosion pressure of 3.5 kg/cm2 (g) in accordance with the National Fire Protection Association, recommendations. Each feeder shall incorporate devices complete with all accessories to detect presence or absence of Coal in the down spout.

17.7 Rotary air lock feeders shall be provided in each Coal feed stream to act as a pressure seal between pressurising combustion chamber and Coal feed system. Each feeder and rotary valve shall deliver Coal to the combustion chamber through an inclined gravity feed chute or drag link feeders connected to combustor or loop/siphon seal Coal feed ports. The feeders shall be link chain operated and flights shall be made of SS 316 material. At each Coal feeder port purge air or booster air shall be provided to assist Coal feeding. Feeder should be operable in both forward and reverse directions.

17.8 Isolation gates shall also be suitably provided in each feed pipe at the combustor for facilitating on line maintenance work of piping/feeder. The isolation gates shall be furnished with electric drives having double pole double throw limit switches, at the full open and full closed position, for integration into BMS, boiler control and pneumatic logic system (BOILERCPLS) and other control systems. One additional manual gate to be provided below the electrical isolation gate. Non metallic expansion joint to be provided between Coal rotary air lock feeder and electrical isolation gate.

17.9 Adequate and suitably located poke/compressed air purge holes shall be provided to clear the feed pipes when they get choked.

17.10 A specified numbers of position indicating contacts to the BMS and BOILERCPLS shall be provided for integration.

17.11 The Tenderer shall furnish schematics of Coal/Limestone/bed material feeding system and primary/ secondary air system for the information and reference of Purchaser with his Tender documents.

17.12 The feed points of the limestone to the combustor should be located at the lowest possible levels to maximise retention time and for better sulphur capture.

18.0 SOOT BLOWING SYSTEM

18.1 Auxiliary steam tap-off connection for soot blowing shall be either from intermediate superheater header or from auxiliary steam header.

18.2 Soot blowers shall be provided at all elevation covering entire heat transfer areas of convective pass. Provision shall be made for the installation of additional soot blowers in the furnace after the unit is commissioned, if the operational experience warrants the same.

18.3 The soot blowing system shall consist of motor operated steam soot blowers of the rotary and retractable type, with drives, pressure reducing, isolation and relief valves, steam traps, complete piping, supports and hangers, insulation, motor control centres and soot blower instrumentation and control system.

18.4 Adequate number of drain valves shall be provided in steam line to warm-up the complete piping before start up of Soot blowing operation. The soot-blowers shall be suitable for





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remote automatic sequential manual and local operation. Suitable manual cranking facility shall be provided for individual blowers.

18.5 The Retractable blowers will be located on both sides of boiler and each will cover the area little more than half of the effective width of the boiler when fully inserted. Suitable half sleeves shall be provided over the coils exposed to the operating range of the individual soot blower.

19.0 AUXILIARY STEAM SYSTEM

19.1 Auxiliary steam system shall consist of four (4) auxiliary pressure reducing and de-superheating stations (PRDS), on the steam line tapped off from the main steam line (MSL). The system shall be complete with the pressure reducing valves, bypass valve and isolation valves, safety relief valves, drains, steam traps, quick closing block spray valve, de-superheaters, steam temperature control valves, bypass valve and isolation valves; complete piping, supports, and instrumentation & control.

19.2 If auxiliary steam parameters are not same for the purposes mentioned during the detail engineering (for e.g. parameters of the steam required for fuel burner atomisation and gland sealing are different), then Tenderer shall provide separate PRDS stations for different usage.

19.3 The spray water for de-superheating station shall be supplied from feed water pump discharge or inter-stage tap-off. The Tenderer shall provide pressure and temperature control valves to meet the requirements of auxiliary steam system.

19.4 The auxiliary steam headers of boiler units shall be interconnected with motorised isolation valves provided on both sides of interconnection.

19.5 The Tenderer shall specifically indicate the consumption of various auxiliary steam requirements in detail for the entire BOILER package including SCAPH, atomising steam, purging steam, steam to de-aerator for pegging and heating, and steam to convective pass soot blowers etc.

19.6 The auxiliary steam header of boiler shall be provided with one spare tapping with an isolation valve.

19.7 Line drains and vents shall be provided for the interconnection bus wherever required with necessary valves and accessories.

20.0 CHEMICAL DOSING SYSTEM

20.1 The phosphate dosing system and Hydrazine dosing system shall be supplied for boiler unit to maintain the drum water chemistry and Oxygen level in feed water respectively. Each system shall consist of one solution preparation tank, one solution dilution tank, 2 x 100% dosing pumps complete with suction / discharge valves, Y-type suction strainers, pressure gauges, dosing pump discharge header sectionalising valves and complete piping with isolating and non-return valves as required.

20.2 Each tank shall be complete with motorised agitator, overflow and drain connections, inlet / outlet isolating valves and side mounted level gauge / level switch with connecting isolating valves. Tenderer shall furnish the chemical dosing system sizing criteria along with the Tender.





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21.0 AUXILIARY COOLING WATER

The auxiliary cooling water supply & return lines will be provided up to the terminal point. The cooling water lines from terminal lines to the individual equipment shall be supplied by the Tenderer, for BOILER unit. The system shall consist of complete piping including piping supports, isolation valves, instruments, etc. Each cooler/ bearing shall be supplied with isolating valves at the inlet and throttling type valves at the outlet. Necessary draining and venting arrangement shall be provided. Adequate number of Pressure and temperature indicators shall be provided. Local flow measurement and view glass to be provided.

22.0 SAFETY VALVES

22.1 Safety valves shall be provided on the drum, superheater headers and shall conform to the IBR code requirements. Design shall ensure that Main Steam line safety valve opens before the drum safety valve. All the safety valves in the Main steam line shall be located in the same elevation at the nearest platform.

22.2 In addition to the safety valves required by the Code, one electromatic relief valve of capacity not less than 10% of BMCR rating, suitable for remote operation shall be provided on superheater outlet header. Each valve shall be complete with controller, solenoid, pilot valve and piping with two shut-off valves.

22.3 One online safety valve testing kit shall be supplied for testing the SH safety valves without actually raising the system pressure from the operating pressure.

22.4 Individual safety valves shall be provided in SCAPH Flash tank, CBD, Steam soot blowing system, Aux. PRDS system etc.

22.5 All steam safety valves shall be provided with adequately sized atmospheric relief to 3.0 m above the boiler roof. Weather shields shall be provided at points where the relief pipes pass through the roof.

22.6 The electromatic relief valve, first spring loaded safety valve and start up vents in super heater shall be provided with silencers.

22.7 Sufficiently sized stand pipes with local drains shall be provided for all the SH safety valves and start up vents. All the stand pipes shall be provided with rain proof cover.

23.0 FLUE GAS CLEANING SYSTEM (ESP)

23.1 One electrostatic precipitator (ESP) shall be provided for boiler. The electrostatic precipitator shall be designed to limit the dust concentration at 20mg/NM3 when all fields are in operation. The ESP casing design pressure shall be compatible with combustor design pressure.

23.2 ESP shall be complete with supporting structural frames, collecting and discharge electrodes, shaft insulators, bush insulators, independent rapping system for collecting and discharge electrodes with automatic rapping controls, high voltage transformers, rectifiers, bus sections with sectionalising and grounding switches and controls, fly ash collecting hoppers with accessories etc. Tenderer to elaborate in the tender the energy efficiency measures adopted for ESP.

23.3 Access doors and corresponding interior walkways shall be provided on each side of the casing before and after each of the fields in series at the bottom and mid point elevations of





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the collecting electrodes in order to facilitate maintenance and inspection of each of the fields.

23.4 ESP Casing shall rest on specially designed bearings which will rest on supporting structures to allow thermal expansion and other load variations.

23.5 Suitable platforms shall be provided for all access doors including hoppers for maintenance purposes. The staircases shall be located in between both the streams of ESP, towards the Boiler side.

23.6 For personnel protection, key interlocks shall be provided to prevent the opening of any inspection and/or access doors until after de-energising of all high voltage equipment that can be reached and/or made contact with, through the inspection and/or access door.

23.7 Each ash hopper shall be provided with a conveniently located 150 mm (6 inch) pipe nipple fitted with a quick removable hinged cap located near hopper outlets to facilitate emergency poking.

23.8 If the Manufacturer’s standard design is such that the roof is pierced with rapper rods, high voltage support insulators, or other components which would require that external insulation, Tenderer shall provide a penthouse/weather enclosure to be erected on precipitator roof.

23.9 The hoist of suitable capacity to permit easy removal of each transformer-rectifier and oil filtering machine from its operating position to grade level shall be provided.

23.10 The rapping system shall be designed for selective remote automatic or manual operation at adjustable intervals. Necessary rapping arrangement with controls shall be provided for perforated gas distribution plate at inlet to and outlet from the ESP. Dummy field shall be provided in the ESP path. Necessary provision shall be made for individual ESP isolation.

23.11 Detailed Scope of Supply for ESP

The scope of supplies shall include, but not limited to the following:

24.11.1 Electrostatic Precipitator complete including all components and accessories stated in this section.

24.11.2 Complete structural steel required for supporting the ESP with all associated beams, cross ties, footplates, foundation materials (bolts, anchor channels, sleeves, etc).

24.11.3 Required stairways and walkways with handrails for the ESP.

24.11.4 All sliding supports for thermal expansion of casing.

24.11.5 Precipitator housing (all walls and roof, with required columns, stiffeners, access door, etc).

24.11.6 Thermal insulation complete with lagging, wire mesh fixing cleats and outer aluminium cladding.

24.11.7 Inlet and outlet funnel with gas distribution devices, deflector plates, flow splitters and all necessary gas flow control devices.





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24.11.8 Ash hoppers complete with required thermostatically controlled heating elements,

inspection doors, level monitoring and indicators, outlet flanges, poke holes etc.

24.11.9 High voltage emitting system with required framework, support arrangement and support insulators emitting electrodes, etc.

24.11.10 Collecting electrode system complete.

24.11.11 Rapping mechanism complete with structural supporting frame, drives, geared motor, local lockable push buttons and automatic rapping control, etc.

24.11.12 Required number of high voltage transformer-rectifier sets, accessories and control cubicle, with automatic electronic control system for the ESP system

24.11.13 ESP shall be designed with required number of independent electrical fields with all associated electrical, controls, cables, panels, hoppers, etc.

24.11.14 Required sets of insulators, heating system for the support and shaft insulators complete with thermostats.

24.11.15 Junction boxes to supply power for heater units and control supplies, as required.

24.11.16 Electronic controller unit for TR sets.

24.11.17 Only Engineering & BOQ for Lightning protection system of ESP buildings.

24.11.18 Only Engineering & BOQ for Lighting system of ESP buildings.

24.11.19 Above ground earthing of all the equipment/panels covered in this specification and Engineering & BOQ of below ground earthing.

24.11.20 Motor Control Centre for providing electric supply for hopper heaters, insulator heaters, rapping motors, TR sets / electronic controllers etc.

24.11.21 High voltage bus duct connection (between the transformer rectifier and high voltage emitting system) including insulator, HV disconnecting switches, for isolating bus section with earthing position.

24.11.22 Complete lifting and handling arrangement for the transformer, rectifier sets.

24.11.23 Mechanical interlock system and electrical interlocks for personnel protection.

24.11.24 Power and control cables between the MCC panel and the various field-mounted equipment of precipitator (with required conduits, trays, racks, supports, lugs, glands, etc) as well as incoming cables.

24.11.25 Complete cabling arrangements in the precipitator control room-connecting all panels as required.

24.11.26 Expansion bellows at the inlet and outlet funnels.

24.11.27 The aspect ratio of the ESP (electrode zone) shall be optimally selected, so as to minimize re-entrainment and carry over of the collected dust, and for assured ESP performance





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24.11.28 The gas velocity should preferably be less than 1 M/sec.

23.12 Flow Model Study

- If necessary the Tenderer shall perform a three dimensional flow model study of the precipitator in the presence of PURCHASER/CONSULTANT to achieve optimum size and layout ducting, good gas distribution, maximum particulate collection, minimum draft loss and minimum re-entrainment. The study shall be conducted to stimulate 90% and 100% of design gas flow.

- The Tenderer shall submit the detailed procedure carrying out flow model study for the approval of PURCHASER.

23.13 Housing

- ESP housing shall be gas tight, weather proof, all welded steel envelope suitably stiffened. The housing shall be designed to withstand 250 Deg.C and a pressure of (-) 400 mmwg. Necessary sealing arrangement to prevent moisture and air ingress into the casing shall be provided. Air ingress shall not exceed 1% of design gas flow. The casing shall be provided with required number of gas tight access doors for inspection and maintenance. The casing steel plate shall be of adequate thickness with minimum of 6 mm thickness. The precipitator casing and hopper shall form a common structure suitably reinforced to withstand the wind load (in accordance with IS: 875), load due to dust in collecting hoppers, etc. A weather proof penthouse shall be provided over the precipitator for the electrical equipment. The housing shall be supported on suitable roller bearings to allow the movements due to thermal expansion.

- Access doors and corresponding interior walkways shall be provided on each side of the casing before and after each of the fields in series at the bottom and mid-point elevations of the collecting electrodes in order to facilitate maintenance and inspection of each of the fields.

- ESP Casing shall rest on specially designed bearings which will rest on supporting structures to allow thermal expansion and other load variations.

23.14 Funnels

- The inlet to and outlet from the precipitator shall be provided with suitable flanged transition funnel equipped with access doors and shall be completely seal welded on the inlet and outside after assembling. Necessary guide vanes, deflector plates, flow split and any other flow control devices warranted by the results of flow model study shall be provided. The funnels shall be complete with supports, stiffeners, bracings, brackets, expansion bellow etc. The funnels plate shall be of adequate thickness with minimum of 6 mm thickness

23.15 Ash Hoppers

- All ash hoppers shall be pyramidal type, identical size and capacity with flanged outlet connection, to connect it with dense phase fly ash handling system to be provided by the PURCHASER. Each Electrical field should have separate hopper with single outlet.





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- Ash storage capacity shall be minimum 8 hours with the rated conditions specified in

this specification. A margin of 10% shall be provided in the hopper capacity over the calculated values.

- Proper densities of worst fuel combination ash shall be considered for the sizing of hopper and the ash discharge valve.

- Hoppers shall be of welded steel plate of 6 mm thickness suitably stiffened.

- Hopper valley angle shall not be less than 70 Deg. with the horizontal for free flow of ash to dust removal system.

- Each hopper shall be provided with adequate number of poke holes with screw caps. Aeration blocks/fluidizing pads to be provided.

- The internal surface of the hopper shall be free from ridges. The outlet of the hopper shall be provided with a thermostatically controlled hopper heating system of adequate capacity to ensure free flow of dust from the hoppers and with a suitable leak proof door to be manually operated.

- Each hopper shall be provided with suitable dust level monitoring system incorporating all the necessary accessories including level switch, local and remote signaling lamps and high level alarm. A timer shall also be provided for de-energising the affected electrical section.

- Bottom of hopper shall be provided with the clear height of 3m from Finished Ground Level.

23.16 Structures, Platforms, Walkways and Stairs

- All supporting steel structures required for precipitator shall be provided in accordance with IS: 800 including columns base plates, anchors, anchor bolts, sleeves, inserts, beams, girders, hangers required for installation, inspection/maintenance.

- The structure shall be designed taking into consideration total ESP weight, hopper dust load, live and dead loads and wind loads in accordance with IS: 875. The design shall also take into account the suitable seismic coefficient.

- Adequate platforms, walkways and stairs shall be provided for easy access during operation and maintenance of all parts of precipitator.

- Platforms and stairs shall be designed for a live load of not less than 500 Kg/Sq.m. Clear head room of not less than 2.2m shall be maintained over platforms and walkways. Minimum clear width of 800 mm shall be provided for stairs and 1100 mm for landings/platforms.





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- The access to the precipitator top shall be by means of normal stairs and not by ring

ladder.

- Plate for platforms, walkways and stairs shall be chequered of adequate thickness. All stairs and platforms shall be provided with handrails.

- RCC footing shall be provided upto 300 mm above Finished Ground Level.

- ESP shall be complete with supporting structural frames, collecting and discharge electrodes, shaft insulators, bush insulators, independent rapping system for collecting and discharge electrodes with automatic rapping controls, high voltage transformers, rectifiers, bus sections with sectionalising and grounding switches and controls, fly ash collecting hoppers with accessories etc. Tenderer to elaborate in the tender the energy efficiency measures adopted for ESP.

- Suitable platforms shall be provided for all access doors including hoppers for maintenance purposes. The staircases shall be located in between both the streams of ESP, towards the Boiler side.

23.17 Thermal Insulation

- All exposed parts which will operate at temperature above the maximum ambient temperature of 50 Deg. C shall be provided with external thermal insulation and cladding. Insulation shall be mineral wool/ceramic blanket of adequate thickness such that the skin temperature does not exceed 20 Deg. C from the ambient temperature. The insulation shall be kept in place by means of adequate number of pins spot-welded to the cover panel.

- The insulation shall be covered with wire mesh of adequate size. The outer casing shall be of plain aluminium sheet with a minimum thickness of 0.6mm.

23.18 Gas Distribution Screens

- For uniform gas flow and distribution throughout the ESP cross-section area gas distribution screens shall be provided at inlet and outlet section of the ESP. The distribution system shall be designed to minimize local velocity regions and re-entrainment of dust and shall not cause undue resistance to the passage of gases. The distribution screens shall be of modular design with suitable cleaning system.

23.19 Emitting Electrodes

- The high tension emitting electrodes shall be made of durable and corrosion resistant material. They shall be accurately centered between the collecting electrodes, duly supported to prevent swinging and shall be properly insulated from the precipitator casing.

- The emitting electrode design, geometry, size, arrangement and material shall be of well proven type, considering the duty conditions for achieving uniform corona effect, reliable operation, performance and long life.

- Provisions made to maintain alignment of electrodes during normal operation, including rapping and thermal transients should be clearly brought out in the offer.





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23.20 Collecting Electrodes

- The collecting electrodes shall be designed on concept of dimensional stability and maintain the collecting efficiency at desired level. The profile of the collecting plates shall be such as to minimize the re entrainment of the collected dust at the time of rapping. The minimum specific collecting area of the ESP shall be 150 Sq.m/Cu.m/Sec.

- Each plate shall be shaped in one piece by roll forming and shall be stiff enough to carry the rapping intensity. The swinging tendencies of plates shall be prevented by suitable means. These means shall be clearly brought out in the proposal.

23.21 Rapping Systems

- Independent rapping system shall be provided for discharge and collecting electrodes with independent control systems. The rapping mechanism shall be of either electric impact type or tumbling hammer type. This shall be adjustable in frequency, intensity and duration to provide an efficient cleaning rate.

- Separate rapping equipment shall be provided for each field so that each mechanism can be suitably adjusted when required.

- It shall be so arranged that the rapping frequency can be independently set from the control room (without requiring any opening up of the panel) in accordance with the dust build up, inlet dust loading and changing gas volumes.

- Sufficient number of rappers and rapper drives shall be provided so that maximum collection area and discharge electrode lengths are rapped at any instant. In case any special features are added to meet this stipulation, the same should be clearly brought out in the offer.

- The rapping system shall be designed for continuous sequential rapping to prevent puffing under any conditions of precipitator operation.

- All internal parts of the rapping mechanism shall be accessible for inspection and they shall be placed on wide access passages. Major part of the rapping mechanism shall be located external to the precipitator. Necessary lubrication system shall be provided for the rapping mechanism.

- The gas distribution screen system shall also be provided with rapping systems.

23.22 Electrical System of ESP

Transformer Rectifier Equipment

i) These shall be suitable for outdoor installation. Transformer rectifier assemblies shall be designed for electrostatic precipitator service and shall be for single-phase energisation with silicon rectifiers connected for pulsating negative polarity double half-wave operation. Means shall be provided for changing to full wave operation, if found desirable, for any reason, through external switching. The access door to the links, required for changing the high voltage connections, or the high voltage switch





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operating mechanism or cover shall be arranged for locking with a padlock. Key interlocking shall be provided on access door or cover to the links required for changing the high voltage connections or the high voltage switch operating mechanism to prevent access while the transformer-rectifier is energised.

ii) Primary taps shall be included on the transformer. Transformer shall have electrostatic shielding between primary and secondary windings and shall have suitable shielding of the high voltage coil to accomplish proper voltage division in the transformer when unit is subjected to surge conditions encountered in electrostatic fly ash precipitator application.

iii) Each output leg of each transformer-rectifier set shall serve one bus section and both bus sections served by each transformer-rectifier set shall be in the same field.

iv) Transformer rectifier assemblies shall be mounted in a heavy gauge welded steel tank designed for a minimum of 0.5 Kg/cm2 test pressure and full vacuum. Insulating and cooling medium shall be non-flammable insulating fluid. Unit shall be adequately sealed to prevent contamination of insulation and cooling medium. Outdoor type construction shall be used except for the high voltage bushings which shall be enclosed by the bus duct.

v) Each transformer-rectifier tank shall be provided with an indicating thermometer, pressure-vacuum gauge, liquid-level gauge, top fill hole, drain valve with liquid, sampling connections and weather-proof terminal box with gasketed removable cover. The terminal box shall contain transformer primary connections, rectifier positive terminals and ground terminal. A catch basin be provided in the event of a tank failure.

vi) All silicon rectifier cells shall be conservatively rated for compatibility with maximum circuit load and demands requirements.

vii) If required suitable low-loss impedance shall be included in the high voltage circuit to limit circuit capacitance discharge current to values compatible with current rating of the rectifying elements used.

viii) Two high voltage bushings, negative polarity, shall be connected to the output of the rectifier and mounted on top of the tank cover. Bushings shall be conservatively rated for the operating conditions and test, and shall have suitable connections to support connection arrangement of bus or cable.

ix) High voltage bus runs shall be adequately supported and protected by ducts. A 150 mm x 200 mm minimum opening with gasketed cover shall be provided at the transformer rectifier high voltage terminals for grounding these terminals during inspection and maintenance. Facility for clearly seeing the grounding switch contacts at the high voltage terminals before removing the cover shall be provided.

x) In the event of arcing, the filter voltage shall be switched off for several half cycles to ensure a satisfactory extinction of the arc. If dust bridging or metal short circuits occur in the precipitator, the precipitator short circuit current shall be limited to the rated current of the installation and disconnected completely after the expiration of a given time.

xi) Supporting insulators shall be located in heated compartments that are maintained above the dew point of the flue gas. They shall be located out of the dirty gas stream.





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These shall be protected from weather by either a common top housing or individual compartments. A steel shroud below the insulator may be provided which will further inhibit dust diffusion. Each compartment shall be pressurised and ventilated by heated filtered air furnished by one or motor driven blowers. Contactors and strip heaters with control thermostats for heating the air, blower motors, and blower motor contactors and control for each compartment as required, for complete hand automatic operation with alarm contacts for high and low temperatures and loss of pressure shall be provided. The filters shall be of the washable type, adequately sized for use in dusty atmosphere.

xii) If strip heaters are used, the wiring to the strip heater terminals shall be nickel-plated copper with 600 volt teflon-glass insulation.

23.23 Control Cubicles

i) Automatic control cubicles shall be supplied for indoor mounting. Units shall be of the high-speed silicon controlled rectifier or magnetic-amplifier type designed to maintain the optimum precipitator voltage and current for variations in rate of gas flow and particle content and with simultaneous supply voltage variations of + 10%. The automatic controls shall have full control from 10% of the power set rating to full rating.

ii) The control system should be capable of:

- Evaluating sparking by intensity and wave shape.

- Regulate power at the threshold of sparkling.

- Break a power arc within around ten (10) milli - sec of its occurrence.

- Automatically control the arc response so that power is restored within around one hundred twenty (120) milli - sec.

- Modify the current wave shape permitting greater power input prior to reaching spark over threshold.

23.24 Motors

i) Drive motors of the rapping mechanism for collecting and discharge electrodes and fans shall comprise 415V, 3 phase, 50 Hz, rated direct-on-line induction motors with IP-55 enclosure.

ii) Each motor shall be connected to its supply by means of a full voltage combination magnetic starter which shall include a moulded case circuit breaker or switch & HRC cartridge link type fuses for the over-current and short circuit protection. All motor starters, heater contactors, etc. shall be mounted in their respective control cabinets. Location of motors shall be such that they are easily accessible for any repair or maintenance.

iii) All components, features and design parameters of the ESP specified herein shall be considered as the minimum requirements. If the Manufacturer’s design dictates that these minimum requirements be exceeded to meet specified performance guarantee and to provide a safe, reliable operating unit, he shall include in his Tender price of all necessary equipment and features beyond these minimum requirements. All accessories and appurtenances required for a complete and operable precipitator installation, whether or not they are specified herein, shall be provided.





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iv) The Tenderer shall optimise gas flow pattern and distribution in the precipitator

sections.

v) The storm water drain piping shall be provided up to the grade level for ESP.

23.25 Control and instrumentation for ESP

i) The controls and instrumentation will be designed for local as well as remote operation.

ii) Control system shall be microprocessor based. All control & protection shall be available for local & remote operation. Tenderer shall supply the backup panel for local operation with necessary mimic and operating hardware. For remote operation and monitoring facility shall be provided from BOILER control room.

iii) Following annunciations in the ESP control room will be provided.

- ESP Faulty

- ESP rectifier faulty

- Individual ESP field status

- Electric supply to ESP failure

- Rapping mechanism motor trip

- ESP Incoming Breaker status

- All Transformers protection Alarm/Trip

- All Controller Protection Alarm/Trip

- Pressurization fan failure (if applicable)

iv) Potential free contacts for ‘ESP faulty conditions’ will also be provided in the ESP control room for annunciation on the Unit control room, when any one of the above conditions occur. However, the Tenderer based on his experience, will also indicate and provide any other annunciations for the ESP control room, which he considers important for the safe and reliable operation of equipment/works specified.

v) Complete control and interlock system to automatically regulate and monitor for safe operation of the ESP shall be provided.

vi) Provision shall be made in each cubicle for auto-manual operation. The control circuit shall be so arranged that when the latter switch is in manual position the ESP control room operator shall be able to control the electrical performance of the ESP by means of a control switch, potentiometer or variable transformers. When the switch is in the auto position, the automatic regulator unit located in the control cubicle shall control the performance of the ESP in accordance with its requirements and settings of the regulator. Manual adjustments of high voltage set points shall be provided.

vii) Adequate numbers of indicating instruments shall be provided on the control cubicles for the purpose of correct monitoring of the performance of ESP and accessories.

viii) Sufficient numbers of alarms shall be provided on the control cubicles.





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DOC. NO : 4 – 3678 – MECH – 001 (R2)

ix) Rapper control system for each bus section or pairs of bus sections served by a

single transformer-rectifier shall :

- Provide manual adjustments of the timing and frequency of operation and the rapping intensity from the control cabinets,

- Provide rapper diagnostic system including miniature indicating lights, digital indicators, etc.

24.0 DE-AERATOR

24.1 The de-aerator shall be capable of satisfactory operation under normal operation, under condition of turbine trip and lowest condenser pressure. Outage of any low pressure feed water heater and minimum condenser pressure shall not affect de-aerator performance in any manner.

24.2 In case of spray cum tray type with direct-contact vent condenser, the flow of steam shall be such that the steam entering the heater will contact the hottest water which is leaving the last row of trays and then proceed upwards through the tray stacks in truly counter-current fashion. Parallel flow of steam and water is not desirable. Tray supports shall be rigid enough to withstand severe vibrations that would be caused due to water hammering during start-up and full load throw-off conditions.

24.3 All materials used inside the de-aerator such as trays, fasteners, support rods, nozzles shall be of Stainless Steel. The sprayer shall be spring controlled spray valves (variable flow area) which ensure fine atomisation of condensate at all loads. The sprayer device shall provide a self regulated system in which disc/piston opening adapts automatically to the changing hydraulic loads.

24.4 The spray cum tray type de-aerator shall be Stork/Sterling design only. The design shall incorporate suitable spray valves of disc type or equivalent, splash plates, baffles, grids, etc. which ensures fine atomisation of incoming condensate, rapid heating up by steam and higher residence time.

24.5 Heating steam shall be introduced into the water stored in the feed water tank through a rake of sparger steam pipes below the minimum water level. The rake shall be suitably supported to prevent vibration. Suitable means shall be provided to prevent back flow of water into steam pipes in case there is any sudden drop in steam pressure.

24.6 A separate heating steam rake to supply heating steam during start-up shall be provided. These heating steam pipes shall be suitably supported to avoid excessive vibration during start-up, normal operation and transients. Steam pipe configuration shall be such as to prevent entrainment of any heating steam into feed water pump suction lines.

24.7 The feed water storage tank shall be sized to have a storage capacity for 10 minutes between normal to minimum water level. The dissolved oxygen content after de-aeration shall not exceed 0.007 ppm.

24.8 The outlet pipes from the feed water storage tank to Feed Water Pumps shall be provided with a vortex breaker and project a minimum of 75 mm above the bottom of the storage tank so as to prevent sludge from getting into the suction pipes of the feed water pumps. The feed water storage tank shall be provided with two manholes of minimum 500 mm size. An additional manhole with hinge shall be provided at a suitable location in the de-aerator section.





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24.9 Low load recirculation flow and balancing device leak off flow systems from the feed water

pumps shall be led to the feed water storage tank.

24.10 The vent from the continuous blow down tank (CBDT) will also be led to the de-aerator.

24.11 The de-aerator level shall be controlled by controlling the condensate inlet flow into de-aerator during normal conditions. The overflow and drain from de-aerator will be led to intermittent blow down tank (IBDT) / condensate storage tank (CST).

24.12 The sprayer shall be designed to ensure fine atomisation of condensate at all loads upto 110% of the design flow.

25.0 FEED WATER PUMP

25.1 The feed water pump group shall consist of 2 x 100% duty feed water pump sets. Each set shall be preferably supplied by a separate down comer from de-aerating feed water heater.

25.2 A feed water pump (FWP) set shall comprise of a main pump, directly or through step-up gears to motor. Possibility of providing FWPs without Booster pumps shall be studied. Possibility of providing PRDS / RH spray from the interstage of the FWPs shall be reviewed and accordingly be designed. Details of the same shall be submitted during the detail engineering.

25.3 In designing the system, attention shall be paid to minimization of slip losses, by adjusting the head between booster and main pump. While adjusting the same adequate attention shall be paid to the NPSH requirements of the main and the booster pumps during normal operation and transients.

25.4 Location of de-aerator and offset of suction piping from pumps shall be such that the margins on net positive suction head (NPSH) required by pump during normal and transient conditions, and flashing/steaming in suction lines is avoided under all operating modes.

25.5 A pump warm-up system shall be included if recommended by pump supplier. In case Tenderer does not recommend provision of same, the same shall be substantiated by proven experience. However rapid start-up of pump set shall be possible from any operational condition i.e. cold or partially warmed-up.

25.6 During normal operation the discharge valve of standby FWP set would be kept normally open. Each FWP set as a whole shall be capable of withstanding the reverse rotational speeds which would result from non-return valve failure under the most severe condition (i.e. remaining normally working pumps operating at full speed). Tenderer shall provide reverse rotation detection system to close discharge valve on detection of same.

25.7 Pump with high suction specific speed not proven in practice is not acceptable. The impeller shall be designed for minimum 40,000 hours operation.

25.8 The pump motor rating shall not be less than the larger of the following:

i) Sufficient to drive the pump through the entire range of run-out flow to shut-off conditions.

ii) 110% of pump design point rating.





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25.9 Care shall be taken to design the pump for the operation of FWP even in under frequency

condition lower than normal frequency.

25.10 All bearings shall be provided with a forced lubrication from a common oil system. The thrust bearings shall be of tilting pad type. Also the design of lubricating oil system should take into account the oil requirements of the motor wherever thrust bearings are fitted. Bearings shall be easily accessible without disturbing the pump. Each bearing housing shall have one oil level indicator and a drain plug.

25.11 All the bearing housing shall be provided with vibration probes and it shall be connected with Purchaser’s DCS system

25.12 All the bearings shall be provided with thermocouples to measure the bearing temperature and it shall be connected with Purchaser’s DCS System.

25.13 FWP shall be provided with suction filters, filter strainers shall be of SS 304. Mesh size shall be selected in order to avoid ingress of any foreign material size more than the pump working clearances. Suction strainer shall be capable to allow 100% flow of pump in 50% strainer clogged condition. Suitable DP gauge is to be provided.

25.14 A suitable axial thrust balancing arrangement preferably balancing drum shall be provided. The balance drum leak-off shall be lead back to pump suction.

25.15 FWP set shall be provided with flexible couplings of approved type between the motor, hydraulic coupling and pumps. The coupling shall be designed to accommodate the existing expansion and movements. They shall be provided with guards. Coupling distance piece length to be sufficient for easy removal of Mechanical seal cartridge in assembled condition.

25.16 Adequate space shall be provided between pump drain connections and base plate for installation of minimum 15 mm drain piping. Pumps shall be supplied with suitable drain pipes or drain rim type base plates with tapped drain connections.

25.17 Each FWP set shall have a single common lubrication system. The lubrication system shall include, but not necessarily be limited to, a shaft driven oil pump, a spare full capacity electric motor driven oil pump, all piping valves, return flow sight gauges, relief valves, oil coolers, pressure and temperature switches, duplex or two simplex filters, pressure gauges, flow control devices, oil level indicators, supply thermometers and return oil thermometers for each bearing and an oil reservoir.

25.18 Boiler feed pumps margin will be 5% on head and 10% on flow

25.19 Mechanical seals

i) The mechanical seals shall have a life expectancy of at least 16,000 hours.

ii) A cooling jacket shall be incorporated in the gland design. This shall consist of a water circulation ring, magnetic filter and sealing water cooler. Auxiliary cooling water shall be used for the cooling and the system shall have a suitable filling, venting and draining arrangement.

26.0 FEED WATER REGULATING STATION

26.1 Feed water regulating station shall have three (3) parallel flow paths, one for start-up and low load operations, capable of regulation for a load range 0-30% of MCR. Each one of the remaining two for higher loads from 30-100% MCR (1 working+1 standby). Each of the





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three (3) control valves shall regulate accurately the rate of feed water flow to the drum. They shall be designed to withstand the effects of throttling the flow especially under low load conditions. The main feed regulating valves shall be designed for operation under preset range of pressure differential across the valves. Also the design shall ensure good flow/lift characteristics so as to minimise turbulence and avoid erosion of the valve seats and body. They shall be capable of being operated in auto and manual regime from the control room.

26.2 All the regulating valves shall be provided on inlet side with motorised isolating valves which shall be capable of being operated from the control room.

26.3 All the regulating valves shall be provided on outlet side with manual isolating valves for CFBC boiler.

27.0 PIPING, FITTINGS AND VALVES

27.1 General

i) The design, engineering, erection, testing, etc. of the complete piping systems shall be to the requirements of power piping code ANSI B 31.1. In addition to this, requirements as laid down in Indian Boiler Regulations (latest edition) shall also be met completely.

ii) All the piping systems and equipments supplied shall be designed to operate with normal maintenance for a plant service life of 30 years and shall withstand the operating parameter fluctuations and cycling which can be normally expected during this period.

iii) The design and engineering shall include, but not limited to, pipe sizing, flexibility and dynamic analysis, hangers, & support engineering etc. and shall be to purchaser’s review and approval.

27.2 Pipe Sizing

i) The design of the piping system shall be based on the fluid and parameters of the system like flow, pressure, temperature, pressure drop available etc. Flexibility analysis shall be made for all piping systems whenever thermal expansions are expected. Suitable expansion loops, hangers and various type of supports shall be considered for the flexibility analysis. Open analysis shall ensure compliance with the applicable codes and to limit the stress within the allowable values.

ii) The velocity of flow in pipes shall be limited to the following values:

Nominal pipe size in mm

Average velocity in Meter / Second

Below 50 mm

50 to 150 mm

200 mm & above

Saturated steam at sub-atmospheric pressure

- 10 - 15 15 - 20

Saturated steam at 0-1 kg/sq.cm.(g)

15 - 20 17 - 30 20 - 30

Saturated steam at 1.1 - 7 kg/sq.cm.(g)

15 - 22 20 - 33 25 - 43

Saturated steam over 7 kg/sq.cm.(g)

15 - 25 20 - 35 30 - 50





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Nominal pipe size in mm

Average velocity in Meter / Second

Below 50 mm

50 to 150 mm

200 mm & above

Superheated steam at 0 - 7 kg/sq.cm.(g)

20 - 30 25 - 40 30 - 50

Superheated steam at 7.1 – 35 kg/sq.cm.(g)

20 - 33 28 - 43 35 - 55

Superheated steam at 35.1 – 70 kg/sq.cm.(g)

22 - 33 30 - 50 40 - 61

Superheated steam over 70 kg/sq.cm.(g)

22 - 35 35 - 60 50 - 75

Compressed air

7 – 10 10 -15 18

Pump suction, condensate

- 0.4 - 0.6 0.6 - 0.7

Pump suction, feed water

- 0.6 - 0.9 0.6 - 0.9

Pump suction, general service

0.6 - 0.9 0.7 - 1.3 0.9 - 1.5

Pump suction, viscous liquid

0.3 0.3 - 0.4 0.4 - 0.5

Pump discharge, condensate

0.9 - 1.2 1.2 - 2.1 1.5 - 2.2

Pump discharge, feed water

1.0 - 1.2 1.5 - 2.1 1.8 - 2.5

Pump discharge, general service

0.9 - 1.0 1.5 - 2.5 1.5 - 2.5

Pump discharge, viscous liquid

1.0 1.0 1.2 - 1.4

Header, general service under 2.0 kg/sq.cm.(g)

- 1.3 - 2.0 1.8 - 2.4

Header, general service 2.0 kg/sq.cm.(g) & up

- 1.5 - 2.4 2.1 - 2.4

iii) The moments and forces imposed at the terminal points by piping provided under this

contract shall be kept within the allowable limits specified by the equipment supplier.

iv) All piping shall be routed so as to avoid interference with other pipes, hangers, supports, electrical conduits, ventilation ducting, structural members and equipment, and to accommodate insulation.

v) 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 operations and maintenance.

vi) Drains shall be provided at all low points and vents at all high points.

vii) All local instruments shall be located on pipelines so as to render them observable from the nearest available platforms.

viii) Pipes shall be sized for the worst operating conditions (i.e. maximum flow,





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temperature and pressure values). In case of FWP suction sizing, transient analysis shall be carried out for optimum sizing of the system in order to establish the pipe inside diameter for minimum pressure drop in system to match with the pump NPSH requirement under worst operating conditions.

27.3 Material Selection

i) Pipe materials for various services and materials for fittings, flanges, fasteners and gaskets shall conform to the specifications as given below. Unless otherwise specifically approved all pipes shall be of seamless drawn steel for the services covered under this specification.

ii) Steam services at temperatures greater than 510 degree C - Alloy steel seamless pipe as per ASTM A-335 Grade P-91 or equivalent.

iii) Steam services at temperatures equal to or greater than 400 degree C and less than or equal to 510 degree C - Alloy steel seamless pipe as per ASTM A-335 Grade P-11/P-22.

iv) Steam services at temperatures less than 400 degree C - carbon steel piping as per ASTM A-l06 Grade B or equal.

v) Feed water, condensate and heater drain piping - carbon steel piping as per ASTM A-106 Grade B or equal.

vi) Other services - carbon steel piping as per ASTM A-106 Grade B or ASTM A-53 (seamless).

vii) Lube oil after filter – Stainless steel

viii) Fittings and flanges - As per applicable Codes conforming to pipe material specification.

ix) Phosphate (HP dosing) and Hydrazine (LP dosing) system / DM water system: Stainless steel to SA 312 TP 304 specification

x) For tubes:

a) Up to 400 Deg C : SA 210 Gr. A1

b) From 401 Deg C to 510 Deg. C : SA 213 Gr. T11/T22

c) Above 510 Deg. C : SA 213 Gr. T91

27.4 Pipe Wall Thickness

i) Thickness calculation shall be made on the basis of procedure and formula given in ANSI B 31.1. Stress values of piping material for calculation shall be selected from tables given in ANSI B 31.1. Thickness, thus calculated shall be checked as per IBR formula (where applicable) and the more stringent of the two shall then be selected.

ii) In any case the thickness selected shall not be less than the standard thickness specified in ANSI B 36.10.

iii) In such cases where thickness calculated does not fall in the standard range of thickness as given in ANSI B 36.10, ID/OD controlled pipes as per ASA-530 shall also be acceptable.





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27.5 Piping Fabrication

i) All pipe fabrications shall satisfy the requirements of Indian Boiler Regulations where applicable. All alloy steel pipes shall not be subjected to any impact or hammer blows when cold which is likely to cause local damage. All precautions shall be taken to avoid such occurrences during handling and all other operations on the pipes.

ii) The pipe fabrication procedure adopted shall be such as to avoid formation of notches or other sharp changes of contour which are likely to cause stress concentrations.

iii) All pipes, pipe bends and tees are to be truly circular in the bore and uniform in wall thickness and the number of joints shall be restricted to the minimum necessary.

iv) All joints for diameters of nominal bore 50 mm and above shall be butt welded. All such butt welding shall be done in accordance with relevant ASME standards.

v) The fabrication limits and tolerances during the pipe fabrication, including pipe bending shall be according to relevant standards.

vi) In any one system of pipe services all pipe work and fittings shall be of similar material unless otherwise specifically agreed to by the Purchaser / Consultant. All piping of 50 mm or larger bore shall be shop fabricated.

vii) Unless otherwise impracticable local stress relieving heat treatment shall not be resorted to, to the pipe joints. All heat treatment operations such as normalizing, stress relieving shall be carried out within prescribed temperature limits of the material.

27.6 Hangers and Supports

i) The Tenderer shall design, fabricate and furnish erection drawings for all hangers, anchors, guides, clamp, stops and supports, auxiliary structures etc., required for the proper installation and support of the piping.

ii) It is desirable that supports should, as far as practicable, be arranged adjacent to the pipe joint.

iii) The variation between hot and cold loads, if variable spring hangers are used, shall not exceed ± 25% of the rated load.

iv) Lugs and additional structural members should be suitably welded to the pipes wherever necessary for hangers and restraints.

27.7 Valves

i) All valves shall be suitable for the service conditions i.e. flow, temperature and pressure under which they are required to operate and those performing similar duties shall be interchangeable with one another unless otherwise approved.

ii) All gate valves shall be of the full way type unless otherwise approved and when in the full open position the bore of the valve shall not be constricted by any part of the gate.

iii) Globe valves shall have curved or spherical seating and the discs shall be free to revolve on the spindle.

iv) All non-return valves shall have an arrow cast or embossed on the side of the valve body to indicate the direction of flow. For severe service conditions cushioned check valves are preferred to obviate valve clatter. In the case of swing-check valves, the body seat shall be inclined at such an angle to the vertical as shall facilitate closing and prevent clatter.





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v) The internal diameter of all valve ends to the connected pipes shall be the same as the

internal diameter of the pipe to which they are joined so as to minimise use of reducers/expanders.

vi) Where applicable valves shall be of the outside screw and yoke type.

vii) Wherever applicable, valves shall be closed by rotating the hand wheels in the clockwise direction when looking at the face of the hand wheel.

viii) In case where the hand wheel is not directly attached to the valve spindle, suitable gearing shall be introduced to achieve the above condition. The face of each hand wheel shall be clearly marked ‘open’ and ‘shut’ with arrows indicating the direction of rotation to which they refer.

ix) Each hand wheel shall also be fitted with a circular name plate indicating the service for which the valve is intended and the valve tag number. All gears used for the valve extension shall be machine cut and shall be cast or forged.

x) All the important valves shall be fitted with indicators so that percentage of valve opening can be readily determined locally and in the control room.

xi) Steam valves shall not be fitted in an inverted position. Eye bolts shall be provided where necessary to facilitate handling heavy valves or parts of valves.

xii) Special attention shall be given to operating mechanism for large size valves with a view to obtaining quick and easy operation and to ensure that minimum of maintenance is required. For valves of size 250 mm and above either bevel or spur gearing shall be provided to facilitate manual operation.

xiii) The materials, design and details of construction of all the types of valves shall be subject to the approval of the Purchaser / Consultant.

xiv) All sampling and root valves furnished shall be of integral body bonnet type.

xv) Gear operation shall be provided wherever required to keep the maximum effort to open/close the valves within 25Kgf.

xvi) The spindles of all valves for use in outdoor locations shall have weatherproof protection covers.

xvii) Drain, vent, instrument tapping and such other connections on piping/equipment shall be provided with double isolation valves in case the normal working pressure exceeds 40kg/sq.cm (a).

xviii) Valves for steam services shall be bubble tight shut off (zero leakage).

xix) The material, design and construction of all types of valves shall be subject to the approval of the PURCHASER / CONSULTANT

27.8 Motor Operated Valves

i) Motor operated valves shall be provided as per Tender P&I.

ii) All valves of nominal size 100 mm or more, for which the normal working pressure is 40 kg/sq. cm(a) or more, shall be provided with integral bypass. For motor operated valves, for which remote operation is desirable, the integral by-pass valves shall also be motor operated.

iii) For the safe and efficient operation of the plant, all the motor operated valves shall be provided with hand operating gear also. The servo-valves of built-in type shall be provided. The necessary controls for automatically stopping the motor when the valve gate has reached the ‘Full Open’ and Full Shut’ position. The motor shall be placed in





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such a position relative to the valve that there is no possibility of leakage steam or water from the valve joints or glands flowing into the motor or control equipment.

iv) ‘Electric Servo-drives’ shall be provided with following independent switches:

a) Two (2) Nos. open position limit switches

b) Two (2) Nos. close position limit switches

c) One (1) No. torque limit switch each for ‘Open’ and ‘Close’ position.

v) Remote indication shall be by coloured lamps initiated by limit switches fitted to the valves.

vi) The limit switches for position indication are to be entirely independent of the control circuits.

27.9 Control Valves

i) Control valves shall be of globe type complete with pneumatic actuators, I/P converters, positioners with gauges, position transmitters with 4 - 20 mA DC signal output, air sets, Hand wheel etc. Wherever line sizes are more than 300 mm, butterfly type control valves shall be considered. Pneumatically operated on-off valves shall be complete with actuator, limit switches, pilot solenoid valves, air sets etc.

ii) All control valves shall be sized such that the valves are controllable over entire operating regime. Those control valves which require to be operated during cold, warm and hot start conditions shall also be controllable during this mode of operation.

iii) The valve sizing shall be suitable for obtaining rated flow conditions with valve opening at approximately 80% of total valve stem travel and minimum flow conditions with valve stem travel not less than 10% of total valve stem travel. All the valves shall be capable of handling at least 120% of the required rated flow.

iv) The design of all valve bodies shall meet the specification requirements and shall conform to the requirements of ANSI (USA) for dimensions, material thickness and material specification for their respective pressure classes.

v) Further, the valve stem travel range from minimum flow condition to rated flow condition shall not be less than 50% of the total valve stem travel. The sizing shall be in accordance with the latest edition of ISA on control valves.

vi) Tenderer shall furnish the sizing calculations clearly indicating the outlet velocity achieved with the valve size selected by him as well as noise calculations, which will be subject to Purchaser’s approval during detailed engineering.

vii) Control valves of steam and water applications shall be designed to prevent cavitation, wire drawing, flashing on the downstream side of valve and downstream piping. Thus for cavitation/flashing service, only valve with anti cavitation trim shall be provided. Detailed calculations to establish whether cavitation will occur or not for any given application shall be furnished during detailed engineering stage.

viii) The valve design shall take into account noise abatement considerations. The design objective will be to limit the generation of valve induced noise to 85 dBA at 1 meter from the valve surface under actual operating conditions. The noise abatement shall be obtained by valve body and trim design and piping arrangement and not by the use of silencers.

ix) By-pass valve shall be of same material as of main valve.

x) Tenderer shall supply quick change type of trim for all control valves. The trim shall





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be removable through the top after bonnet removal without any cutting or welding of the valve. Where applicable plugs shall be designed to include pressure balancing for cage guided valves.

xi) Bonnet joints for all control valves shall be of the flanged and bolted type or other construction acceptable to the Purchaser. Bonnet joints shall be designed for easy disassembly and or assurance of correct valve steam alignment. Bonnet joints of the internal threaded or union type will not be acceptable.

xii) Plugs shall be of one piece construction either case, forged or machined from solid bar stock. Plugs shall be screwed and pinned to valve stems or shall be integral with the valve stems. Valve gland packing material shall be Grafoil for all valves.

xiii) All valves connected to vacuum on downstream side shall have double vee type chevron packing (pressure and vacuum packing).

xiv) Tenderer should select the compatible body material to suite the fluid, service condition and piping material to which it is welded and shall be subject to Purchaser's approval. In general, cast or forged carbon steel bodies shall be provided for non-corrosive process application up to 375 Degree C. Alloy steel castings shall be provided when the media is non corrosive and the temperature exceeds 375 Degree C and is within 550 Degree C. Tenderer shall recommend material for these valves considering the service conditions which will be subject to Purchaser approval at detailed engineering stage.

xv) All control valves shall have stems, guide bushings, plugs, seat rings, stem lock pins, stuffing box parts and other trim parts made of stainless steel. Valves guide posts and bushings shall be stellite faced for valves wherever required. Stellite faced guide posts and bushings shall be differential hardened. For applications involving high pressure drop as also for flashing and cavitation service trim material shall be properly chosen to ensure required degree of hard facing so as to avoid erosion. Valve seat and plug shall be hardened through stelliting. Where stellite facing is not specified, hardened stainless steel shall be furnished for all surfaces subject to wear.

xvi) All valves shall be tested in accordance with the quality assurance programme agreed between the Purchaser and the Tenderer and shall meet the requirements of IBR and other applicable codes.

27.10 Other requirement

i) All drain lines in Feed water side, SH and MSL leading to the respective drain headers/IBD shall be provided with two valves and one valve shall be motor operated from unit control room.

ii) Drains from steam drum, headers, gauge glasses and integral piping of boiler shall be terminated into one or more drain collection headers which will be connected to IBD tank. IBD tank vent shall be liberally sized to avoid pressurisation and shall be terminated 3 meters above the boiler roof.

iii) Facility for draining the steam drum during emergency when the boiler is in operation shall be provided. The drain shall be led to IBD directly with expander. The valves shall be located at operating floor. Both valves at EBD shall be motor operated and shall be quick opening type.

iv) All the air vents shall be routed to one place to form an air vent station. The drain line of all air vents stations to be brought up to boiler zero meter elevation and terminate in the drain trench.

v) For Nitrogen (N2) blanket and N2 preservation, suitable connections up to gas





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cylinders.

28.0 SAFETY PROVISIONS

28.1 Staircases on either side of walkways and galleries shall be provided so that all areas of the Boiler including ESP are safely and conveniently accessible for operation and maintenance. Staircases shall be provided at front and rear of Boilers to quickly approach various floors. All staircases / platforms shall be provided with 2 rail safety handrails of 100 cm high and Top rail, middle rail and vertical post shall be 32 NB (medium) tube conforming to IS: 1239. The spacing of vertical post shall not exceed 1.5 m. The height of handrail shall be 1.0 m with knee rail at mid height. At platform and landings toe guard of 100x6 mm (t) shall be provided.

28.2 The railing shall be of ERW mild steel tubes of double hand rail type. The top rail shall be of at least 32mm (32NB (i.e., OD: 42.1mm)) in diameter while the bottom will be at least 25 mm diameter.

28.3 The top and bottom rails will be at a height of not less than 1050mm and 600mm respectively from the platform level.

28.4 Steel stanchions of suitable type shall be provided on centres not exceeding 2000 mm apart to which the hand-railing must be attached firmly.

28.5 All platforms and staircases shall be provided with gratings and only operating floor shall be provided with chequered plates. Interconnecting platform shall be provided between Boiler and ESP.

28.6 Platforms and Walkways

Size of platforms shall be in such a way that the equipment to be attended shall be approachable from all sides. Minimum width of platforms and walkways shall be 750 mm. Minimum headroom above the top of platform or walkway should be 2200 mm. The allowable deflection for structural members shall not be more than L/325.

28.7 Stairs and Ladders

All stairs shall have a minimum clear width of 750 mm and the slope shall not exceed 45 degree angle with horizontal. Minimum width of tread of stairs shall be 225mm and the rise shall not exceed 200 mm. Length of landing should not be less than 900 mm or the clear width of stair, whichever is greater. Maximum number of risers in a flight shall be restricted to 16. Treads on open stairs should overlap not less than 16 mm and shall have a slip resistant nosing not less than 25 mm wide.

Fixed ladders shall be provided to platforms / roofs, which do not require frequent access by the operating personnel. Ladder should preferably of a sloping type with a maximum inclination of 15 deg. to the vertical. Clear width between strings shall be 450 mm. Minimum thickness of strings shall be 10mm. Rungs shall be MS rounds of 20 mm diameter, spaced at 225 mm (min) and 275 mm (max). Minimum clear space of 230 mm shall be provided behind each rung to allow foot room. Wherever the heights of the stair exceed 6.0 metres an intermediate platform shall be provided. Safety cages shall be provided wherever the height of ladder exceeds 4.5 metres. The cages may start at a height of 2.5 metres from the lower level. The diameter of the cage shall be 700 mm (min) with 5 nos. of 50x6 flats for vertical and 50x6 flat at a spacing of 900 mm (max) for rings.





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28.8 Burner platforms shall provide adequate space for servicing, maintaining and operating

burners and auxiliary equipment. All burner withdrawals shall be within the Boiler room enclosure. No structural member shall be provided on the passage to burners. All oil burners shall have a roof above oil burner station for protection purposes.

28.9 Burner platforms located within 2000mm of burner station covering oil valves and oil guns shall be welded steel chequered plate floor with welded-in-place drains and collecting pan arrangement to prevent lighter oil spilling from spreading.

28.10 Personnel access requirements

a. Class-I – Regularly attended access areas shall have operating platforms, which are fully accessible from elevators landings. The access shall confirm to LPA/TAC requirements.

b. Class-2 – Maintenance access areas requiring access only monthly or annually shall have access platform of adequate size to permit two people work (1.5sq.m.) with access ladders and maintenance access walk ways. Access shall be provided on both sides of safety valves.

c. Class 3 – Maintenance access areas, where access is only required for painting, re-insulation, or replacement of-components which have a service life of 10 years or more shall have facilities to enable the purchaser to erect patent scaffolding, temporary ladders, and platforms.

d. Provide service platform, as specified for class-2 above, for equipment furnished by others, but installed directly on the Boiler.

e. Provide escape ladders from any platforms having dead ends at the rear of the Boiler.

i) Floor grating

a. Gratings shall be of structural steel with a minimum depth of 25 mm and a minimum width of 300 mm and shall conform to BS: 4952 Part I.

b. Minimum thickness of load bearing and space bars shall be 3 mm. Thickness of outer binding bars shall be minimum 6 mm. Clear distance between the load bearing bars shall not exceed 40 mm for diamond pattern and 30 mm for rectangular pattern. The deflection of grating panel shall not exceed span / 200 or 10 mm whichever is smaller.

ii) Cladding

Corrugated Aluminium cladding of 1.0 mm shall be provided with adequate ventilation. The Boiler shall be provided with weather proof roofing and side cladding from lowest feeder floor to bunker bay top with necessary structures at the topmost level.

iii) General

All the cables in the Boiler shall be routed such that cable entry to Boiler MCC from the Boiler house shall be avoided. Installation of any I & C tapping below fire hydrant tapping shall be avoided.





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iv) Joint design

Generally all shop connections shall be welded and field connection welded or bolted. All moment connections, if bolted shall be of High strength friction grip bolts. Shear and other minor connections, if bolted may be made with mild steel / high strength bearing bolts.

28.11 Specific Design Requirements for Emergency Conditions

The Boiler shall be adequately safeguarded during normal power supply failure due to grid disturbance or due to any other reasons. All the necessary equipment, piping, valves, fittings, instrumentation etc. shall be provided by the Tenderer. The measures proposed to safeguard the CFBC Boiler during emergency condition shall be clearly explained in the Tender.

29.0 FABRICATION AND ERECTION

29.1 All structural steel shall be of tested quality and shall conform to IS: 2062. High tensile steel. When supplied, shall conform to IS: 961. All bolts and nuts shall confirm to IS: 1363 and IS: 1364 and unless shown or specified otherwise shall be hexagonal. All nuts shall fit tight. Mechanical properties shall conform to IS: 1367. Mild steel and high tensile steel electrodes shall conform to IS: 814.

29.2 All workmanship shall be equal to the best practice in modern structural shops. Greatest accuracy shall be observed in the manufacture of every part of the work and all similar parts shall be strictly interchangeable.

29.3 Shearing or flame cutting may be used at the TENDERER’s option provided that the resulting edge shall be reasonably clean and straight. Sheared members shall be free from distortion at sheared edges. Unless clean, square and true to shape, all flame cut edges shall be planed.

29.4 The welding and the welded work shall conform to IS: 816 unless otherwise specified. The permissible stresses for welding shall be taken as 75 per cent of those specified in IS:816 where welds are not tested either by radiographic or ultrasonic methods. All butt welds in critical structures such as girders, heavy columns, bunkers, etc. shall be tested either by radiographic or ultrasonic methods. As much work as possible shall be welded in shops and the layout and sequence of the operations shall be so arranged as to eliminate distortion and shrinkage stresses to the satisfaction of the site incharge.

29.5 The field assembling of the component parts of a structure shall involve the use of method of appliances not likely to produce injury by twisting, ending or otherwise deforming the metal. No member slightly bent or twisted shall be put in place until the defects are corrected and members seriously damaged in handling shall be rejected.

29.6 The Tenderer shall assume full responsibility for the correct setting out of all steel work and erecting it correctly as per alignment and levels shown on the drawings and plumbing of vertical members. Datum points will be fixed by the site incharge. Notwithstanding any assistance rendered to the Tenderer by the site incharge, if at any time during the progress of the work any error should appear, on being required to do so, the Tenderer at his own cost shall remove and amend the work to satisfaction of the site incharge.

29.7 Where the steel has been delivered painted, the paint shall be removed before field welding, for a distance of atleast 50 mm on either side of the joints.





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29.8 Correction of minor misfits, a reasonable amount of reaming and cutting of excess-stock

from rivets will be considered a legitimate part of the erection.

29.9 Any error in shop work which prevents the proper assembling and fitting up of parts by the moderate use of drift pins or a moderate use of reaming and slight chipping or cutting shall immediately be reported to the site incharge and his approval of the method of correction obtained.

29.10 Bolts shall be inserted in such a way so that they may remain in position under gravity even before fixing the nut. Bolted parts shall fit solidly together when assembled and shall not be separated by gaskets or any other interposed compressible materials. When assembled, all joint surfaces, including those adjacent to the washers, shall be free of scales except tight mill scales. They shall be free of dirt, loose scales, burns and other defects that would prevent solid seating of the parts. Contact surfaces within friction type joints shall be free of oil, paint, lacquer, or galvanizing.

All high tensile bolts shall be tightened by any of the following methods:

Turn-of-nut method. Torque wrench tightening method.

30.0 MAINTENANCE REQUIREMENT

30.1 The Tenderer shall provide facilities for carrying out on-load and off-load maintenance of the boilers and its ancillaries. This should include adequate handling equipment, working space, platforms and safety devices and adequate lighting.

30.2 All the cablings from the boiler house to control rooms, MCC shall be routed only at the sideways and in any case shall not pass through the boiler house area. The layout should ensure that no C& I provisions will be installed below any of the fire hydrant provisions in the boiler area. Power plant piping shall be routed to avoid hindrance for personnel and material movement.

30.3 Access and cleanout doors shall be provided to permit access to the furnace, superheater, the area between the tube banks and drums, economiser and any other areas requiring access. Access doors on both sides of the last pass shall also be furnished.

30.4 All access doors provided for furnace, ESP, ducts, etc., shall be of minimum 450 mm x 450 mm and accessible from boiler operating platforms.

30.5 All the instrument tapping, valves and dampers in the combustor and convective pass shall have working platforms of sufficient area.

30.6 In order to carry out on-load maintenance, it is necessary that the equipment supplied can be readily disassembled, repaired and assembled in the shortest period.

30.7 Drains and vents of water and steam system shall not be terminated on the boiler structures and shall be properly connected to the nearest plant drainage.

30.8 Maintenance/access platforms for fuel, steam, water and oil piping and fittings and for dampers shall be provided.





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30.9 Access platforms, staircases and walkways with toe boards shall be provided for all the

critical equipment viz. soot blowers, air pre-heaters, ID, SA/FD, PA fans, valves of critical services, transmitter racks, junction boxes, etc.

30.10 Interconnecting platforms between both boilers and turbine building shall be provided at control room floor and de-aerator floor.

30.11 All transmitter racks and junction boxes shall be protected by suitable canopies. Toe guards plate shall be provided on all four sides of all platforms around combustor and convective pass, Cyclone, TAPH, ESP, SCAPH tank etc.

30.12 Material handling equipment consisting of monorails, hoists and trolleys (Electric operated) with all other ancillaries including supporting structure as required, shall be provided for ID, SA / PA, fan drives, blowers and ESP maintenance.

30.13 However all the valves, dampers, instruments, manholes etc., shall be located as closer to the operating platforms as possible. No vertical ladder (monkey/cat ladder) shall be permitted in the entire Boiler area.

30.14 Maintenance and access platforms are to be provided for these material handling equipments. Also, maintenance platforms shall be provided for valves, instruments, manholes located above 1.5 m above ground floor.

30.15 One number approved type furnace inspection and maintenance equipment (similar to sky climber) common for both the steam generating units shall be supplied by the Tenderer.

30.16 A pent house shall be formed above the roof of the boiler for attending to tubes and headers and thermocouples in this area. In order to avoid fly ash infiltration, through the space around the tubes coming out from the furnace in this area, all welded seals between furnace gas pass and pent house shall be provided. The pent house shall be provided with two access doors at both front and rear side of the Boiler.

30.17 Pent house roof, enclosures at firing aisle platforms and at drum level shall be covered with GI sheet.

30.18 The maintenance tools required for routine maintenance of equipment shall include in the offer and the list shall be provided along with the offer. The Tenderer shall also furnish a comprehensive list of other maintenance tools recommended by him.

30.19 Canopies shall be provided to protect all outdoor installed auxiliaries with related electrical and instrumentation portion from dust and water.

31.0 VIBRATION AND NOISE LEVELS

31.1 The design of boiler and its auxiliaries shall ensure maintenance of vibration and noise levels within the limits specified in the following paragraphs over the entire operating range and during load fluctuations.

31.2 The gas path design shall prevent the generation of excitation forces conducive to resonant vibration.

31.3 ID, PA and SA fans vibration at the bearings shall meet the requirements of ISO 10816–2.





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31.4 The ducting shall be adequately stiffened to absorb pressure pulsations. Guide vanes shall be

provided at bends as required preventing turbulence. Fan induced duct vibrations shall be avoided.

31.5 The measured noise level produced by any rotating equipment shall not exceed 85 dBA at a distance of 1.5 m from its boundary in any direction under any load condition.

31.6 The noise produced in valves and piping associated with handling compressible and incompressible fluids shall be attenuated to 90 dBA at a distance of 1.5 m from the source by the use of low noise trims, baffle plate silencers/line silencers, acoustic lagging (insulation), thick-walled pipe work as and where necessary.

31.7 All pipes and valves downstream of pressure control valve (including pressure control valve) shall be one schedule higher than needed by pressure considerations to attenuate the noise.

31.8 For safety relief valves the allowable noise level shall not exceed 115 dBA for one quarter hour or less per day. The Tenderer shall outline the methods adopted to limit the vibration and noise levels within specified values.

32.0 INSULATION

32.1 The Tenderer shall provide thermal insulation and lagging for entire BOILER, flue gas/ air ducting, ESP etc.

- Insulating materials for all types as specified/required.

- Finishing materials of all types including cement, protective coating, and sheeting, as specified/required.

- Angles, irons, clamps, lugs, etc. for supporting insulation on pipes, ducts, furnace, valves & fittings and equipment.

- Wire mesh, lacing/binding wires, bands, straps, screws, etc. as required.

- Weather hoods.

- Refractory, insulating and red brick works with suitable bonding material.

- Any other material as may be required for making the refractory and insulation work complete.

32.2 General Design Requirements

- The Tenderer shall furnish all required details of insulating materials and also furnish curves of thermal conductivity plotted against mean temperature. The Tenderer shall also state maximum permissible hot face temperature, which the insulating material can withstand without deterioration and the weight per unit volume of each material offered.

- All exposed portions of the plant which operate at temperatures of 60C and above during normal operation shall be thermally insulated so that the temperature on the outer surface of the cladding shall not exceed by more than 20C above ambient, based on an ambient temperature indicated in site data.





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- Unless otherwise specified, the Tenderer shall calculate the insulation thickness

based on the insulating material properties.

- The specified insulation thicknesses shall not include the thicknesses of wire netting, finishing cement or any other finishing or weatherproofing application.

- In refractory walls suitable expansion gaps shall be provided at regular intervals.

- Removable insulation arrangement shall be provided for manholes and hand holes.

- Perfect leak tight arrangement of sealing shall be provided for points at furnace roof/wall where superheater tubes penetrate. Detailed arrangement sketches shall be submitted for the approval of the PURCHASER/CONSULTANT.

- Insulation shall not fill the contours of the expansion bellows.

32.3 Personnel Protection.

- Piping and equipment that are not insulated but having a surface temperature exceeding 60 Deg.C shall be insulated for personnel protection.

32.4 Insulating Materials

- The insulating materials and any component of the finished insulation job shall not react chemically singly or in combination, with water or moisture to form substances which are more actively corrosive to the applied surface than water or moisture alone. The materials shall not offer sustenance to fungus or vermin and must not pose a health hazard. The Tenderer shall submit with the Bid, details of application of protective coatings or other methods, he proposes to use for corrosion protection of insulated surfaces.

- Compressed Resin bonded mineral wool mattress insulating material shall be of the required grade. The application density of insulation for temperature upto and including 400 Deg. C shall be 100 Kg/Cu.m. The application density for temperatures above 400 Deg.C shall be 125 Kg/Cu.m.

32.5 Sheeting Material

- The sheeting material for all insulated piping and equipment shall be aluminium conforming to relevant IS codes. The thickness of aluminium sheeting to be used shall be as follows:

- Pipes of 450 mm (18 in.) and above, over outside diameter of insulation-1.219 mm (18 SWG)

- Pipes of 150 mm (6 in.) and above, over outside diameter of insulation but less than 450 mm (18 in)-0.914 mm (20 SWG)

- Pipes less than 150 mm (6 in) over outside diameter of insulation-0.711 mm (22 SWG)

- Flues and ducts, not less than 1.0 mm

32.6 Piping





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- All vertical pipes shall be provided with suitable insulation supports to prevent the

insulation from collapsing due to its own weight. Any welding required shall be done by the Tenderer with the prior permission of the PURCHASER/Engineer and only under his direct supervision. Where welding is not permitted, suitable clamped supports shall be used by the Tenderer. The insulation shall be applied starting from bottom to top.

- The insulation shall be formed to fit the pipe and applied with edges pulled together tightly at the longitudinal joint and secured by lacing wire. The insulation shall be turned to bring this joint to the lower side. Adjacent length shall be butted closely and laced together with lacing wire. For insulation thickness of more than 75 mm, where application will be in two or more layers, each layer of mattress shall be backed up with wire netting chosen from 20 SWG galvanized steel wire and having hexagonal opening of 25 mm size. If the interface temperature is 400 Deg.C or more, the wire netting shall be from 20 SWG stainless steel wire and having hexagonal opening of 25mm size.

- The ends of all wire loops shall be firmly twisted together with pliers, bent over and carefully pressed into the surface of the insulation.

- All insulation shall be protected by an outer covering of aluminium sheeting. All insulation sheeting joints shall be sealed and made effectively weather and waterproof. Extreme care shall be taken during the designing and installation of the insulation and the outer sheeting keeping in mind that the boiler will be installed outdoors. All flat surfaces shall be adequately sloped to prevent pools of water collecting. The sheeting shall be protected internally with 2 coats of bitumastic paint. The jackets shall be installed with the longitudinal lap joints at 45 Deg.C below the horizontal for horizontal pipes and the joints sealed with bitumastic paint.

- On vertical pipes the jacketing shall be applied working from bottom up. Each section of jacketing shall have a minimum lap of 50 mm longitudinally and circumferentially. Each circumferential joint shall be made weather proof by securing with an aluminium / galvanized steel strap and sealing with bitumastic paint. Longitudinal lap joints shall be fixed with zinc plated screws on approximately 150 mm centres.

32.7 Valves and Fittings

- All valves fittings and specialties shall be covered with the same type and thickness of insulation as specified for the adjoining pipe, with the special provisions and/or exceptions as listed below.

- All valves and flanges shall be completely insulated with removable type of boxes fabricated from aluminium sheets of same thicknesses as used on adjoining pipes. Pipe insulation adjoining flanges shall be beveled back to permit removal of the bolts and nuts.

- Flanges on lines covered with the minimum thickness of insulation (lower temperature range) shall not be insulated. Flanges on all other lines shall be covered with provisions for making the insulation removable and replaceable.

- Unions shall not be insulated.

- Non-metallic expansion joints shall not be insulated.





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- Safety valves, traps and safety valve discharge lines shall not be insulated. However,

trap discharge lines shall be insulated for personnel protection.

- Nozzles and other connections on tanks, heaters and other equipment shall be insulated in the same manner as the pipes.

- Valves shall be insulated upto and including their bonnet flange.

- Pipe hanger clamps shall be covered with insulation along with the pipe. When pipe hangers pass through insulation on piping outdoor, a metal hook placed with waterproof sealing material shall be supplied and installed. Care shall be taken to ensure that the upper bolts of hangers clamps are not insulated.

32.8 Equipment

- Mineral wool blanket insulation to the specified thickness shall be provided. The Tenderer shall tack weld suitable 9 SWG wire lugs atleast 25 mm longer than the required length to support the insulation in place. These lugs shall be bent and secured with the metal fabric of the blanket, after the insulation has been applied. Where welding is not permitted, clamps of mild steel flats with bolts, nuts and lugs welded over the flat shall be used. The lugs shall be spaced at approximately 300 mm centres. Spacer rings, at 1000 mm shall be provided for fixing aluminium sheets. All blanket joints shall be butted tightly and the blankets shall be secured with 10 mm wide 25 SWG galvanised bands. After banding, all blanket edges shall be laced tightly.

- All equipment shall have a smooth sheet aluminium jacket, applied in a manner similar to that specified for piping. All vertical and horizontal sheets shall be overlapped at a minimum of 50 mm. The longitudinal lapped joints of adjoining sections of sheets shall be secured with zinc plated screws. On all vessels over 2.5 metre diameter, the jacketing shall be further secured by circumferential bands at approximately one more centres. Each sheet joint shall be sealed with bitumastic paint. The roof sections shall overlap the sidewalls to prevent water seepage between insulation and the vessel wall. Side wall sheets shall be securely banded at inter-sections of the side wall and roof sections.

- All equipment and vessel manholes, hatches, bolted or screwed cover plates, flanged ends, etc. shall have removable box type insulation, with same thickness of insulation as for adjacent surfaces. Insulation adjoining such equipment or vessel openings shall be tapered towards these openings to permit removal of bolts, screws, heads, covers or plates with no damage to adjacent surface insulation or cover.

- The insulation applied to equipment shall be reinforced with 25 mm (1 inch) 20 SWG galvanized wire netting with hexagonal mesh. One course of wire netting shall be applied to the surface of the equipment, with an additional course per 40 mm of thickness. All irregularities of the surface shall be filled and leveled over with insulating cement. Mineral wool blankets as specified shall be applied over the dry cement surface and secured with annealed lacings.





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33.0 REFRACTORY

- All necessary refractories and setting materials shall be supplied. The refractory bricks supplied shall be of the best quality consistent with temperature obtained at various zones. The refractory and insulation thickness of all sides of the boiler shall be such that the temperature on the surface of the casing would be low enough from the point of view of safety of the operating personnel and also consistent with the permitted heat losses.

- On the refractory portion of the boiler walls necessary access doors and observations ports shall be provided. Boiler surfaces, which are to be insulated, shall have insulation lugs fitted.

- Where castable refractories are used special care shall be taken to see before it is applied that its ‘shelf life’ period is not over.

- Necessary anchors for supporting the castable refractory to be provided and the same shall be coated with bitumen paint to allow for differential expansion of anchors and refractory. All parts of tubes and drums to which the castable refractory is applied shall be coated with aluminium or bitumen paint and allowed to dry thoroughly before refractory is applied.

33.1 The refractory shall be capable of withstanding the following :

- Temperature surge and sudden thermal shock due to unit trip.

- Frequent thermal cycling.

- Slight positive pressure and oxygen deficient atmosphere in lower furnace region.

- Continuous attack by erosive high-velocity particles.

- Both oxidising and reducing atmosphere which may occur at any Boiler point under normal operation and transients.

- A minimum of 12 to 15 cold start-ups every year for the first two years of operation.

33.2 Since good insulating materials generally have poor erosion resistance, the refractory protection shall be made up of several materials applied in layers.

33.3 In the inlets of the cyclones, where possibility of erosion is severe, abrasion resistant phosphate bonded castable shall be used to improve the wear resistance.

33.4 The barrel and cone of the uncooled cyclones shall preferably consist of silicate blocks next to the shell, an insulating fibre brick layer in the middle and a dense abrasion resistant mullite or special duty bricks on the hot side.

33.5 In case of steam /water cooled cyclones the thin refractory linings shall be provided and the refractory linings shall be of high conductivity abrasion resistant high alumina, phosphate bonded refractory with stainless steel reinforcing fibres mounted on a high density stud pattern similar to that to be provided in the furnace. The entire assembly in this case shall be shop fabricated to the largest practical sections as dictated by transport and erection limitations. The shop installed and cured refractory (castables) shall be used to the maximum extent possible.





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33.6 Normal conventional insulation and lagging shall be provided over the cyclone area,

identical to standard Boiler wall covering practice as indicated earlier.

33.7 In freeboard areas where tubes are left exposed Tenderer shall specifically confirm that the above is a Tenderer's proven standard practice, by providing evidence of satisfactory commercial operation of other CFBC Boiler installations already in service.

33.8 Tenderer shall substantiate the basis of selection of refractory in the Tender document.

33.9 All internal refractory required for furnace wall, cyclone and FBHE shall be from reputed supplier who has supplied the same refractory material for the services indicated above and have undergone successful commercial operation for a period of not less than 16,000 hrs each in at least two similar or higher capacity CFBC Boilers.

33.10 Refractory for furnace roof, and bank tubes, deflection arc etc. Necessary castable refractory material shall be applied in all the areas requiring casing.

33.11 The refractory bricks if required supplied shall be of the best quality consistent with temperature obtained at various zones.

33.12 Necessary anchors, wherever necessary, for supporting the castable refractory to be provided and the same shall be coated with bitumen paint to allow for differential expansion of anchors and refractory. All parts of tubes and drums to which the castable refractory is applied shall be coated within aluminium or bitumen paint and allowed to dry thoroughly before refractory is applied.

33.13 Miscellaneous

- Approval of the PURCHASER Engineer shall be obtained for samples of all insulating refractory and sheeting materials and necessary test certificates of approved national laboratories, shall be sent to the PURCHASER before dispatching these materials to Site. Insulation shall not be applied until specific approval is given by the PURCHASER/CONSULTANT.

34.0 BOILER / ESP SUPPORTING STRUCTURES

34.1 The boiler structure shall be designed to support all loads including loads introduced on the structure from piping, enclosures, adjacent structures and equipment located on the structure.

34.2 Loading due to wind and seismic conditions shall be computed based on IS: 875 and IS: 1893 respectively. Criteria for designing the steel structure are to be described by the Tenderer.

34.3 The supporting structure shall be designed for the following:

i) Live / imposed loads.

ii) Dead loads.

iii) Seismic or wind loads.

iv) Static and dynamic loads of piping, movable equipment and maintenance parts.

v) Cantilever loads of not less than 2000 kg/metre at a distance of 1200 mm from the external face of the columns, on both sides of the ESP, for cable trays and walkways.





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vi) Cantilever loads of not less than 500 kg/metre at a distance of 1200 mm from the

external face of the columns, on both sides of the Boiler, for cable trays and walkways.

vii) Dry ash piping supported from the main columns of ESP structure.

viii) Ash water piping supported on the outermost row of Boiler column.

ix) Temperature variation of +/- 25 degree C for atmospheric temperature variations.

x) Temperature variations under ESP operating condition.

xi) The loads listed above indicate the minimum requirements.

34.4 Roof shall be covered with permanently colour coated galvanised MS trough sheet of approved profile having a minimum of 0.8 mm base metal thickness. Proper drainage of the roof shall be provided by means of gutters and down take pipes. Down take pipe shall be GI pipes with threaded connections.

34.5 Side cladding shall be of permanent colour coated sheet as above but minimum base metal thickness of 0.6 mm.

34.6 Boiler supporting structures shall be so configured that the temperature of steel does not exceed 60 degree C unless specified otherwise. Brackets shall be provided on both sides of the outermost row of columns of both the Boiler and ESP for supporting cable trays and walkways at a height not exceeding 10 m. The exact levels shall however be decided during detail engineering. Each ESP hopper shall be supported at four corners by providing four columns from the ground.

34.7 Dry ash transportation pipes and supply air pipes shall be supported on the structural members of the ESP. The ESP hopper outlet flanges shall be terminated at a height of 3.5 m above ground level.

34.8 The bracings in the Boiler structure shall be provided such that under no circumstance normal/convenient access to all points in the Boiler is blocked or obstructed.

34.9 Boiler and ESP supporting structures shall be checked for differential settlement of foundations, which shall be restricted to 1 in 1000 of span or 8 mm whichever is less.

34.10 In design of Boiler / ESP supporting structures dynamic piping loads need not be considered acting simultaneously with wind or seismic loads. Increase in permissible stresses shall be allowed in load combinations where dynamic piping loads are considered and shall be as permitted under seismic load conditions.

34.11 Canopy shall be provided for all field instruments /panels/skids. Necessary Platforms shall be provided to access/maintain all field instruments.





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ELECTRICAL SYSTEM





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SECTION – 5

ELECTRICAL SYSTEM

1.0 GENERAL

1.1 This specification covers the details of electrical equipment to be installed for the Boiler unit. The Tenderer’s scope shall include supply, erection, testing, commissioning, obtaining statutory approvals and handing over to the Purchaser the complete electrical equipment required for the satisfactory operation of the Boiler plant. The attached key single line diagram and power distribution scheme shall be referred for the total plant operation and power distribution system at the steam generating units respectively.

1.2 All the Boiler auxiliaries shall be suitable for 6.6kV / 415 V (3 phase) / 230 V (1 Phase), 50 Hz.

1.3 The Tenderer shall arrange. MCCs, with 50% load on the MCC, for connecting the complete loads of the equipment under the scope of the Tenderer. The MCC shall be supplied with the required P.F. correction capacitors and associated control gear to automatically raise the P.F. to 0.95 lag.

1.4 The panels shall be provided with minimum one spare feeder per module size. For similar ratings of modules of 6 Nos. or more, minimum two spare modules to be provided.

1.5 Control switches with fuse for space heater supply at the outlet of fuse switch of motor feeders shall be provided, wherever space heaters for motors are envisaged.

1.6 Motors for PA, SA and ID fans shall be of variable frequency drive type. All other motors shall be squirrel cage type.

Starting method of various loads shall be as given below:

a. Feed Water Pump Motors Suitable soft starter arrangement

b. PA, SA and ID Suitable variable frequency drive cum star delta starter.

c. Biomass Feeder Motors Variable-frequency drives cum star / delta starter

d. Other Motors DOL

2.0 SCOPE

2.1 Design, supply, installation and testing of 415 V non-draw out type MCCs, distribution boards & local control panels, as required, for the control and power supply of all equipment in Tenderer’s scope.

2.2 Design, Supply, Installation and Testing of separately mounted starters including variable frequency type (for fans rated above 90 kW), Soft starter (for feed pumps) and variable frequency drives for feeders.

2.3 Supply, installation and commissioning of drive motors.





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2.4 Supply, lay and terminate cables and other electrical items for satisfactory completion and

commissioning of equipment and interconnection of cables between MCC and various loads / equipment in cable trays / racks in cable trenches.

2.5 Supply, installation and commissioning of local push button stations, marshalling cabinets, junction boxes, earthing, lightning protection, etc.

2.6 The Tenderer’s scope of work includes preparation and submission of necessary drawings and documentation for CEIG approval and to liaison and obtain safety / clearance certificates from the statutory authorities.

3.0 MOTOR CONTROL CENTRE

3.1 General

Medium voltage Switch board shall be dust, damp & vermin proof construction sheet steel clad totally enclosed, floor mounted, self standing type with single front compartmentalised cubicle design with single TPN bus bar arrangement with front access and rear access and with cable entry and outgoing from bottom of the switch board. All the MCC’s will have two incomer feeders.

3.1.1 The Switchboards shall be suitable for the following operating system.

Rated Voltage : 415 V, 3 Ph, 4 Wire

Rated Frequency : 50 Hz

Fault Level : 65 kA for 1 sec.

Enclosure : IP 52

3.1.2 The panel shall be designed for an ambient temperature of 50 Deg. C and the maximum operating temperature shall not exceed 85 Deg. C

3.1.3 The design, manufacture and testing of the various equipment covered by this specifications shall comply with the relevant, latest issue of IS, IEC standards and IE rules, guidelines, regulation of CEIG.

IS : 772 : AC Electricity meters

IS : 1248 : Specification for direct acting electrical Indicating instruments

IS : 2705 : Specification for current transformer

IS : 3231 : Electrical relays for power system Protection

IS : 5082 : Material data for aluminium busbars.

IS : 5578 : Guide for marking of insulated

Conductors

IS : 8623 : Factory built assemblies of switchgears





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And control gears upto 1000 V

IS : 9224 : Low voltage fuses

IS : 10118 : Code of practice for selection, installation and maintenance of switchgear and control gear not exceeding 1000 V

S : 11353 : Guide for uniform system of marking and identification of conductors and apparatus terminals

IS : 13947 : LV Switchgears and Control gear

EC-144 : Degree of protection of enclosure for Low voltage switchgears and Control gear.

IEC-185 : Current Transformers

IEC-186 : Potential Transformers

IEC-255 : Electrical Relays

IEC-269 : LV Fuses

IEC-439 : LV Switchgears and Control gear Assembly

IEC-947 : LV Switchgears and Control gear

3.2 Panel Design Requirements

3.2.1 The switchgear shall be formed using distinct vertical sections each comprising following compartments:

a) A completely metal enclosed horizontal busbar compartment running horizontally at top.

b) Individual feeder modules organised in multitier mode.

c) Completely enclosed vertical bus bars serving all feeder modules in the vertical panel.

d) Cable termination compartment.

3.2.2 The front of the board shall comprise of individually enclosed fuse switch modules, starter modules and Air Break Circuit Breaker modules.

3.2.3 All auxiliary devices for control, indication, measurement and protection such as control and selector switches, indicating lamps, ammeters, voltmeters, kWH meters protective relays shall be mounted on the front side of the respective compartment only.

3.2.4 The MCC shall have two incomers with Bus coupler to arrange to transfer total load on one incomer incase of eventuality manually and auto with bus PT signals of each bus.





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DOC. NO : 4 – 3678 – MECH – 001 (R2)

3.2.5 ACB to be used for feeder greater than 630 A and MCCB for less than 630 A.

3.2.6 Each outgoing circuit shall have MCCB. The number of outgoing circuits shall be as per the requirement plus five numbers for Purchaser’s use and 20% spare.

3.2.7 Each outgoing Power feeder shall have MCCB / MPCB (up to 7.5kW). The number of outgoing circuits shall be as per the requirement plus two numbers of highest rating for Purchaser’s use and highest rated plus commonly used rating of each one per MCC as spare.

3.2.8 MCCB / MPCB (Up to 7.5kW) along with bi-metallic overload relay and contactor (of minimum 16A and 1.25 times the rating required as per type 2 coordination charts) to be provided for motors up to 55 kW. However electronic over load relay (The relay shall have overload, short circuit, earth fault, stalling and single phasing protective features) for motors above and including 55kW and below 110 kW. For motors including and above 110kW shall be with numerical comprehensive motor protection relays.

3.3 Construction

3.3.1 The complete board shall be of co-ordinated design so that shipping groups of the board are easily assembled together at site into a continuous lineup. Necessary standard connecting material shall be supplied.

3.3.2 Name plates of elegant and durable design and quality shall be fixed to the individual compartments-feeder modules, bus risers, bus-bars, cable alleys etc.

3.3.3 The board covered by this enquiry shall be designed, manufactured and tested in accordance with the latest revisions of the related applicable standards listed elsewhere in this document.

3.3.4 The framework of the board shall be constructed of preformed steel channels, angles and side sheets bolted together and suitably reinforced to form a rigid, self supporting, compact assembly to function properly under both normal and short circuit conditions.

3.3.5 The bus compartments shall comprise of ONE horizontal TPN bus unit with vertical risers for connection to the individual modules. The panel shall have bottom cable entry for the incomer and bottom outgoing from the feeders.

3.3.6 The board shall be of totally metal-enclosed ventilated multiple unit construction. End units shall include provisions for future main bus extensions and installation of additional units on either side with the framework suitably drilled to receive the additional modules and the busbars fitted with fish plates and associated hardware enabling future extension without involving major fabrication works on the panel in service.

3.3.7 Metallic barriers shall be provided between vertical sections and also between adjacent modules to ensure prevention of accidental contact with live parts during routine inspection/maintenance of functional units or cable terminations of one or more functional units when working on those of adjacent units. These barriers shall have insulating inserts as necessary for taking the interconnection etc.

3.3.8 Doors and covers shall be of sheet steel of thickness not less than 2 mm cold rolled and the edges shall be reinforced against distortion by rolling / bending or by addition of welded reinforcement members. The doors shall have concealed type of hinges.

3.3.9 Cut outs shall be true in shape and free from sharp edges.





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DOC. NO : 4 – 3678 – MECH – 001 (R2)

3.3.10 The panel shall be provided with integral metal base channel 75 mm in height for

facilitating grouting on the floor.

3.3.11 Dust excluding gaskets of neoprene shall be used on all doors to ensure dust tightness of the interior while the board is in service. Suitable ventilating louvers designed in such a way as to prevent entry of falling dust shall be provided at the sides and top so that a free circulation of air through the equipment under thermal cycling conditions is ensured.

3.3.12 The louvers shall be provided with fine screened brass meshes to prevent entry of vermin.

3.3.13 The hardware shall be cadmium plated & passivated; these shall be of the captive type to obviate loss of these bolts / screws etc., when the doors/covers are opened for servicing / inspection.

3.3.14 Cold Rolled Sheet Steel of 2.5 mm thickness shall be used for all members except for doors, covers and partitions where it may be of 2 mm.

3.3.15 All components including the bus-bars shall be accessible and capable of being removed from front. The cable alleys shall also be at the front of the board.

3.3.16 All the doors for the feeder modules in the front shall have individual sheet steel hinged doors with concealed hinges ; these doors shall be capable of being physically lifted off the main base shell and fixed back in position while the panel is in service without necessitating removal of any screws or welding etc and with the adjacent modules in service with their doors closed.

3.3.17 The bus bar chamber shall have screwed covers at the front, on the sides and for the top.

3.3.18 The covers for the cable chambers and other compartments shall have covers screwed on with captive screws so that these do not fall off when the panel is in use while the operating / maintenance personnel have occasion to open & replace these covers.

3.3.19 Removable undrilled gland plates of 10 SWG shall be provided at the bottom of the switchboard.

3.3.20 Cable clamping arrangements shall be provided in the cable alley.

3.3.21 The switchboard shall have uniform height. The height of the operating handle for the feeder modules, indicating lamps, instrument fuses etc., in the topmost tier which may need adjustment / replacement shall all be not more than 1950 mm for the finished operating level on the floor so that these are easily accessible for the operating / maintenance personnel without having to take recourse to ladders/steps etc.

3.3.22 The minimum operating height of the switch handles shall not be less than 400 mm from the finished floor level including the safety rubber mat.

3.3.23 All live parts shall be suitably shrouded with non deteriorating Insulating barriers so as to prevent any accidental contact with these by the operating / maintenance personnel while the panel is in service and the modules are opened for inspection / servicing etc.

3.4 BusBars

3.4.1 The busbar arrangement, clearance and connections shall generally conform to IS: 5578/IS: 11533 unless otherwise specified. The busbars shall be of Hard drawn high conductivity





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DOC. NO : 4 – 3678 – MECH – 001 (R2)

electrolytic grade Aluminium conforming to IS: 5082. The design current density shall not exceed 1.0 A/Sq. mm. The busbars shall be of uniform cross section along its entire length. No tapering of the busbar cross section is allowed. The main busbars shall have continuous current rating as required but in no case less than the current rating of incoming isolator / breaker. The busbars shall be so designed and dimensioned that with the passage of normal rated current the temperature rise does not exceed 40 Deg. C over an ambient of 45 Deg. C. The busbars shall be suitable to withstand without damage the effect of the maximum short-circuit current of 50 kA RMS for one second.

3.4.2 The busbars shall be colour coded as per IS for phase identification. All busbars shall be taped / sleeved with PVC for full operating voltage.

3.5 Earthing Connections

3.5.1 The panel shall be connected to an earth busbar running throughout the length of the switchboard. The min. earth bus size shall be 300 sq.mm copper. All doors and movable parts shall be connected to the earth bus with flexible copper connections. Provision shall be made to connect the earthing busbar to the plant earthing grid at two ends. All non-current carrying metallic parts of the mounted equipment shall be earthed. Earthing bolts shall be provided to ground cable armour.

3.6 Circuit Breaker Compartments

3.6.1 The circuit breaker compartment shall have the following interlocks:

3.6.2 Compartment doors shall be interlocked against opening when breaker is in closed or ON condition. However, it shall be possible to bypass this interlock for inspection purposes.

3.6.3 It shall be possible to operate a circuit breaker only in the defined `Full In’ or ` Service’ and `test’ position inside the panel. It shall not be possible to operate the breaker in intermediate position while inserting or withdrawing a circuit breaker or while in `Full Out’ position inside the panel.

3.7 Circuit Breakers

3.7.1 Circuit breakers shall be air break, draw out type. The ratings shall be rated based on maximum connected load rating.

3.7.2 The circuit breakers shall be provided with mechanically operated emergency tripping device. This device shall be available on the front of the panel. Mechanically and electrically operated `closing’ device shall be provided. It shall be possible to remotely close and trip the circuit breaker.

3.7.3 The circuit breakers shall be provided with minimum 5 Nos. normally open and 5 Nos. normally closed spare auxiliary contacts wired and available for Purchaser’s use. If spare auxiliary contacts are not available, an auxiliary relay of approved make shall be used to multiply the available spare auxiliary contact.

3.7.4 Circuit Breaker positions shall be indicated by indicating lamps. The following indicating colours shall be used.

Breaker ‘Close’ - Red

Breaker ‘Open’ - Green





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DOC. NO : 4 – 3678 – MECH – 001 (R2)

Breaker ‘Auto Trip’ - Amber

Breaker Spring `Charged’ - White

3.7.5 Circuit Breaker positions (Open & Close), location (Service & Test) and spring charged conditions shall also be indicated mechanically.

3.7.6 Releases (Shall be microprocessor based LSIG)

The releases shall have the following features:

a) The overload release shall be provided with a setting range of 70% to 110% of the breaker rated current.

b) The short circuit release shall be provided with minimum two settings corresponding to 750% to 1000% of the rated current and shall be provided with adjustable time delay range of 25 ms to 350 ms.

c) Earth fault setting rating of 10% to 40%.

3.8 Switch Fuse / Fuse Switch Modules

3.8.1 The switch modules shall have doors made out of 14 SWG steel or heavier with all edges flanged 5/8 in. deep minimum. Doors shall be mounted on adjustable and removable pin type concealed hinges and so arranged that unit doors may be removed without disturbing the unit doors above or below.

3.8.2 The switches shall be rated for AC 23 duty. Each feeder control module shall comprise of one switch each with 3 poles and neutral link and a set of 3 HRC fuse links for the three phases on the load side for protection & one neutral link capable of being disconnected with ease for testing purposes.

3.8.3 The switches shall be of the double break load break fault make type with the fixed contacts completely enclosed within insulating shrouds. An interlock shall ensure that the switch must be open before the door can be opened and a defeat interlock shall be provided for maintenance purposes.

3.8.4 The switch operating handles shall be capable of being padlocked in the OFF position.

3.8.5 For the purpose of standardisation, similar components in the switch board shall be of the same make/brand, identical and interchangeable.

3.8.6 Only the operating handle of the load break switch shall be accessible for operation with the related door closed.

3.8.7 The doors shall be interlocked with the associated load break switch so that the door can be opened only when the switch is in the de-energised (off) position and the doors shall not be capable of being closed with the switch in the energised (on) position.

3.8.8 Each compartment door shall have its own set of terminal blocks for connecting up the feeder cables; suitable name plate shall be fixed on the cover in distinct colour to designate the feeder number, feeder designation, current rating & HP / kW of the related equipment.





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DOC. NO : 4 – 3678 – MECH – 001 (R2)

3.8.9 The Fuses shall be non deteriorating HRC cartridge link type, with operation indicator. The

Fuses shall be pressure fitted type and shall preferably have ribs on the contact blades to ensure good line of contact. The switch rating shall be selected from standard sizes, namely 32, 63, 125, 250, 400 & 630.

3.9 Motor Feeder Starter Modules

3.9.1 The coil voltage for all contactors shall be 110V. The contactors shall pick up properly even at 85% of the rated coil voltage. The drop out voltage for the contactor coils shall be 45% of the nominal voltage.

3.9.2 The attached typical schematic diagrams shall be referred for the various motor starting methods.

3.9.3 The starter modules shall have doors made out of 14 SWG steel or heavier with all edges flanged 5/8 in. deep minimum. Doors shall be mounted on adjustable and removable pin type concealed hinges and so arranged that unit doors may be removed without disturbing the unit doors above or below.

3.9.4 The contactors shall be capable of interrupting 10 times the rated current for rated sizes upto 100 amps and 8 times the rated current for larger sizes. Contactors shall be selected for AC3 duty.

3.9.5 Only the operating handle of the load break switch set, and the RESET push buttons shall be accessible for operation with the related doors closed.

3.9.6 The MCCB/MPCB rating shall be suitably co-ordinated with main contactor rating and overload relays for type ‘2’ category.

3.9.7 The fuse rating in the load-break switch fuse units shall be suitably co-ordinated with main contactor rating and overload relays for type `2’ category.

3.9.8 The fuse bases and carriers shall be made of unbreakable non inflammable and non-hygroscopic materials like phenolic mouldings.

3.9.9 Thermal over load relays shall be of triple pole, ambient temperature compensated, inverse time lag, hand reset type, bi-metallic with adjustable setting and built-in single phase protection. Relays for heavy duty motors shall be suitably selected for satisfactory starting conditions.

3.9.10 O/L relays shall be of suitable range to match the rating of the motors protected. O/L relay shall be selected to suit the starting time of the drive. The O/L relays shall be provided with 1 NO + 1 NC contact.

3.9.11 Electronic motor protection relays shall be provided for motors rated 45 kW and above. The relay shall have overload, short circuit, earth fault, stalling and single phasing protective features.

3.10 Interconnections

Power interconnections inside the panel shall be done with 650/1100 V grade single core PVC insulated copper conductor upto 63 Amps rating and above 63 Amps rating by aluminium flats. Control wiring shall be done with 650/1100 V grade PVC single core





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DOC. NO : 4 – 3678 – MECH – 001 (R2)

copper conductor of minimum cross section 1.5 Sq.mm Power wiring shall be of minimum 2.5 Sq.mm Copper.

3.11 Terminal Blocks

3.10.1 The terminal blocks provided in the switchboard shall be ELMEX type and these shall be mounted near the bottom of each module unit, at a slightly upward angle, to provide clear and easy access to the terminals.

3.10.2 Each wire at the terminal blocks shall be distinctly identified with appropriate number / letter ferrules at each end in accordance with the schematics.

3.10.3 Wiring to the door shall be done by flexible cable & the cables shall be bunched, sleeved and cleared so that no mechanical damage can occur to the cables when the door swings.

3.10.4 Not more than 2 wires shall be terminated at one control terminal.

3.10.5 All terminations shall be of adequate current rating and size to suit individual feeder requirements.

3.10.6 Outgoing power terminations shall be designed for connecting PVC aluminium cables. Suitable provision shall be made for termination of higher size cables.

3.10.7 Each control terminal block shall have 10% spare terminals.

3.10.8 The Control circuits in each module shall be provided with MCBs

3.12 Current Transformers

3.12.1 The current transformers shall be of bar primary wound secondary cast resin type and have a short time withstand rating equal to that of the associated switchgear for one second. It shall be the responsibility of the vendor to coordinate the burden of the CTs with the actual requirements of relays, instruments, leads etc., associated with the particular CTs. The minimum requirement shall be 10 VA burden, accuracy class 1.0 and an instrument safety factor of 5.

3.12.2 The CTs shall be provided with the following :

a) Test links in both secondary leads to carry out phase angle & current measurement tests.

b) Earth link to which the leads of the CTs shall be connected so as to facilitate easy measurement of Insulation Resistance of the CTs.

3.13 Indicating Instruments

The meters shall have a scale with compressed overload range so as to permit estimation of starting current of AC motor. Ammeters may be directly connected for currents upto 50 A full load current and ring type current transformer shall be used for higher currents. The meters shall be of:

a) Multi function meters with Ammeters and voltmeters having selector switches for Incomers.





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DOC. NO : 4 – 3678 – MECH – 001 (R2)

b) For motor feeders, Ammeters with suppressed scale to indicate motor starting current.

c) Black numerals with a white dial free from parallax errors.

d) Square pattern.

e) Flush mounting.

f) With provision for zero adjustment outside the cover

g) With incomer ammeter and voltmeter with selector switch

h) All feeders need to be provided with ammeters.

i) kW transducers to be provided for incomers.

3.14 Pilot Lamps

The indicating lamps shall be:

a) Cluster type LEDs of low watt consumption, easily replaceable from the front.

b) Provided with series resistors.

c) Provided with translucent lamp covers of the following colours, easily replaceable from the front RED for `ON’ GREEN for `OFF’.

d) ON / OFF / TRIP indications for motor feeders.

e) ON / OFF indications for incomer feeders and outgoing SFU / FSU feeders

3.15 Painting

3.15.1 All metallic surfaces shall be chemically cleaned, degreased and pickled in acid to produce a smooth surface, free of scale, grease and rusts.

3.15.2 After cleaning, phosphating and passivation treatment, the surface shall be given two (2) coats of zinc rich epoxy primer and baking in the oven.

3.15.3 After primer, it shall be given two (2) coats of stoving type enamel paint in light grey as per IS: 5 shade 631.

3.15.4 Sufficient quality of touch up paint shall be furnished for application at site.

3.16 Marking of Wires, Cables and Modules

3.16.1 All wirings & cables at the terminations at the switchboard shall have distinct marking by means of ferrules with letters / numerals printed corresponding to the wiring diagram to be furnished by the Tenderer.

3.16.2 All labels shall comprise white letters on a black background; the size of the lettering shall be 10 mm.

3.16.3 The switchboard shall carry the following distinct markings / nameplates.

a) The manufacturer’s name / brand name.

b) The module nos. with the load designation and rating of the module in kW / Amps.

c) Danger boards as per the IE Rules and the statutory regulations of the Range Electrical Inspector.





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DOC. NO : 4 – 3678 – MECH – 001 (R2)

3.17 Documents to be supplied during Contract Stage

The following documents shall be supplied for approval:

a) Connection diagram for the individual units.

b) Schematic diagram for the complete switchboard.

c) Terminal connection diagram of the main terminal boards.

d) Sketches of the overall dimensions of the board – Plan, elevation and section views clearly showing the bus size and incoming cable specification, number of runs etc.

e) Brand names of all components incorporated like, circuit breakers, load break switches, contactors, pilot device, pilot lamps, current transformers, HRC fittings / links, terminal blocks, wirings, cable sockets, meters, selector switches for instruments, instrument fuse fittings/links etc.

f) Guaranteed technical particulars for the critical components.

g) Certificates of tests giving the results of tests conducted as per the appropriate Standards on similar switchboard and interior components.

h) Shipping dimensions of the board and its weight – gross & net (without packing).

3.18 Installation

3.18.1 These shall be installed with utmost care as per the recommendations of the manufacturers and drawings. The TENDERER shall be responsible to replace or repair the part free of cost if it gets damaged during the installation or mishandling of equipment.

3.18.2 All connections shall be made as per Tenderer’s drawings & before commissioning the gear, overload and relay settings shall be adjusted as directed by the equipment Tenderer.

3.18.3 If switchgear is supplied in sections, assembly of the same will be Tenderer’s responsibility. Relays and instruments, if received separately, will be installed by Tenderer.

3.18.4 Installation of switchgear shall conform to IS: 10118.

3.19 Tests

Switchgear shall be subjected to tests as specified in IS: 8623. Certified copies of all type and routine test certificates shall be submitted for the Purchaser / Consultant’s approval before despatch of the switchgear.

4.0 AUXILIARY DRIVE MOTORS, DRIVES & CONTROLS – LT MOTORS

4.1 All AC motors driving various auxiliaries of the Boiler shall be designed to operate in humid atmosphere with a maximum ambient temperature of 50 degree C. The motors shall be squirrel cage / induction machines of totally enclosed fan cooled (TEFC) design with a degree of protection IP54 and shall conform to IS : 325 / IEC-34. Motors for outdoor application shall be IP55 degree of protection with sheet steel canopy.

4.2 The motor windings shall be provided with Class F insulation. The motors shall be suitable for 415 V ± 10% voltage variation and 50 Hz ± 5% frequency variation with maximum temperature rise limited to limits of `Class-B’ insulation.





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DOC. NO : 4 – 3678 – MECH – 001 (R2)

4.3 The minimum permissible voltage shall be 85% of the rated voltage during motor starting

4.4 Motors shall be capable of starting and accelerating the load with the applicable method of starting, without winding temperatures reaching injurious levels, when the supply voltage is in the range of 85% of the rated motor voltage to maximum permissible voltage .

4.5 The locked rotor current of the motor shall not exceed 700% of full load current (subject to tolerances as per the applicable standard) unless otherwise specified.

4.6 Motors shall be capable of developing the rated full load torque even if the supply voltage drops to 70% of the rated voltage. If such operation is envisaged for a period of one second, the pull out torque of the motor shall be at least 205% of full load torque.

4.7 Motors when started with the driven equipment coupled shall be capable of withstanding at least two successive starts from cold conditions & one start from hot condition without injurious heating of windings. The motors shall also be suitable for three equally spread starts per hour under the above referred supply conditions.

4.8 Continuous duty motors shall be capable of three equally spread starts per hour under normal condition or two starts in quick succession from hot, under rated load conditions.

4.9 The windings of motors for variable frequency application shall be VPI treated and two coat enamelled. These motors shall be sized to operate satisfactorily under lowest speed conditions and shall be provided with thermistors for windings. The drives shall be suitable for 50°C ambient and voltage / frequency variations of ± 10% and ± 5%. The drives shall be of IGBT based with necessary filters / chokes to compensate for reflected wave phenomenon. All drives shall be individually provided with suitably sized contactors, bimetallic relays and isolators, with bypass provision to enable operation of the motor by Star Delta starting. The drives should be compatible with Purchaser’s DCS system to receive / send analog and digital signals. The Tenderer shall furnish detailed description on the drives and protection / display features. Panels for accommodating the drives and other components shall have IP-52 protection, and shall be provided with sufficient exhaust fans for heat dissipation.

Installation of induction motors shall conform to IS: 900 and of motor starter to IS: 13947 Part – 4.

4.10 Insulation

The insulation shall be given tropical and fungicidal treatment for successful operation of the motor in hot, humid and tropical climate.

4.11 Constructional Features

Motors weighing more than 25 kg shall be provided with eyebolts, lugs or other means to facilitate safe lifting.

4.12 Bearings

a) Unless otherwise specified specifically, motor bearings shall not be subjected to any external thrust load and shall have an estimated life of at least 40,000 hrs.

b) The bearings shall permit running of the motor in either direction of rotation.





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DOC. NO : 4 – 3678 – MECH – 001 (R2)

c) When forced oil lubrication or water cooling is required, prior approval from the

purchaser shall be obtained.

d) When forced oil lubrication or water cooling is required, the machine shall be suitable for starting & continuous operation for at least 10 minutes, without the availability of lubrication or cooling system

e) If the bearings are oil lubricated, a drain plug shall be provided for draining residual oil & an oil level sight gauge shall be provided to show the precise oil level required for stand still and running conditions.

f) It shall be possible to lubricate the bearings without dismantling any part of the motor.

4.13 Terminal Box

a) Terminal boxes shall have a degree of protection of at least IP 55 for out door applicable

b) Unless otherwise approved, the terminal box shall be capable of being turned through 360° in steps of 90°.

c) Terminals shall be of stud type & the terminal box shall be complete with necessary lugs, nuts, washers.

d) When single core cables are to be used the gland plates shall be of non magnetic material.

e) Sizes of terminal boxes and lugs shall be as given in Table-1

TABLE-1

415 V MOTORS - SIZES OF CABLES, STUDS, TERMINAL LUGS & TERMINAL BOXES (TO BE PROVIDED ON MOTORS BY VENDOR)

Sl. No.

Motor Rating in kW

1100V Al Conductor

armoured PVC Cable in

Cores x mm2

Stud Size

Terminal lug size of DOWELL MAKE/

equivalent to DOWELL'S CAT

No.

Minimum Terminal Box

Size H x W x D in mm

1. Upto 3 3x4 M6 CUS/06 100 x 100 x 60

2. 3.1 - 7.5 3x6 M6 CUS/07 100 x 100 x 60

3. 7.6 - 15 3x16 M6 CUS/09 100 x 100 x 60

4. 16 - 25 3x35 M8 CUS/12 150 x 150 x 75

5. 26 - 40 3x70 M10 CUS/17 200 x 200 x 100

6. 41 - 55 3x120 M12 CUS/22 400 x 400 x 125

7. 56 - 70 3x185 M16 CUS/28 450 x 450 x 150





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DOC. NO : 4 – 3678 – MECH – 001 (R2)

Sl. No.

Motor Rating in kW

1100V Al Conductor

armoured PVC Cable in

Cores x mm2

Stud Size

Terminal lug size of DOWELL MAKE/

equivalent to DOWELL'S CAT

No.

Minimum Terminal Box

Size H x W x D in mm

8. 71 - 85 3x240 M20 CUS/30 500 x 500 x 200

9. 86 - 110 3x400 M20 CUS/33 600 x 600 x 200

10. 111 - 175 3x1Cx500 M20 CUS/34 600 x 200 x 200

(3 separate cable boxes for the 3 single core cables)

4.14 Paint and Finish

All motor parts exposed directly to atmosphere shall be finished and painted to produce a neat and durable surface which would prevent rusting and corrosion. The equipment shall be thoroughly degreased, all rust, sharp edges and scale removed and treated with one coat of primer and finished with two coats of grey enamel paint.

4.15 Heating During Idle Period

Motors rated above 30 kW shall have space heaters suitable for 240V, single phase, 50 Hz, AC supply. Space heaters shall have adequate capacity to maintain motor internal temperature above dew point to prevent moisture condensation during idle period. The space heaters shall be placed in easily accessible positions in the lowest part of the motor frame.

4.16 Accessories

Two independent earthing points shall be provided on opposite sides of the motor, for bolted connection of the PURCHASER'S earthing conductors. These earthing points shall be in addition to earthing stud provided in the terminal box.

Except when otherwise specified, the motors shall be provided with a bare shaft extension having a key slot and a key at the driving end.

4.17 Tests

Motor shall be subjected to all the routine tests as per applicable standard in the presence of the Purchaser’s representative. Copies of test certificates of type and routine tests, shall be furnished, for the Purchaser’s approval. The Tenderer shall ensure to use calibrated test equipment/instruments having valid calibration test certificates from standard laboratories traceable to national/international standards.

5.0 HV INDUCTION MOTOR





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DOC. NO : 4 – 3678 – MECH – 001 (R2)

5.1 Motors shall be capable of starting and accelerating the load with the applicable method of

starting, without exceeding acceptable winding temperatures, when the supply voltage is 80% of the rated voltage.

5.2 Motors shall be capable of satisfactory operation at full load at a supply voltage of 80% of the rated voltage for 5 minutes, commencing from hot condition.

5.3 Motors shall withstand the voltage and torque stresses developed due to the vector difference between the motor residual voltage and the incoming supply voltage equal to 150% of the rated voltage, during fast change over of buses. The duration of this condition is envisaged for a period of one second.

5.4 The locked rotor current of the motors shall not exceed the following values which are inclusive of 20% tolerance.

5.5 600% of full load current for motors upto and including 1500 kW.

5.6 450% of full load current for motors above 1500 kW.

5.7 The locked rotor withstand time under hot conditions at 110% rated voltage shall be more than the starting time at minimum permissible voltage by atleast three seconds or 15% of the accelerating time whichever is greater.

5.8 When a speed switch is mounted on the motor shaft , the same shall remain closed for speeds lower than 20% and open for speeds above 20% of the rated speed. The speed switch shall be capable of withstanding 120% over speed in either direction of rotation. If the speed switch requires any auxiliary voltage, it shall be suitable for the auxiliary voltages as specified

5.9 Insulation Treatment

Motors shall be given power house treatment. Additional treatments to withstand heavily salt polluted or similar atmospheric conditions shall be given based on the location.

5.10 Embedded Temperature Detectors (ETD'S)

At least six resistance type temperature detectors for the stator winding each having D.C. resistance of 100 ohms at 0oC, embedded in the stator winding at locations where highest temperatures may be expected, shall be provided. The material of the ETD's shall be platinum. One ETD shall be provided for each of the motor bearing & shall be wired up to the terminal box. The temperature detectors shall be of 3 wire, duplex type.

5.11 Bearing Thermometers

Each bearing shall be provided with a dial type thermometer. Each thermometer shall consist of 2 potential free contacts. They shall be designed to close independently at two different temperatures - one for 'Alarm' and another for 'Trip'.

The contact rating of the potential free contacts shall be 1A at 240V AC & 0.1A at 110V DC.Any auxiliary supply, if required shall be indicated by the Tenderer.

The thermometers shall be located at a convenient height for easy reading and handling.

One bearing shall be insulated to prevent shaft currents.





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DOC. NO : 4 – 3678 – MECH – 001 (R2)

5.12 Drain Plugs

Motors shall be provided with drain plugs, so located to drain water, resulting from condensation or due to other causes, from all pockets in the motor casing.

5.13 Flow Switches

Flow switches shall be provided for monitoring cooling water flow if CACW motors are specified.

5.14 Vibrating Pads

Vibration pads shall be provided when called for in the specification.

5.15 Terminal Box

Separate terminal boxes shall be provided for each of the following:

a) Stator Leads

b) Rotor leads (wound motors)

c) Space Heaters

d) Temperature Detectors

e) The three phases shall be segregated by barriers of metal or fibre glass.

f) The cable box design shall be suitable for any type of cable termination kits available.

5.16 Earthing Pad

The earthing pads shall be of non-corrodible metal welded or brazed at two locations on opposite sides complete with suitable bolt and washers for connecting the PURCHASER'S earthing flat.

5.17 Rating Plate

The following details, in addition to those specified in applicable standards shall be included on the rating plate.

a) Temperature rise of windings in degree centigrade at rated load, rated voltage, frequency and ambient conditions and the method of measuring temperature rise. (Thermometer/ Winding resistance).

b) Type of bearings, recommended lubricant, lubricating interval & re-lubricating quantity.

5.18 Tests

Type test certificates for similar motors shall be furnished with the Bid.

Extra price for performing type tests on the motor as per applicable standard shall be quoted.

For motors rated 3.3 kV and above, the induced shaft voltage shall be measured at the manufacturer's works during shop testing. The maximum value of induced voltage in the motor shaft shall not exceed 250mV.





BOILER

DOC. NO : 4 – 3678 – MECH – 001 (R2)

The polarisation index test shall be carried out on all motors rated at 3.3 kV and above. The

minimum value of the polarisation index shall be 2 when determined as per IS-7816.

Coils of HV motors shall be tested as per IEC-34-15.

Loss tangent measurement of coils for motors rated 6.6 kV & above shall be done as per IS-13508.

All other routine tests shall be carried out as per applicable standards.

6.0 MOTOR OPERATED VALVE ACTUATOR

6.1 Each valve actuator motor operating mechanism shall essentially consist of the following components:

a) AC electric motor

b) Reduction gear unit (with thrust bearing if required)

c) Torque switch mechanism

d) Limit switch mechanism

e) Hand wheel, for manual operation

f) Valve position indicator

g) Manual-Auto lever with suitable locking arrangement

h) Valve position transmitter

i) Space heater for enclosure

j) Thermostat

6.2 For valve actuator with integral starter The following components in addition to those indicated above shall be provided

a) Integral reversing contactor starter complete with overload relays of suitable range and adequately rated control fuses

b) Local / Remote selector switch

c) Local control switch / push buttons

d) 415V / 110 V - 240V AC control & space heating transformer or if space heater is rated for 110V AC, space heating supply shall be derived from 415V / 110V control transformer (Control transformer required for 415V, 3 phase, 3-wire system only). For 3-phase, 4-wire system control supply and space heating supply shall be 240 V AC derived between phase-neutral

e) A white lamp for supervision of main supply to be provided locally.

f) A potential free contact shall be provided to annunciate over load trip / main supply failure on remote panel.

g) A blinker relay and lamp shall be provided such that the lamp shall blink as long as the actuator is running; either to close or to open position.

h) Two (2) DC interposing relays for matching the low voltage of remote commands with the control voltage.

6.3 Constructional and Technical Requirements





BOILER

DOC. NO : 4 – 3678 – MECH – 001 (R2)

The constructional and technical requirements of actuators including motor shall be as per

IS 9334, except as noted in this specification.

6.4 Reversing Contactor Starters For Valve Actuators

a) Forward and reverse contactors shall be mechanically and electrically interlocked with each other.

b) The contactors shall have a minimum thermal rating of 9A and shall be suitable for class AC4 duty as specified in applicable standards. The contactor shall have 20% margin over the rated current of the motor.

c) The thermal overload relays provided with the reversing starters shall be three element, positive acting, hand reset type, ambient temperature compensated, time lagged, thermal overload relay with adjustable settings and built in single phasing preventer. The setting range shall be properly selected in accordance with the rating of the motor.

d) ‘Stop’ push button of the starter and hand reset push button for the thermal overload relay shall be separate from each other.

e) Overload relay hand reset push button shall be brought out to the front and made easily accessible.

f) Overload relay shall be provided with at least one ‘NO’ and one ‘NC’ or one change-over contact.

6.5 Tests

a) The routine and acceptance tests specified in IS 9334 shall be conducted on each valve actuator. In addition to the above tests the following shall also be conducted as part of routine tests.

b) Visual checks of workmanship, dimensions, component assembly, number of torque and limit switches, cable entry and valve position transmitter.

c) Mechanical checks of gear ratio and torque clutch operation.

d) Wiring check as per approved Tenderer drawing.

e) Resistance values of potentiometric type position transmitter and 4-20mA dc signal of transducer type position transmitter shall be measured at various positions of the valves.

f) Insulation resistance test (Meggering) using 1000V megger for power terminals and 500V megger for control terminals.

g) High voltage test at 1.5 kV AC for 1 sec.

h) Performance test (at no load) to check the operation of the actuator limit switches and torque switches. Measurement of torque and motor currents shall be done and the values at which the torque switch operates, noted.

6.6 For actuator with integral starters, all the above tests shall be performed in addition to the following :

a) The wiring of the starter shall be checked as per the approved Tenderer drawing.

b) The operation of the starter shall be checked.

c) Tests as per standards.





BOILER

DOC. NO : 4 – 3678 – MECH – 001 (R2)

6.7 Type test certificates for type tests carried out as per IS 9334 on similar actuators shall be

furnished for Purchaser’s review. If type test has not been carried out on similar actuators, then Tender shall carry out the tests.

6.8 All instruments used for testing shall have valid calibration certificates, which shall be produced at the time of inspection.

6.9 All test reports shall be submitted for Purchaser’s approval.

7.0 CABLES AND ACCESSORIES

7.1 General

7.1.1 The Tenderer shall include in his scope of supply, installation and termination of high voltage power cable, 1.1 kV grade power cables between the 415 V MCCs and to various motors / controls of the Boiler, complete interconnection of control cables and signal cables between various equipment covered under this specification shall be included in scope. Heat retardant cables shall be considered for Boiler area. The LT power cabling from the Purchaser’s load centre substation to the 415V MCCs for Boiler will be done by the Purchaser. However, the information regarding incoming cable size, number of runs etc, shall be furnished by the Tenderer.

7.1.2 The scope shall also include cable tray / tracks, cable termination kits, cable lugs, armour clamps, cable glands, identification tags, insulating tapes and compounds, sleeves, supporting structure, bolts, nuts washers and all other installation materials. Cable trays shall be of galvanized ladder / perforated type.

7.1.3 Installation of wires and cables shall be in accordance with IS: 732. The cable shall be terminated in a manner that the insulation will not be damaged at the time of installation or in service. Care shall be exercised to avoid any moisture in terminations. The cable shall be in one length and in between no straight joint shall be allowed. Insulations shall be removed for making termination in such a manner that the conductor is not damaged. Conductors shall be clean and free from burrs.

7.1.4 The current carrying ability of the terminations is equal to or greater than the wire being terminated, without depending on solder. The termination shall be mechanically secure, without depending on solder. Solder and soldering flux, if used, shall be non-corrosive and approved by the cable or wire manufacturer.

7.1.5 All control cables shall be minimum 1.5 sq.mm copper. Power cable of cross section upto 6 sq.mm shall be of copper. All cables above 6 sq.mm size can be of aluminium. All wire and cable runs under poured concrete or road beds and through wells shall be in a conduit sleeve or Hume pipe respectively. No wire or cable shall be run through equipment foundations unless specifically called for on the drawings. Cables shall, be kept atleast 300 mm away from steam or other hot lines, where closer, asbestos barrier shall be used between pipe and wire. The armour of all armoured cables shall be electrically continuous from switchgear to equipment and shall be terminated by an appropriate gland fitting and grounded at both ends. Minimum bending radius shall be 12 times the outside diameter of the cable.

7.1.6 All the Cables shall be of armoured type.





BOILER

DOC. NO : 4 – 3678 – MECH – 001 (R2)

7.1.7 Termination of wires and cables at MCC, fixtures, etc. are to be done preferably with

solderless terminal lugs duly crimped and using appropriate inhibiting compound at all connections.

7.1.8 All cables shall be designed for operation in tropical humid climate subject to heavy rainfall at the required capacity and shall be de-rated for an ambient temperature of 50° C.

7.1.9 Minimum size of cables shall be suitable for system fault level as specified.

7.1.10 All cables shall be suitably designed to carry system earth fault current through metallic screen and armouring. In case the standard screen and armouring is not adequate to carry the earth fault current, the cross section of the metallic screen and/or armouring shall be suitably increased to carry specified earth fault current within circuit-breaker tripping time as specified. For 3-core cables the combined screening of all the three conductors shall be considered.

7.2 Design feature

7.2.1 The 11/6.6 kV grade cables shall be of aluminium conductor cross-linked polyethylene insulated, screened, PVC sheathed type designed, manufactured and tested conforming to IS: 7098 (Part-2). All 11/6.6 kV cables shall be of unearthed, armoured type. The armouring for 3-core cables shall have galvanised steel strips and shall conform to IS: 3975.

7.3 1.1 kV grade PVC insulated, XLPE sheathed power and PVC control cables

7.3.1 1.1 kV grade XLPE insulated power and PVC insulated control cables shall have aluminium or copper conductor respectively as called for, having the sizes and number of cores as specified in the specification. Generally power cables shall have aluminium conductors and control cables shall have copper conductors. Up to 2.2 kW motor, 3 x 2.5 copper power cables should be used. These cables shall be of armoured type, PVC insulated, PVC inner and outer sheathed and manufactured in accordance with IS: 1554 (Part-1).

7.3.2 The conductors shall be of electrical grade purity aluminium or annealed high conductivity

copper wires in conformity to IS: 8130. Only stranded conductors shall be provided unless specified otherwise.

7.3.3 The insulation shall consist generally of XLPE for power cables and PVC for control cables,

compounded suitably with softeners and plasticisers. It shall be uniform in quality and thickness and shall have resistance to abrasion, flame and moisture. All Cable shall be FRLS type.

7.3.4 The inner sheathing of multi-core cables shall be polyvinyl chloride applied by extrusion as

per IS: 1554 (Part-1). Power cable cores shall have colour code identification and control cables shall have number identification.

7.3.5 The overall insulation shall consist of XLPE & polyvinyl chloride or equivalent material,

compounded suitably with softeners and plasticisers. It shall be sound, uniform in quality and thickness. The protective covering shall be corrosion-proof, resistant against abrasion, sunlight, moisture, oils, acids and alkalies likely to be present in the atmosphere as well as in the soil. It shall have requisite mechanical strength and shall not crack or get damaged when the cable is bent to its minimum installation radius.





BOILER

DOC. NO : 4 – 3678 – MECH – 001 (R2)

7.3.6 The armouring of multi-core XLPE & PVC insulated cables shall be of galvanised round

steel wires where the calculated diameter below armouring does not exceed 13 mm. Where this exceeds 13 mm, galvanised steel strips may be adopted. The armouring of single core cables shall be of aluminium strip

SPECIFIED DESIGN DATA

POWER & CONTROL CABLES

Unit Data

11/6.6 KV cables Voltage grade KV 11/6.6 Conductor - Stranded Aluminium Conductor screen - Semi conducting compound Insulation - XLPE Inner sheath - Extruded PVC

Outer sheath FRLS - PVC

LV Power Cables Voltage grade KV 1.1 Conductor - Stranded Aluminium Insulation - XLPE Inner sheath - Extruded PVC Outer sheath FRLS – PVC Control cables Voltage Grade KV 1.1

Conductor -

Stranded Copper (min 1.5 mm²)

Insulation - PVC Inner sheath - Extruded PVC Outer sheath FRLS - PVC FRLS Properties Oxygen index - Not less than 29 Smoke density - Not more than 60% Acid gas generation - Not more than 20% by weight

7.4 All cables shall be sized for the following criterion:

- Continuous current capacity

- Running voltage drop of ±3%

- Starting voltage drop of ±10%

- Derating factors due to higher ambient temperature and grouping of cables

- Minimum cable size as per system short circuit current (Fault withstands time for outgoing motor/transformer feeder cables is taken as 0.3 sec. & for generator / incomer / Tie cable feeders it is taken as 0.8 sec).

- Standardization of the cable size to minimize too many sizes of cables

7.5 Power and control cables shall be tested in accordance with the following standards:





BOILER

DOC. NO : 4 – 3678 – MECH – 001 (R2)

IEC 885 : Electrical test methods for electric cables.

IEC 502 : Extruded solid dielectric insulated power cables

for rated voltages from 1kV to 30 kV.

IS 7058 part-1 : Specification for XLPE insulated cables for working up to 1.1 kV.

IS 7058-part2 : Specification for XLPE insulated cables for working voltages from 3.3 kV to 33kV.

IS 7058-part3 : Specification for XLPE insulated cables for working voltages from 66 kV up to and including 220 kV.

IS 5831 : Specification for PVC insulation and sheath of electric cables

IS 10810 : Method of test for cables

IS 1554 : Specification for PVC insulated cables for working voltages part-1upto and including 1100 volts.

IEC 243 : Methods of tests for electric strength of solid insulating materials.

7.6 To prove the FRLS characteristics, the following tests shall be conducted for each size

and type of power and control cable.

a. Oxygen index test as per ASTM D 2863. b. Flammability tests on finished cables as per IEEE 383 & IEC 332-1. c. Smoke generation by outer sheath under fire as per ASTM D 2843. d. Acid gas generation by outer sheath under fire as per IEC 754-1

8.0 LOCAL PUSH BUTTON STATIONS

8.1 Local push button stations shall be provided near each drive motor for operation of the motor in case of an emergency and during maintenance as per Indian Electricity Rules. These shall have key lockable OFF push buttons in dust and oil tight enclosure made of die cast aluminium.

9.0 DATA TO BE FURNISHED ALONG WITH BID / OFFER:

i) Total electrical load list for each boiler and each ESP with segregation of HT, LT, LT –Emergency, DC and Normal working, standby , Numbers, Power factor ,efficiency and margin over BKW considered.

ii) HV and LT Incomer cable sizes and number of runs considered.





BOILER

DOC. NO : 4 – 3678 – MECH – 001 (R2)

iii) Boiler and ESP MCCs ratings and numbers outlay considered.

iv) Makes of equipment considered.

10.0 DOCUMENTS TO BE SUBMITTED AFTER AWARD OF CONTRACT FOR APPROVAL / INFORMATION.

i) Engineering design, BOQ for Below ground earthing, Lighting and Lightning protection system of Boiler and ESP.

ii) Cable tray layout of Boiler and ESP Island,

iii) Earthing layout of Boiler and ESP,

iv) All motors data sheets, drawings comprising of GA, Terminal box arrangement, Chs. Curves for :

a) Torque-Speed at various % of voltages along with Load torque ; b) Load-Pf-Eff; c) Speed –Time at various % of Voltages; d) Hot and Cold LR current withstand ability; e) Negative seq. current withstand ability;

v) Cable sizing calculations and data sheets for HV/ LV/ Control / special cables;

vi) Data sheets for Earth strips and cable trays;

vii) GA; SLD; MBOM; Three line Power; Control schematics of Boiler and ESP MCCs.

viii) Relay setting calculations and charts at every outgoing motor feeders, Power feeders and Incomers / Bus couplers of MCCs in scope.

ix) Drawings and documents of VFDs wherever applicable.

x) Quality assurance plan for all the equipment under scope;

xi) Type test certificates of all the equipment under scope.

xii) Revised and Final documents listed under 9.0 above.





BOILER

DOC. NO : 4 – 3678 – MECH – 001 (R2)

INSTRUMENTATION AND CONTROL SYSTEM





BOILER

DOC. NO : 4 – 3678 – MECH – 001 (R2)

SECTION – 6

INSTRUMENTATION AND CONTROL SYSTEM

1.0 GENERAL

The major design aspects of the system will be as follows:

1.1 The design and installation of instruments shall be generally in accordance with ISA recommended practices and other applicable standards like BIS, IBR etc. Material specifications and practices shall, in general, conform to appropriate ASTM or equivalent standards. All standards, code of practices shall be of the latest edition.

1.2 All instruments and equipments shall be suitable for use in a hot, humid and tropical industrial climate. As a minimum, all instruments and enclosures in field shall be dust proof, weather proof to NEMA 4 and secured against the ingress of fumes, dampness, insects and vermin. All external surfaces shall be suitably treated to provide anti-corrosion protection.

1.3 The instruments like control valves, thermo-well, orifice flanges, level instruments etc. coming on pipes and vessels under IBR shall be certified by IBR.

1.4 Instrumentation shall be fully tropicalised and shall have moisture, dust and surge protection suits the condition of the plant environment.

1.5 Control signals and measured value signals shall not be affected by stray AC voltages, or other interference of any type normally found in a power station. The contractor shall supply shielded cables and surge arresters where necessary

1.6 Each instrument shall be identified and tagged with a tag number, according to job standards.

1.7 Process Measurements

1.7.1 All the instruments which will be used for plant efficiency supervision and control and which shall have the best possible performance characteristics, and shall be the industrial type, field proven design wherever mentioned in this specification.

1.7.2 Major instrumentation shall be microprocessor based and final control elements shall be pneumatic.

1.7.3 Microprocessor based Electronic instruments shall generally operate on 220 V AC 50 Hz and shall have transmission and output signal generally of 4 to 20 mA DC. Transmitters shall be two wire and shall be capable of delivering rated current into external load of at least 600 ohms when powered with 24 V DC.

1.7.4 All electronic instruments shall be immune to Radio frequency interference.

1.8 Units of measurement

Flow Liquid : kg/hr

Steam : kg/hr

Gas & Vapour : N.Cum/hr





BOILER

DOC. NO : 4 – 3678 – MECH – 001 (R2)

Pressure : kg/Sq.cm/ mmWC

Temperature : deg.C

Level : %

Analysis : % ppm

Graduations

Flow with DP cells : 0 to 10 square root

Pressure : Reading

Level : 0 to 100 Linear

Temperature : Direct Reading

Multiplying factors for flow scales shall be specified on manufacturer’s name plate.

1.9 Instrument Connection

1.9.1 The connection of Instruments installed on Boiler, pipes tanks and piping shall be approved by Purchaser / Consultant’s.

1.9.2 Pneumatic connection for signal and air supply shall be ¼” NPT (F).

1.9.3 Electrical connection shall be ½” NPT (F).

1.9.4 Threaded end connection shall be to NPT as per ANSI 2.1. Flanged end connections shall be as per ANSI B 16.5.

1.9.5 In the field end cable gland shall be double compression type.

.





BOILER

DOC. NO : 4 – 3678 – MECH – 001 (R2)

1.10 Technical requirement of instruments

AP

PL

ICA

TIO

NS

• S

ucti

on/D

isch

arge

of

Pum

ps/F

ans

• C

omm

on H

eade

r of

P

umps

/Fan

s, e

tc.

• In

lets

/out

lets

of

Hea

t E

xcha

nger

s an

d D

esup

erhe

ater

s

• S

ucti

on p

ress

ure

for

perm

issi

ve a

nd tr

ip o

f pu

mps

/Fan

s, e

tc.

• D

isch

arge

pre

ssur

e lo

w f

or

auto

sta

rt o

f St

andb

y pu

mp

• P

re-t

rip

alar

m c

ondi

tion

s •

Whe

re tr

ansm

itte

rs a

re n

ot

prov

ided

for

the

sam

e ap

plic

atio

n

• S

ucti

on a

nd D

isch

arge

of

Mai

n P

roce

ss/P

umps

•

For

all

con

trol

led

para

met

ers

• P

ress

ure

cond

itio

ns o

f m

ajor

ves

sels

like

Boi

ler

Dru

m, D

eaer

ator

Hot

ewel

l, t

•

Acr

oss

filt

ers/

stra

iner

s

SP

EC

IFIC

R

EQ

UIR

EM

EN

TS

150m

m d

ial s

ize,

316

SS

B

ourd

on T

ube,

M

icro

met

er a

djus

tabl

e po

inte

r E

poxy

coa

ted,

Die

ca

st a

lum

iniu

m c

asin

g

Epo

xy C

oate

d D

ie c

ast

Alu

min

ium

Cas

ing,

316

S

S E

lem

ent,

2 S

PD

T

cont

acts

rat

ed f

or 0

.2A

at

220V

DC

Epo

xy c

oate

d D

ie c

ast

Alu

min

ium

/ Fi

bre

glas

s ca

sing

4-2

0mA

DC

out

put.

Z

ero

span

and

ran

ge

adju

stm

ent w

ith

2-w

ay

man

ifol

d.

Epo

xy c

oate

d ca

sing

, 6"

dial

, 316

SS

dia

phra

gm/

bell

ows;

wit

h &

3-w

ay

man

ifol

d.

EN

CL

.

IP65

IP65

IP65

IP65

AC

CU

RA

CY

+ 1

.0%

+ 1

.0%

(+

0.5%

R

epea

tabi

lity

)

+ 0

.25%

+ 0

.5%

TY

PE

Dir

ect

Non

- In

dica

ting

/ In

dica

ting

T

ype

SM

AR

T

wit

h L

CD

In

dica

tor

+

HA

RT

Dir

ect

INS

TR

UM

NE

T

Pre

ssur

e In

dica

tor

(PI)

Pre

ssur

e S

wit

ches

(P

S)

Pre

ssur

e T

rans

mitt

ers

(PT

)

Dif

fere

ntia

l P

ress

ure

Indi

cato

r (D

PI)

SL

. N

O

1.

2.

3.

4.





BOILER

DOC. NO : 4 – 3678 – MECH – 001 (R2)

A

PP

LIC

AT

ION

S

• A

cros

s fi

lter

s/st

rain

ers

for

high

ala

rm a

nd tr

ip o

n ve

ry

high

val

ue

. • F

low

mea

sure

men

ts o

f co

nden

sate

, ste

am

• L

evel

mea

sure

men

t •

Dif

fere

ntia

l pre

ssur

e m

easu

rem

ent

• M

ain

proc

ess

pum

p di

scha

rge

• W

here

ver

ther

e is

a c

hang

e of

tem

pera

ture

in th

e pr

oces

s •

Inle

t/ou

tlet

of

Hea

t E

xcha

nger

s, d

esup

erhe

ater

s,

etc.

for

bot

h m

edia

• F

or b

eari

ng te

mpe

ratu

re

alar

m a

nd in

terl

ock/

pr

otec

tion

•

Whe

reve

r te

mpe

ratu

re

abno

rmal

ity

to b

e al

arm

ed

(non

-cri

tica

l app

lica

tion

s)

• W

here

ver

equi

pmen

t/sy

stem

to b

e tr

ippe

d on

hig

h te

mpe

rate

mpe

ratu

retu

re

SP

EC

IFIC

R

EQ

UIR

EM

EN

TS

Epo

xy C

oate

d D

ieca

st

Alu

min

ium

Cas

ing,

316

S

S E

lem

ent,

2 S

PD

T

cont

acts

rat

ed f

or 0

.2A

at

220V

DC

Epo

xy c

oate

d D

ieca

st

Alu

min

ium

/ Fi

bre

glas

s ca

sing

4-2

0mA

DC

out

put.

Z

ero

span

and

ran

ge

adju

stm

ent w

ith

cond

ensa

te p

ot

Indu

stri

al ty

pe, M

ercu

ry in

st

eel w

ith

sepa

rabl

e T

herm

o w

ell.

Vap

our

fill

ed s

yste

m w

ith

bulb

and

cap

illa

ry tu

be

wit

h sn

ap a

ctio

n

swit

ch,3

16S

S T

herm

o w

ell

(Bar

sto

ck)

EN

CL

.

IP65

IP65

IP65

IP65

AC

CU

RA

CY

+1.

0% (

+0.

5%

Rep

eata

bili

ty)

+0.

25%

+1%

(R

espo

nse

tim

e of

2-4

S

econ

ds)

+1%

TY

PE

Non

-in

dica

ting

SM

AR

T

wit

h L

CD

In

dica

tor

+ H

AR

T

Dir

ect

Non

-in

dica

ting

INS

TR

UM

NE

T

Dif

fere

ntia

l P

ress

ure

Sw

itch

es

(DP

S)

Dif

fere

ntia

l P

ress

ure

Tra

nsm

itter

s (D

PT

)

The

rmom

eter

s (T

I)

Tem

pera

ture

S

wit

ch (

TS

)

SL

. N

O

5.

6.

7.

8.





BOILER

DOC. NO : 4 – 3678 – MECH – 001 (R2)

A

PP

LIC

AT

ION

S

• A

ll c

ontr

ol a

ppli

cati

ons

• F

or a

ll te

mpe

ratu

re

mea

sure

men

t not

exc

eedi

ng

150o C

for

rem

ote

disp

lay.

•

For

all

con

trol

app

lica

tion

s an

d m

onit

orin

g po

ints

whe

re

maj

or te

mpe

ratu

re c

hang

es

occu

r •

For

all

tem

pera

ture

m

easu

rem

ent e

xcee

ding

15

0o C f

or r

emot

e di

spla

y.

• F

or a

ll c

ontr

ol a

ppli

cati

ons

and

mon

itor

ing

poin

ts w

here

m

ajor

tem

pera

ture

cha

nges

oc

cur

• F

or p

erfo

rman

ce te

st

• A

cros

s al

l Hea

t E

xcha

nger

s, d

esup

er-

heat

ers,

etc

. for

bot

h m

edia

•

For

RT

D, T

C/S

, TS

, TI,

TW

SP

EC

IFIC

R

EQ

UIR

EM

EN

TS

4-20

mA

DC

out

put

line

aris

ed, c

onfi

gura

ble

Pla

tinu

m, 3

-wir

e, d

uple

x w

ith

316

SS

The

rmo

wel

l, A

NS

I, D

IN, I

EC

Sta

ndar

d.

Spr

ing

load

ed f

or b

eari

ng

tem

pera

ture

mea

sure

men

t.

Mat

eria

l sel

ecti

on a

s pe

r IS

A, A

NS

I, D

uple

x w

ith

316S

S T

herm

o w

ell

pack

ed w

ith

Mgo

in

sula

tion

, and

spr

ing

load

ed h

igh

spee

d of

re

spon

se.

316S

S, d

esig

n as

per

A

NS

I, D

IN, B

ar s

tock

, fl

ange

type

for

air

& f

lue

gas

and

M33

X 2

for

oth

er

serv

ices

EN

CL

.

- - - -

AC

CU

RA

CY

+0.

20%

Res

pons

e ti

me

for

bare

RT

D 1

5 S

ec. a

nd w

ith

T/W

30

Sec

.

Res

pons

e ti

me

bare

wit

h T

/W o

f 5

to 6

sec

.

-

TY

PE

SM

AR

T

wit

h L

CD

In

dica

tion

+

HA

RT

- Cr.

A

lum

iniu

m

K-T

ype

-

INS

TR

UM

NE

T

Tem

pera

ture

T

rans

mitt

ers

(TT

)

Res

ista

nce

Tem

pera

ture

D

etec

tor

(RT

D)

asse

mbl

y

The

rmoc

oupl

e (T

/C)

asse

mbl

y

The

rmo

wel

ls

(TW

)

SL

. N

O

9.

10.

11.

12.





BOILER

DOC. NO : 4 – 3678 – MECH – 001 (R2)

A

PP

LIC

AT

ION

S

• C

oola

nt f

rom

the

equi

pmen

t •

Coo

lant

fro

m th

e sa

mpl

e co

oler

s •

On-

line

upt

o 4

inch

pip

e an

d by

pass

type

abo

ve 4

inch

pi

pes

• C

omm

on o

utle

t hea

der

of

iden

tica

l equ

ipm

ent

• O

n-li

ne m

eter

s up

to 4

inch

si

ze

• B

ypas

s ty

pe a

bove

4 in

ch

size

• C

omm

on o

utle

t hea

der,

of

iden

tica

l equ

ipm

ent f

or lo

w

alar

m

• M

easu

rem

ent o

f fl

ow o

n oi

l li

nes

• R

efer

und

er "

Dif

fere

ntia

l P

ress

ure

Tra

nsm

itte

rs"

SP

EC

IFIC

R

EQ

UIR

EM

EN

TS

Rot

ary

type

wit

h P

yrex

te

mpe

red

glas

s. T

he b

ody

mat

eria

l sha

ll b

e ca

rbon

st

eel w

ith

bron

ze w

ette

d pa

rts

CS

bod

y w

ith

316

SS

flo

at

and

scal

e

CS

bod

y w

ith

316

SS

el

emen

t wit

h co

ntac

ts

CS

bod

y w

ith

316

SS

w

ette

d pa

rts

-

EN

CL

.

- - IP-6

5

IP-6

5

-

AC

CU

RA

CY

-

+/-

2.5

0%

+0.

5%

+0.

5% o

f ra

te o

f fl

ow

+0.

25%

TY

PE

• O

n-li

ne

• B

ypas

s

Var

iabl

e A

rea

On-

line

Pos

itiv

e di

spla

cem

ent

type

Dp

type

S

MA

RT

+

HA

RT

INS

TR

UM

NE

T

Flo

w

Gla

ss (

FG

)

Flo

w I

ndic

ator

s (F

I)

Flo

w S

wit

ches

(F

S)

Flo

w I

ndic

ator

s (F

I)

Flo

w

Tra

nsm

itter

s (F

T)

SL

. N

O

13.

14.

15.

16.

17.





BOILER

DOC. NO : 4 – 3678 – MECH – 001 (R2)

A

PP

LIC

AT

ION

S

• F

or li

quid

met

erin

g •

Upt

o 30

0 lb

s A

NS

I ra

ting

•

316

SS

ori

fice

pla

te

asse

mbl

y w

ith

SS

spo

ol

piec

es te

rmin

ated

wit

h R

F

flan

ge (

SS

) fo

r D

M w

ater

an

d m

ake-

up w

ater

flo

w

mea

sure

men

t

• F

or s

team

flo

w

mea

sure

men

ts

• F

or a

ll a

ppli

cati

ons

of 6

00

lbs

AN

SI

rati

ng a

nd a

bove

• F

or a

ir f

low

mea

sure

men

ts

in a

ir d

ucts

• A

ll s

urfa

ce m

ount

ed/

over

head

tank

s, H

otw

ell,

Dea

erat

or a

nd a

ny s

tora

ge

tank

s •

Ref

lex

type

for

two

phas

e ap

plic

atio

ns

• T

ubul

ar ty

pe f

or li

quid

ap

plic

atio

ns

SP

EC

IFIC

R

EQ

UIR

EM

EN

TS

Fla

nge

Tap

s w

ith

3 pa

irs

of

conn

ecti

ons

or a

s re

quir

ed,

Des

igne

d as

per

AN

SI,

BS

, D

IN S

tand

ard,

316

SS

or

ific

e pl

ate

316S

S f

low

noz

zle

wit

h 3

pair

s of

con

nect

ions

m

ount

ed a

nd c

onde

nsat

e po

t.

316

SS

Bod

y m

ater

ial

Com

plet

e w

ith

auto

mat

ic

ball

che

ck v

alve

, gua

rd

rods

, mic

a sh

ield

and

il

lum

inat

ion

whe

re p

lant

il

lum

inat

ion

is n

ot

adeq

uate

EN

CL

.

- - - IP-6

5

AC

CU

RA

CY

+1%

UR

V

+1%

UR

V

-

TY

PE

Ori

fice

as

sem

bly

Flo

w

nozz

le

asse

mbl

y

Aer

ofoi

l

Mec

hani

cal

INS

TR

UM

NE

T

Flo

w E

lem

ents

(F

E)

Lev

el g

auge

s (L

I)

SL

. N

O

18.

19.





BOILER

DOC. NO : 4 – 3678 – MECH – 001 (R2)

A

PP

LIC

AT

ION

S

• F

or a

ll ta

nks/

sum

ps f

or

low

and

hig

h al

arm

•

For

all

tank

s/su

mps

for

ve

ry lo

w f

or p

ump

prot

ecti

on

and

very

hig

h to

trip

sup

ply

pum

p •

For

all

tank

s/su

mps

for

no

rmal

for

sta

rtin

g of

the

pum

p •

Ste

am li

ne d

rain

pot

s, f

or

low

leve

l and

hig

h le

vel f

or

open

ing

clos

ing

of d

rain

va

lves

and

hig

h al

arm

.

• F

or a

ll le

vel m

easu

rem

ent

wit

h tw

o ph

ase

flui

ds a

nd n

ot

exce

edin

g 80

0 m

m le

ngth

for

bo

th m

onit

orin

g an

d co

ntro

l ap

plic

atio

ns

For

Air

hea

ters

SP

EC

IFIC

R

EQ

UIR

EM

EN

TS

• C

S b

ody,

316

SS

flo

at

exte

rnal

cag

e w

ith

SP

DT

co

ntac

t rat

ed f

or 0

.2A

, 22

4 V

DC

, for

sur

face

m

ount

ed ta

nks

• T

op m

ount

ed f

or

sum

ps.

Ext

erna

l cag

e w

ith

CS

body

and

SS

wet

ted

part

s,

4-20

mA

DC

out

put

Ext

erna

l cag

e w

ith

CS

bo

dy a

nd S

S w

ette

d pa

rts,

4-

20 m

A D

C o

utpu

t

Junc

tion

box

, in

terc

onne

ctin

g ca

bles

EN

CL

.

IP-6

5

IP-6

5

IP-6

5

IP-6

5

AC

CU

RA

CY

-

- +0.

5%

For

th

erm

ocou

ple

= +

0.5%

TY

PE

Mec

hani

cal

Flo

at

Typ

e

Con

duct

ivit

y Pr

obe

Typ

e

Cap

acit

ance

/Ult

raso

nic

K-t

ype

ther

moc

oupl

e w

ith

scan

ner

and

spee

d sw

itch

INS

TR

UM

NE

T

Lev

el S

wit

ches

(L

S)

Lev

el

Tra

nsm

itter

s (L

T)

Air

hea

ter

fire

se

nsin

g de

vice

an

d ai

r he

ater

st

oppa

ge a

larm

SL

. N

O

20.

21.

22.





BOILER

DOC. NO : 4 – 3678 – MECH – 001 (R2)

A

PP

LIC

AT

ION

S

• C

ondu

ctiv

ity

anal

ysis

for

D

M w

ater

, Fee

d w

ater

be

fore

eco

nom

iser

, Blo

w

dow

n w

ater

, Mai

n st

eam

. •

Dis

solv

ed o

xyge

n an

alys

er

for

cond

ensa

te a

fter

de

aera

tor

but b

efor

e do

sing

•

Ph

anal

yser

for

Fee

d w

ater

be

fore

eco

nom

iser

, Ste

am

drum

, Blo

w d

own,

Mai

n st

eam

, DM

wat

er in

let t

o de

aera

tor

• H

ydra

zine

ana

lyse

r fo

r F

eed

wat

er a

t eco

nom

iser

in

let

• In

divi

dual

Sil

ica

anal

yser

fo

r M

ain

stea

m a

nd d

rum

w

ater

. F

or v

aria

ble

spee

d dr

ives

like

F

WP

and

for

turb

ine

For

ther

moc

oupl

es f

ro, T

/C

head

to th

e JB

/ tr

ansm

itte

rs /

DC

S

F

or T

G s

haft

/ be

arin

g vi

brat

ions

and

HT

mot

or a

nd

pum

p be

arin

g, v

ibra

tion

pad

s on

bot

h X

& Y

dir

ecti

on

SP

EC

IFIC

R

EQ

UIR

EM

EN

TS

• T

herm

al s

hut o

ff v

alve

s

1100

V tw

iste

d pa

ir, 1

.5 m

m2

dia,

arm

oure

d, P

CV

in

sula

ted

& ja

cket

ed, F

RL

S,

As

per

stan

dard

AN

SI

MC

.9-

1

Sen

siti

vity

of

15 m

v/m

m/s

, IP

65,e

ncl.,

pic

kups

for

X &

Y

dir

ecti

on, m

icro

proc

esso

r ba

sed,

vel

ocit

y fo

r lo

w s

peed

an

d ac

cele

rate

met

er f

or h

igh

spee

d m

achi

ne.

EN

CL

.

AC

CU

RA

CY

TY

PE

K-t

ype

INS

TR

UM

NE

T

Tap

ping

for

the

Wat

er a

nd S

team

A

naly

sers

sys

tem

Spe

ed

Com

pens

atin

g ca

bles

Vib

rati

on

mon

itor

ing

syst

em

(VM

S)

SL

. N

O.

23.

24.

25.

26.





BOILER

DOC. NO : 4 – 3678 – MECH – 001 (R2)

A

PP

LIC

AT

ION

S

• P

neum

atic

act

uato

r, H

and

whe

el, P

osit

ioer

, A

ir f

ilte

r re

gula

tor,

Air

lock

dev

ice,

Non

-co

ntac

t typ

e po

siti

on tr

ansm

itte

r, L

imit

sw

itch

es, B

onne

t wit

h co

olin

g fi

ns f

or h

igh

tem

pera

ture

. •

To

be d

esig

ned

wit

h 15

% o

peni

ng f

or

min

imum

and

85%

ope

ning

for

max

imum

CV

co

ndit

ions

. Tri

m E

xit v

eloc

ity

not t

o ex

ceed

30

M/S

ec.,

nois

e le

vel t

o be

less

than

85

dBA

. •

No

flas

hing

or

cavi

tati

ons

to o

ccur

in th

e va

lve.

•

No

exte

rnal

dev

ice

shal

l be

used

for

noi

se

abat

men

t. •

Mul

tist

age

cage

gui

ded

trim

s fo

r ca

vita

tion

s se

rvic

es.

• P

neum

atic

act

uato

r, H

and

whe

el, P

osit

ione

r, A

ir f

ilte

r re

gula

tor,

Air

lock

dev

ice

non-

cont

act t

ype

posi

tion

tran

smit

ter,

lim

it s

wit

ches

and

link

ages

. •

As

per

proc

ess

requ

irem

ents

, for

con

trol

val

ves,

pne

umat

ic b

lock

val

ves

• D

irec

t ope

rate

d w

ith

IP65

enc

losu

re.

• B

ody

mat

eria

l of

bron

ze, p

luge

mat

eria

l of

316

SS

, rat

ed f

or in

sula

tion

Cla

ss 'F

' an

d sh

ut-o

ff le

akag

e C

lass

-IV

. •

Tor

que

swit

ch o

pen,

Tor

que

swit

ch c

lose

, Lim

it s

wit

ch o

pen,

Lim

it s

wit

ch c

lose

, P

osit

ion

tran

smit

ter

SP

EC

IFIC

R

EQ

UIR

EM

EN

TS

E

NC

L.

• B

alan

ce m

odul

atin

g gl

obe

and

cage

gui

ded

valv

es

• C

5 al

loy

stee

l bod

y fo

r se

rvic

es

wit

h te

mpe

ratu

re a

bove

300

o C,

and/

or f

lash

ing

appl

icat

ions

, W

CS

bod

y fo

r al

l ser

vice

s be

twee

n 11

0o C to

300

o C, S

S

body

for

DM

wat

er a

nd m

ake-

up

wat

er s

ervi

ces,

car

bon

stee

l bod

y fo

r ot

her

serv

ices

. •

Tri

m (

both

sea

t & p

lug)

sha

ll

be S

S31

6 st

elli

ted

for

plug

and

17

-4H

for

sea

ts.

AC

CU

RA

CY

T

YP

E

Con

trol

Val

ves,

D

esup

erhe

ater

s an

d pn

eum

atic

blo

ck v

alve

s (a

s ap

plic

able

) -

as p

er p

roce

ss

requ

irem

ents

Con

trol

dam

per

driv

es -

A

s pe

r pr

oces

s re

quir

emen

t.

Sol

enoi

d V

alve

s

Mot

oriz

ed v

alve

INS

TR

UM

NE

T

SL

. N

O

27.

28.

29.

30.





BOILER

DOC. NO : 4 – 3678 – MECH – 001 (R2)

A

PP

LIC

AT

ION

S

Mic

ropr

oces

sor

base

d, B

icol

our

disp

lay

- lo

cal

and

rem

ote

for

each

sid

e, c

onta

cts

for

alar

m a

nd

trip

, int

erco

nnec

ting

cab

les.

Illu

min

ator

sha

ll b

e pr

ovid

ed.

For

bot

h si

de o

f th

e fu

rnac

e, D

uple

x K

-typ

e th

erm

ocou

ple,

acc

urac

y of

+/-

0.5

%, I

P65

en

clos

ure

for

junc

tion

box

, loc

al s

tart

er w

ith

rem

ote

star

t / s

top

faci

lity

, pos

itio

n tr

ansm

itte

r fo

r re

mot

e in

dica

tion

s.

Pro

visi

on s

hall

be

prov

ided

for

mea

suri

ng C

O &

O

2 at

flu

e ga

s pa

th b

efor

e ai

r he

ater

s.

Dis

trib

uted

sen

sors

whe

re

leak

is e

xpec

ted.

For

Fue

l oil

sup

ply

&

retu

rn f

low

SP

EC

IFIC

R

EQ

UIR

EM

EN

TS

Mic

ropr

oces

sor

base

d an

d el

ectr

onic

s in

the

cont

rol r

oom

4-20

ma,

9 d

igit

di

spla

y w

ith

rese

t, S

S31

6 m

ater

ial

EN

CL

.

Con

duct

ivit

y pr

obe

wit

h pr

essu

re

vess

el f

or b

oth

side

of

the

Stea

m

drum

Bi c

olou

r ty

pe f

or b

oth

side

of

the

Ste

am d

rum

IP65

AC

CU

RA

CY

+/-

0.5

% a

nd r

ange

ab

ilit

y =

1:1

0

INS

TR

UM

NE

T T

YP

E

Ele

ctro

nic

wat

er le

vel

indi

cato

r (E

WL

I)

Boi

ler

wat

er le

vel g

auge

(S

GW

LG

)

Fur

nace

tem

pera

ture

pro

be

(FT

P)

Flu

e ga

s an

alys

er

Cor

ex g

as a

nd b

last

fur

nace

ga

s le

ak d

etec

tion

and

ala

rm

syst

em a

roun

d th

e B

oile

r

Pos

itiv

e di

spla

cem

ent t

ype

flow

met

er

SL

.N

o.

31.

32.

33.

34.

35.

36.





BOILER

DOC. NO : 4 – 3678 – MECH – 001 (R2)

2.0 SPECIFICATION FOR MATERIAL, INSTALLATION, TESTING AND

COMMISSIONING

2.1 Erection material

The Tenderer shall ensure and supply all erection hardware required for installation of all instrumentation, which form a part of the Boiler Instrumentation unit. This includes items like cables, cable glands, junction boxes, instrument valves, mounting accessories, impulse piping/tubing, piping/tube fittings, pneumatic signal tubes, air line pipes, filter regulators, steam /electrical tracing, insulation materials, cable rays, conduits, identification tags, structural material

The above broadly covers the items required for any typical plant, however the Tenderer shall supply all necessary items to make the erection and commissioning work complete in all respects, irrespective of whether erection and commissioning is included in his scope or not.

The following are the minimum acceptable salient features of some of the erection materials.

2.1.1 Cables

All cables shall be PVC insulated and primary insulation shall be 90 degree C PVC. The insulation grade shall be 660 V / 1100 V as minimum. All cables shall be FRLS type.

2.1.2 Signal Alarm Cables

Single pair shielded signal / alarm cables shall be used between field instruments / alarm switches and junction boxes / local control panels.

The signal cables shall have 16 AWG, 7 stranded conductors for single pair and 20 AWG 7 stranded conductors for multi pair of electrolytic grade copper.

Drain wire shall be provided for individual pair and overall shield, which shall be of 18 AWG 7 stranded tinned copper conductor.

2.1.3 Control Cables

Single pair control cables shall be used between field mounted trip switches / solenoid valves and junction boxes / local control panels.

These control cables shall have 1.5 Sq.mm 7 stranded conductors of electrolytic grade copper, as minimum conductor size.

3 - Core twisted triad shielded cables shall cables shall be used between resistance elements / junction boxes and local control panel mounted instruments.

The minimum of spare in each multi pair cable is 20% cores.

Cable Glands shall be supplied required for glanding the above mentioned cables at field instrument, junction boxes and panels.





BOILER

DOC. NO : 4 – 3678 – MECH – 001 (R2)

2.1.4 Junction Boxes

Tenderer shall supply junction boxes wherever required. These shall be of die cast aluminium alloy body and shall be weather proof.

These boxes shall have terminals suitable for min 4 sq.mm cable termination (clip on) mounted on rails. 20% spare terminals shall be supplied in each junction box.

Telephone shoe shall be provided in junction boxes.

Tenderer shall supply instrument valves (miniature type) and valve manifolds wherever required.

Body material and rating shall be as per piping class or SS whichever is better and shall be forged type.

Valve trim material shall be 316 SS as minimum or superior as required by process conditions.

2.1.5 Impulse piping / tubing

In general ½” x 0.065” thick ASTM A 269 TP 316 stainless as minimum seamless tubes for impulses lines shall be supplied.

Where the pressure (operating) exceeds 70 kg/Sq.cm (g) seamless pipes of size ½” NB of required thickness shall be supplied with material as per piping class.

Seamless tubes shall have a hardness of max. 80 RC as typical.

2.1.6 Pipes and tube fittings

The Tenderer shall supply swage lock / Parker Hamifen / Ermeto / Excel Hydro pneumatic type of compression fittings for tube fittings.

The ferrule hardness shall be greater than 90 RC and of stainless steel in general.

Socket-weld-type forged pipe fittings of suitable material and ratings shall be supplied for pipe fittings. The minimum rating shall be 3000 lbs.

2.1.7 Pneumatic signal tubes

Tenderer shall supply 6 mm OD x 1 mm thick PVC covered fully annealed electrolytic grade copper tubes as per ASTM B 68.74 A CU. No. 122 (DH) for pneumatic signal tubes.

Tenderer shall avoid use of intermediate connections and shall estimate single length for each instrument location.

2.1.8 Instrument airlines fittings and Valves

Seamless galvanized inside and outside carbon steel pipes used for instrument air distribution, shall be as per IS 1239 class Heavy.

Galvanized forged screwed carbon steel fittings shall be used.





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Isolation valves on instrument air service shall be packless gland type full bore ball/ globe valves.

The filter shall have 25 micron sintered bronze/ceramic filter element and shall be provided with manual drain and 2’ nominal size pressure gauge.

2.1.9 Cable trays

All cables / tubes shall run on cable trays.

These cable trays shall be made out of galvanised MS and shall be of sheet steel of minimum 2 mm thick.

Perforated cable trays shall be used for field end to junction boxes and ladder trays shall be used for junction boxes to control room/panel board.

2.1.10 Instrument support / structural steel

Tenderer shall supply steel for instrument stands (stanchions and other structural steel material) required for supporting the cables.

2.2 Installation

2.2.2 Tenderer shall be completely responsible for installation of all instruments within his battery limit, as per the standard installation sketches

2.2.3 While identifying the locations Tenderer shall ensure that the locations are easily accessible for maintenance, away from hot zones.

2.2.4 Tenderer shall ensure the provision of proper walkways, platforms, railings, ladders, protective covers, for easy approach for the porpoise of maintenance.

2.2.5 Detailed erection / Fabrication drawing shall also be prepared during detailed engineering by the Tenderer and the same shall be subject to Purchaser’s review.

2.2.6 The local junction boxes shall have weather protection, which confirms to minimum IP55 and suitable for the environment under which it has to operate.

2.2.7 Adequate protection shields / covers for each of the JBs etc. shall be provided which needs to be located on areas which are prone to steam leaks.

2.2.8 All cables must be routed through proper trays / conduits and all accessories like connectors glands etc., shall also be provided.

2.2.9 The Tenderer shall prepare detailed instrument hook-up drawings for each and every transmitter, switches / gauges etc.,

2.2.10 The instrument air scheme shall be submitted for approval. The pneumatic piping shall be of Galvanized Iron. Copper tubing shall be PVC coated and tube fittings shall be of brass.

2.2.11 All direct mounted instruments like thermocouple, thermo-wells, temperature gauges, pressure gauges, pressure switches etc. shall be installed in such a way that they have better readability and accessibility.





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2.3 Commissioning

This activity shall be carried out in a systematic manner so as to avoid any accident to plant and operating personnel.

During the plant start up all the instruments calibration, controller configuration, trip point settings etc., shall be trimmed so as to meet the operational requirements. The same shall be realised by the integrated Distributed Control System for which the Tenderer’s has to provide necessary details and coordinate with the Distributed Control System vendor.

3.0 INSTRUMENT LIST

The instrumentation is to be provided with the following as minimum requirements for Boiler but not limited or restricted, for safe and smooth operation of the Boiler unit:

3.1 3-element drum level control

a) Drum level transmitter

b) Main steam flow nozzle-2 nos

c) Main steam flow transmitter-2 nos

d) Feed water flow transmitter- 2 nos

e) Flow Orifice for water flow-2 nos

f) Flow Nozzle for steam flow-2 nos

g) Steam flow transmitter-2 nos

h) Control valve for feed water

i) I/P converter for feed control valve

j) Flow Orifice for water flow-2 nos

k) Drum pressure transmitter

l) Drum level very high, high, low, very low switches

m) Drum pressure very high, high, low, very low switches.

n) Digital drum water level indicator in the Boiler floor.

o) Level transmitter for remote drum level indication

3.2 Combustion Control

a) Combustion air flow element (Aerofoil) – PA outlet

b) PA fan air damper actuator – power cylinder

c) I/P converter for PA fan actuator.

d) Flow nozzles for steam flow-2 nos

e) Flow transmitters for steam flow-2 nos

f) I/P converters for steam flow-2 nos

g) Pressure transmitters for bed pressure control-3nos

h) Temperature element -1 no

i) Pressure transmitters-4 nos

j) Pressure control valve with I/P Converter.





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DOC. NO : 4 – 3678 – MECH – 001 (R2)

k) Flue gas outlet Pressure -1 no

l) Flue gas outlet temperature-3 nos.

3.3 Furnace

a) Furnace Pressure very high, high, low, very low pressure transmitters.

b) Furnace temperature elements-4 nos

c) Furnace temperature elements-5 nos to AV Block with limit value monitor.

d) Pressure transmitters to draft control-3 nos

3.4 Furnace draft control

a) Furnace pressure transmitter

b) ID fan suction damper power cylinder

c) I/P converter for suction damper power cylinder

d) ID fan outlet pressure

e) ID fan outlet temperature

3.5 Steam temperature control – Desuperheater

a) Thermocouple

b) Steam temperature transmitter

c) I/P Converter

d) Control valve

3.6 Continuous blow down tank level control

a) Level switch

b) Solenoid valve

c) On/off valve

d) Level transmitter

e) Control valve with I/P Converter

3.7 Soot Blower pressure control

a) I/P converter

b) Control valve

c) Soot Blower sequence operation

d) Pressure Transmitter

e) Temperature element

3.8 De-aerator

a) Deaerator pressure transmitter

b) Deaerator pressure control valve

c) Deaerator pressure gauge

d) Deaerator temperature gauge





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e) Deaerator level gauge-2nos

f) Deaerator level transmitter

g) Deaerator level very high

h) Deaerator level high

i) Deaerator level low

j) Deaerator level very low

k) Deaerator level control valve

l) Deaerator temperature element

3.9 Feed water pump

a) Differential pressure across FWP-1

b) Differential pressure across FWP-2

c) Feedwater outlet flow orifice

d) Feedwater outlet flow transmitter

e) Feedwater pump inlet pressure gauge

f) Feedwater pump-1 discharge pressure gauge

g) Feedwater pump-2 discharge pressure gauge

h) Feedwater pump inlet temperature element

i) Feedwater pump discharge header temperature element

j) Feedwater pump inlet temperature gauge

k) Feedwater pump discharge header temperature gauge

l) Feed water pump temperature element- 2 nos each

3.10 Pressure gauges

a) Drum pressure- 2 Nos. with 250mm dial

b) Auxiliary steam pressure – 2 Nos.

c) Spray water line pressure

d) De-aerator pressure

e) Steam pressure to De-aerator

f) Feed water pressure before Economiser.

g) Feed water pressure after Economiser

h) CBD tank pressure

i) Feed transfer pump pressure

j) Seal blower pressure

k) Instrument air pressure (At the Tenderer’s entry point)

l) ESP inlet & outlet pressure

3.11 Draught Gauges

a) FG after ESP





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b) FG at chimney inlet

c) PA fan discharge

d) PA air after air heater

e) SA fan discharge

f) FG after boiler bank

g) FG after economiser

h) FG after air heater

i) FG at furnace outlet

j) FG at superheater 1 outlet

k) FG at super heater 2 outlet

3.12 Temperature Gauges

a) Steam temperature SH1 outlet

b) SA fan discharge air temperature

c) FG after air heater temperature

d) FG after mechanical dust collector temperature

e) PA air after air heater temperature

f) Deaerator outlet temperature

g) Temperature after Economizer

h) Water to De-super heater temperature

i) Seal blower temperature

j) ESP inlet & outlet temperature

k) De-aerator temperature

3.13 Temperature elements

a) Feed water temperature after Economiser (RTD)

b) Feed water temperature before Economiser (RTD)

c) Feed water temperature Deaerator outlet (RTD)

d) PA air after air heater (RTD)

e) FG after Economiser (RTD)

f) FG after boiler bank (K TypeT/C)

g) Steam temperature after DSH (K Type T/C)

h) Furnace temperature (K type T/C)

3.14 Level switch

a) Feed water storage tank

b) De-aerator level





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3.15 Limit Switches

a) Close and open limit switches on the inlet and outlet dampers of the various fans,

3.16 Level gauges

a) Drum level (2 nos.)

b) Feed water storage tank

c) Deaerator tank

d) IBD tank

e) CBD tank

3.17 List of important parameters to be considered for annunciation

a) Drum level low

b) Drum level very low

c) Drum level high

d) Drum level very high

e) Deaerator level low

f) Deaerator level very low

g) Deaerator pressure low

h) Deaerator pressure low low

i) Main steam temperature low

j) Main steam pressure low

k) Feed water storage tank low

l) Furnace pressure high

m) Furnace pressure low

n) Furnace pressure very high

o) Furnace pressure very low

p) ID fan trip

q) PA fan trip

r) FWP trip

s) SA fan trip

3.18 Pressure switches

a) FWP suction pressure low

b) Furnace pressure low

c) Furnace pressure high

d) Air to furnace pressure low

e) Instrument air pressure low.





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DOC. NO : 4 – 3678 – MECH – 001 (R2)

TOOLS & TACKLES AND SPARES





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DOC. NO : 4 – 3678 – MECH – 001 (R2)

SECTION – 7

TOOLS & TACKLES AND SPARES

1.0 TOOLS & TACKLES

1.1 The Tenderer shall supply with the equipment one complete set of special tools and tackles required for the assembly, disassembly & maintenance of the equipment.

1.2 These special tools will also include special material handing equipment, jigs & fixtures for maintenance and calibration/ re-adjustment, checking & measurement aids etc. All the tools & tackles shall be new

1.3 A list of such tools & tackles shall be submitted by the Tenderer along with the offer. Detailed description of each tool/tackles, its function along with the equipment/part for which it is meant for and the price of each tool/tackles shall also be indicated in the offer.

1.4 These tools & tackles shall be separately packed and sent to site before the first unit commissioning. The Tenderer shall also ensure that these tools are not used for erection purpose.

2.0 SPARES

2.1 General

2.1.1 The Tenderer shall indicate and include in his scope of supply all the necessary start-up and commissioning spares

2.1.2 The Tenderer shall quote separately for mandatory and recommended spares. The Purchaser reserves the right to buy any or all mandatory and recommended spares. The Tenderer shall also state for each item of spares both mandatory and recommended, the normal expected service life.

2.1.3 All spares supplied under this contract shall be strictly interchangeable with the parts for which they are intended to replace. The spares shall be treated and packed for long storage under the climatic conditions prevailing at the site, e.g. small items shall be packed in sealed transparent plastic bags with desiccator’s packs as necessary.

2.1.4 Each spare part shall be clearly marked or labeled on the outside of the packing with the description. When more than one spare part is packed in a single case, a general description of the contents shall be shown on the outside and a detailed list enclosed. All cases, containers and other packages must be suitably marked and numbered for the purposes of identification.

2.1.5 All cases, containers or other packages are liable to be opened for examination as may be considered necessary by the Engineer.

2.1.6 All mandatory and recommended spares shall be delivered to site within one to three months prior to the scheduled date of the trial operation of the plant. However, they shall not be dispatched before the dispatch of the associated main equipment.

2.1.7 The spares are to be identified by the equipment tag, item number or part number and priced separately.

2.1.8 Terms and conditions shall be clearly stated as they pertain to all spare parts quoted. Three (3)





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sets of sectional drawings and/or parts lists shall be attached for part identification.

2.1.9 The Tenderer shall also guarantee supply of spare parts which will be made based on manufacturer's drawings on special order from the Purchaser for 25 years after commissioning of the plant.

2.1.10 Warranty period for all kinds of spares shall be six thousand (6000) hours of operation, except normal wear or eighteen (18) months from the date of receipt at site, whichever is later. In case of failure or non-conformance to specifications, the Tenderer shall replace them free of cost.

2.1.11 All spare parts are to be packaged and shipped separately from the equipment, unless otherwise stated in the Purchase Order.

2.2 Commissioning Spares

2.2.1 Commissioning spares are those spares which may be required during the start-up and commissioning of the equipment/system. All spares used until the plant is handed over to the Purchaser shall come under this category.

2.2.2 The Tenderer shall submit a complete list of all such commissioning spares. Costs of the above spares which are consumed before the handing-over of the plant shall be deemed to have been included in the lump sum proposal price of the package, and the Tenderer shall have no claim on this account to the Purchaser.

2.2.3 Said spares, properly marked, shall be supplied together with the main equipment and shall be used by the Tenderer, if needed, during commissioning stage. All such spares which remain unused till issuance of Taking Over Certificate by the Purchaser, shall be returned to the Purchaser during time of handover, along with an equipment wise quantitative consumption report. The list of commissioning spares to be brought by the Contractor to ensure smooth commissioning of the plant shall be subject to the Engineer's approval.

2.3 Recommended Spares

2.3.1 The Tenderer shall provide a list of recommended spares giving unit prices and total prices for 2 years of normal operation of the plant for spares of indigenous origin, and for 3 years of normal operation for spares of non-indigenous origin. This list shall take into consideration the mandatory spares specified elsewhere in the specification and should be a separate list.

2.3.2 The price of recommended spares will not be used for the evaluation of bids. The price of these spares shall remain valid for a period as specified elsewhere in the specification from the date of Award of the Contract.

2.3.3 Where the recommended spares are the same as mandatory spares, the prices shall be the same. The prices of any recommended spares which are not common with mandatory spares shall be subject to review by the Purchaser, and shall be finalised after mutual discussion.

2.4 Mandatory Spares

2.4.1 Mandatory Spares are the parts and assemblies or complete warehoused units to be quoted, evaluated and purchased with the original equipment because of cost factors, engineering, fabrication, testing and fitting requirements, long delivery problems or are specified by the Purchaser. Mandatory spares are usually one of a kind assemblies or units manufactured at the same time as the original parent equipment, such as rotor assemblies, reduction gear sets,





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special forgings, etc.,

2.4.2 The Purchaser considers some of the spares are essential for running the equipment irrespective of whether they are included in the list of recommended spares by the Tenderer as mentioned above.

2.4.3 Since the components involved can not be foreseen at the bidding stage, only broad requirements of the Purchaser in this respect are outlined hereinafter. The Tenderer shall include in his proposal, on the basis of these guidelines, an item wise list of all components and the quantity, unit prices & total price thereof, offered as mandatory spares for each equipment. This list shall be separate from the list of recommended spares and shall be used for bid evaluation purposes. Any clarification in this respect may be obtained by the Tenderer at the pre-bidding stage.

2.4.4 Mandatory spare parts will be purchased along with the original equipment wherever practical. The mandatory spares should be supplied to the Purchaser at least one month before the trial run of the first Unit. The dispatch programme is subject to approval of the Purchaser/Consultant after award of contract.

3.0 SPARE PARTS SELECTION – GUIDELINES

3.1 The recommendation, selection and procurement of spare parts are best accomplished through the combined experience and knowledge of the Tenderer and the Purchaser.

3.2 The Tenderer is expected to base his recommendations on his special experience with the equipment and parts usage in similar applications and the particular requirements of this project.

3.3 The following factors and their impact on plant operations shall be considered in making recommendations.

i) Spared or single train unit

ii) Critical nature of the service

iii) Severity of the application including jobsite environment

iv) Availability of qualified craft maintenance personnel

v) Accessibility of the jobsite to qualified service engineers

vi) Availability of local stock at the jobsite

vii) Long delivery items

viii) Deterioration in storage

ix) Economics of ordering high-cost items with the original equipment such as rough machined forgings, spare rotor assemblies, or complete spare units and subassemblies.

3.4 Spare parts recommendations are to include all components, auxiliaries, accessories, controls, drivers etc. included on the Request for Quotation or Purchase Order, even if supplied by other manufacturers.

3.5 All buy-out items including sub suppliers and subcontractors equipment requiring spare parts shall be fully identified as stated in the instructions for SPIR completion in the summary of spare parts requirements.





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3.6 All component parts of assemblies, kits, etc. shall be listed and identified immediately below

the item recommended.

3.7 Special tools required for field maintenance and repairs shall be recommended and identified. Tenderer is to advise of optional provisions available for the loan or rental of expensive, specialized tools or appliances when required.

3.8 A maximum effort will be required to isolate and identify interchangeability of parts. Project-wide interchangeability of common items such as mechanical seals, anti-friction bearings, O-rings, exchanger tubes, filters, pressure switches, etc. requires that the Tenderer provide complete identification, such as nameplate data, serial number, size, model and manufacturer.

3.9 Interchangeability within the equipment furnished by the Tenderer must be readily identified to assure the availability of the proper parts in sufficient quantities.

3.10 Where sizing, range, fit, clearance and tolerance are essential to parts or assembly identification the Tenderer shall provide the information.





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QUALITY ASSURANCE PLAN





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SECTION – 8

QUALITY ASSURANCE PLAN

1.0 INTRODUCTION

1.1 The minimum Quality Assurance / Quality Control (QA/QC) requirements and the services the Tenderer is expected to provide, is described in this section, to assure conformity with the contract specification. Quality Assurance/Quality Control procedures proposed by the Tenderer should address the QA/QC requirements under the following phases of the project:

i) Engineering

ii) Procurement

iii) Construction including commissioning testing

1.2 Tenderer shall submit documents to demonstrate that the Tenderer and his sub-vendors possess QA/QC programs meeting the minimum requirements set forth in this section. Tenderer shall submit a quality assurance plan along with the bid.

1.3 These quality plans and reference documents/standards etc. shall be subject to Purchaser’s approval without which manufacture shall not proceed. These approved documents shall form a part of the Contract. In the approved Quality Plans, the Purchaser/Purchaser’s representative shall identify the Purchaser Hold Points (PHP).

1.4 The Tenderer must submit an organisation chart along with the proposed QA/QC program for this particular project. This chart and write up should identify the personnel responsible for the Engineering Quality Assurance Plan for the complete duration of the project.

2.0 ENGINEERING

2.1 Prior to finalisation of the Contract, the Tenderer shall prepare and submit a project Quality Assurance Plan that covers the engineering phase of the Works. The plan will be designed for this project and will address the specifics of how the Tenderer will control, monitor and verify the requirements contained in this section. Purchaser will review the plan prior to utilisation and upon issue the plan will become the basis by which Purchaser will evaluate the Tenderer’s engineering QA/QC activities as they relate to this project.

2.2 The Purchaser reserves the right to audit and verify procedures set forth in the Engineering Quality Assurance Plan. This audit right in no way relieves the Tenderer from performing the control verification procedures outlined in the plan.

2.3 The Tenderer’s Engineering Quality Assurance Plan shall set forth in detail the procedures to satisfy these QA/QC requirements.

2.3.1 Design Control

The Tenderer will define, document and advise the appropriate handling of the following design controls:

i) Establish internal as well as external discipline relationships

ii) Establish audit procedures to ensure that the design conforms to the requirements





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iii) Define and outline the number of multi-discipline design reviews

iv) Establish procedures for handling design changes

v) Establish guidelines to handle all issues in pre-award, award and pre-fabrication with Manufacturer’s and Sub-contractors.

2.3.2 Document Control

The Tenderer must include in its QA/QC Plan the document control procedures defining

i) Authorised use of documents

ii) Receipt, logging and distribution of documents

iii) Procedure for updating and implementation of additions and revisions

iv) Procedure for document transmittal to Purchaser/ Purchaser’s representative. Some of the requirements for document transmittal maybe covered in other parts of this specification.

2.3.3 Audits

All documents shall be audited by the Tenderer for conformance with the QA/QC procedures. The Purchaser reserves the right to review design details, either directly or through their Consultants.

2.3.4 Engineering Sub-Contractor

The subcontracting of detailed engineering to third parties does not relieve the Tenderer the responsibility for Engineering Quality Assurance.

3.0 PROCUREMENT

3.1 Source Quality Control

3.1.1 It is the Purchaser’s intent that the Tenderer deal only with Sub-contractors and Manufacturers (Vendors) who have established and demonstrated effective quality assurance and quality control programs. Purchaser does require, however, that the Tenderer perform such normal inspection of Sub-contractors’/Vendors’ work as is necessary to obtain equipment and materials conforming to the project specifications and their supporting documents (applicable codes and industry consensus standards) and good engineering, fabrication practices as described herein. Source Quality Control is also a valuable input for confirmation of delivery performance.

3.2 After Award of Sub-Contract

Once Sub-contractors and manufacturers are established, Purchaser and the Tenderer shall review item-by-item all major engineered equipment and systems and any special fabrication/fitting to reach an agreement on the need for prefabrication/pre-inspection meetings.

3.3 Purchaser’s Participation





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3.3.1 The Purchaser reserves the right to audit the performance of the Sub-

contractors/Manufacturers and the Tenderer’s inspection effort.

3.3.2 Tenderer will identify notification points as per the quality plan approved by the Purchaser. The Purchaser reserves the right, however, to make announced spot-checks to facilitate evaluation of the Sub-contractor and/or the Tenderer’s inspection effort.

3.3.3 During audit visits to fabricator shops, Purchaser may elect to spot-check base materials and welds to verify proper metallurgy using whatever methods.

3.4 Communication

3.4.1 Direct, timely communication between the Tenderer’s Inspectors and Purchaser’s auditing Inspectors is mandatory, especially in purchaser hold points and in the event of problems. Purchaser shall be advised in a timely manner of all situations where changes or compromises in specifications are considered or where non-conformances are being encountered.

3.4.2 The Purchaser, his duly authorized representative and/or an outside inspection agency acting on behalf of the Purchaser shall have access at all reasonable times to inspect and examine the materials and workmanship of the works during manufacture or erection and at the Tenderer’s or his sub-contractor’s works/premises.

3.4.3 The Tenderer shall give the Purchaser/Inspector fifteen (15) days written notice of any material being ready for inspection/ testing. The Purchaser/Inspector, unless the witnessing of the tests is virtually waived, will attend such tests within fifteen (15) days of the date on which the inspection of equipment is notified as being ready for test/inspection, failing which the Tenderer may proceed with test which shall be deemed to have been made in the Tenderer/Inspector’s presence and he shall forthwith forward three (3) copies to the Tenderer/Inspector duly certified test reports.

3.4.4 The Purchaser or Inspector shall within fifteen (15) days from the date of Inspection as defined herein give notice in writing to the Tenderer, of any objection to any drawings and all or any equipment and workmanship which in his opinion are not in accordance with the Contract. The Tenderer shall give due consideration to such objections and shall either make modifications that may be necessary to meet the said objections or shall confirm in writing to the Purchaser/Inspector giving reasons therein, that no modifications are necessary to comply with the contract.

3.4.5 When the factory tests have been completed at the Tenderer’s or sub-contractor’s works, the Purchaser/Inspector shall issue a certificate to this effect within fifteen (15) days after completion of tests. But if the tests are not witnessed by the Tenderer/Inspector, the waiver shall be issued by the Purchaser/Inspector within fifteen (15) days of the receipt of the Tenderer’s test certificate. Failure of the Purchaser/Inspector to issue such a waival shall not prevent the Tenderer from proceeding with the works. However, in case of waivals, the Tenderer shall ensure to carry out the testing as per approved quality plans and specification requirements and send two copies of all the test results to the Purchaser for his review and approval.

3.4.6 To facilitate advance planning of inspection, in addition to giving inspection notice, the Tenderer shall furnish quarterly inspection program indicating scheduled dates of inspection against each Purchaser Hold Points and final inspection stages.





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3.4.7 Rejection reports shall be faxed from the Tenderer’s Inspector to Purchaser’s Representative

at the same time as faxed to the Tenderer’s home office.

3.5 Procurement QA/QC Requirement

3.5.1 Inspection plans with detailed instructions for the Inspector’s guidance shall be provided for each item.

3.5.2 One individual in the Tenderer’s key inspection office shall be designated to fill the function outlined and must report to the Tenderer’s Manager of Inspection.

3.5.3 The Tenderer shall submit with their QA/QC Manual, resumes detailing the experience, education and qualifications of Tenderer’s inspectors for Purchaser’s approval. The Inspectors shall have sufficient prior experience and qualifications for the equipment assigned.

3.5.4 The Inspector shall perform as a minimum the following NDE activities during progressive inspections:

i) Radiographic examination (RE)

ii) Ultrasonic examination (UE)

iii) Magnetic particle examination (MPE)

iv) Liquid penetrant examination (LPE)

v) Hardness testing - production welds

3.6 Inspection Reports

3.6.1 Inspection reports for interim inspection visits shall be consecutively numbered and identify non-conformance and exceptions found/corrected at that time. Final check lists should indicate all items inspected during interim inspections.

3.6.2 Inspection rejection reports shall be by tele-fax/mail to the key office and Purchaser when the Sub-contractor’s proposed resolution deviates from order specifications, or would require repairing.

3.6.3 Final inspection reports shall be by check off for all major equipment and bulk piping components. The check off indicates the inspections were performed and would be covered on an interim inspection report.

3.6.4 Inspection release certificate shall be issued by the assigned Inspector only after all the requirements of the purchase order have been met.

4.0 CONSTRUCTION

4.1 Purchaser’s Participation

4.1.1 Purchaser will have a Quality Assurance/Quality Control Inspector to audit the Tenderer’s QC effort. The assigned Purchaser’s personnel will provide assurance to Purchaser’s management that the Work meets specifications, however, the basic inspection and quality control responsibility is vested with Tenderer.





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4.1.2 Purchaser’s auditing may include spot checks of materials in the field to assure that

inadvertent substitutions have not been made in the fabrication shops or in field ordered materials.

4.2 Communication

4.2.1 Direct, informal communication between the Tenderer’s field Inspectors and Purchaser’s auditing Inspectors is mandatory. Further Purchaser shall be advised when major problems related to design or fabrication is uncovered.

4.2.2 Tenderer’s in-progress inspection reports, follow up/punch out sheets, records of radiograph inspections, etc. shall be available to Purchaser’s auditing Inspectors during the course of the Work.

4.2.3 At the end of the Work, Tenderer’s standard inspection reports, check off sheets, radiographs, master copy of loop diagrams, electrical test data sheets, etc. shall be turned over to Purchaser in an organised, agreed upon format. Tenderer shall verify that all of the required documentation of the equipment has been received and placed in the equipment files. The Tenderer is responsible for obtaining any outstanding documentation from the suppliers.

4.3 Construction QA/QC Requirements

4.3.1 Prior to finalization of Contract award, the Tenderer shall submit a detailed Field Quality Assurance Program for Purchaser’s review. The program must be tailored to show compatibility with engineering design, compliance with applicable codes, specifications, standards, drawings, support documents, governmental regulations and this document.

4.3.2 The system which shall ensure that all quality assurance records are maintained for ready reference and shall also provide for the accumulation, evaluation, retention and distribution of QA/QC records.

4.3.3 Periodic reporting of QA/QC activities (once a month or earlier) as required shall be submitted.

4.3.4 Tenderer shall perform final inspection of the Work in accordance with the Contract documents.

4.3.5 Calibration of tools, gauges, instruments and other measuring and testing devices shall be carried out on regular basis to ensure the accuracy of them.

4.3.6 Tenderer along with Purchaser shall carry out audits to verify implementation of the QA/QC program on a regular basis shall be included.

4.3.7 Where participation of statutory authorities is required, for testing, witnessing and inspection shall be arranged by the Tenderer.

4.3.8 Non-conformance s of on-site fabrication and installation records shall be maintained to control on-site fabrication and installation items which do not conform to the engineering design or for which the engineering design is incorrect.

4.3.9 For the construction period, the Tenderer shall provide a full time, dedicated Quality Assurance Organisation. As a minimum the Tenderer’s Construction Quality Assurance Program shall include the following :





BOILER

DOC. NO : 4 – 3678 – MECH – 001 (R2)

i) Quality control program

ii) Organisation, authority and responsibility

iii) Inspector qualifications

iv) Document control

v) Receiving control

vi) Receiving inspection

vii) Sub-contractor non-conformance

viii) Storage and Maintenance of Materials and Equipment

4.4 Inspection and Testing of On-site Fabrication and Installation

4.4.1 Inspection of work in progress to determine conformance with drawings, specification, and any field definition agreed to shall be included. Some of the inspections are listed below:

i) Performing random dimensional check and visual material verification of field fabricated pressure equipment and of any piping, vessel, electrical and instrument installation.

ii) Internal checking of all vessels for cleanliness and proper internals

iii) Witness testing and installation of items

iv) Final checking of installed facilities, completing check out forms, and signing on behalf of the Tenderer documents attesting completion of the Work, as called for in the Contract documents.

v) Monitoring or inspecting the work of Sub-contractors.

vi) Perform final check of installed facilities with Purchaser’s representatives to verify completeness and accuracy in accordance with P & ID’s/Engineering Flow Diagrams and other scope documents as may be required

vii) See that proper protective procedures are employed and maintained for early installed equipment and equipment stored in offsite staging areas.





BOILER

DOC. NO : 4 – 3678 – MECH – 001 (R2)

INSPECTION REQUEST FORM

From :

To :

Attn: Mr.

Dear Sirs,

Items detailed below are ready for inspection. Please arrange inspection and confirm the date of inspection:

1. Purchaser :

2. Project :

3. Purchaser’s order reference :

4. Consultant’s reference :

5. Sub-order reference :

6. Sub-contractor’s name and full address :

7. Place of Inspection (full address) :

8. Contact person, telephone no. and fax no. :

9. Description of item and quantity :

10. Nature of inspection required :

11. Proposed date(s) :

We confirm that the items have been fully inspected/tested by us at all stages, of inspection as per quality plan, and all material test certificates, QC records., test Reports, calibration records of measuring/testing instruments with tractability to national level are available with us.

Thanking you and awaiting your confirmation,

Yours faithfully,

cc : Sub-contractor

NOTE: 1. Following clear notice periods (date of receipt to date of inspection) are required:

(a) Local Inspection (within India) : 15 days

(b) Overseas Inspection (Outside India) : 30 days

2. Weekly Holidays for Purchaser / Consultant : Sunday





BOILER

DOC. NO : 4 – 3678 – MECH – 001 (R2)

PAINTING SYSTEM





BOILER

DOC. NO : 4 – 3678 – MECH – 001 (R2)

SECTION – 9

PAINTING SYSTEM

1.0 SCOPE

1.1 This section covers the painting requirements for the power plant equipment, structures, piping etc. and any other surface required to be painted. Tenderer to carry out the painting as applicable.

2.0 CODES AND STANDARDS

2.1 Painting of equipment shall be carried out as per the specifications indicated below and shall conform to the relevant IS specification for the material and workmanship.

2.2 The following Indian Standards may be referred to for carrying out the painting job :

IS:5 : Colours for ready mixed paints and enamels

IS:1303 : Glossary of terms relating to paints

IS:2379 : Colour code for identification of pipelines

IS:1477 : Code of practice for painting of ferrous metals in buildings (Parts I & II)

IS:2524 : Code of practice for painting of non-ferrous metals in buildings (Parts I & II)

IS:158 : Ready mixed paint, brushing, bituminous, black, Lead-free, acid, alkali, water and heat resisting

IS:2074 : Ready mixed paint, air drying, red Oxide Zinc Chrome, priming

IS:104 : Ready mixed paint, brushing, Zinc Chrome, priming

IS: 2932 : Enamel, synthetic, exterior (a) undercoating (b) finishing

3.0 PREPARATION OF SURFACES

3.1 All surfaces to be painted shall be thoroughly cleaned of all grease, oil, loose mill scale, dust, rust and any other foreign matter. Mechanical cleaning by power tool and scrapping with steel wire brushes shall be adopted to clear the surfaces.

3.2 However, in certain locations where power tool cleaning cannot be carried out, sand scrapping may be permitted with steel wire brushes and/or abrasive paper. Cleaning with solvents shall be resorted to only in such areas where other methods specified above have not achieved the desired results. Cleaning with solvents shall be adopted only after written approval of the Engineer.





BOILER

DOC. NO : 4 – 3678 – MECH – 001 (R2)

3.3 All pressure parts with headers shall be cleaned prior to shipment, in accordance with the

manufacturer's standard procedures. Oil piping used for lubrication systems shall be cleaned and dried and shall be free of mill scale and other contaminants.

3.4 The following surfaces shall be protected during surface preparation and coating/painting operations:

i) Area within 50 mm of surfaces to be welded after coating.

ii) Steel surfaces to be embedded in concrete.

iii) Name-plates and other instruction plates.

4.0 PRIMER PAINT

After the surface is prepared, one coat of red oxide zinc chromite shall be applied. After this first coat is dried up completely, second coat of red oxide primer shall be applied. Primer shall be applied by brushing to ensure a continuous film without ‘holidays’. The dry film thickness of each coat shall be minimum 30 microns.

5.0 FINISH PAINT

Synthetic enamel paint conforming to IS:2932 shall be used for finish coats. The colour/shade shall be as approved by the Purchaser’s representative. After cleaning the dust on the dried up primer, first coat of synthetic enamel shall be applied. After this first coat dries up hard, the surface is wet scrubbed cutting down to a smooth finish and ensuring that at no place the first coat is completely removed. After allowing the water to get evaporated completely, the second finish coat of synthetic enamel paint shall be applied.

6.0 SUGGESTED COLOUR CODES FOR PAINTING

SL.

NO.

ITEM/SERVICE COLOUR IS-5 COLOUR (BAND)

IS-5

1.0 Structures, platforms, ladders and handrails

Dark Admiralty Grey

632 - -

2.0 Fans, pumps, motors, Light Grey 631 - -

3.0 Tanks (without insulation and cladding)

3.1 Outdoor Aluminium - - -

3.2 Indoor Light grey RAL 7032

- -

4.0 Vessels & all other proprietary equipment (without insulation & cladding)

Light grey RAL 7032

- -

5.0 Switchgear Light grey 631 - -

6.0 Control & relay panels Light grey 631/7078 of IS

- -





BOILER

DOC. NO : 4 – 3678 – MECH – 001 (R2)

SL.

NO.

ITEM/SERVICE COLOUR IS-5 COLOUR (BAND)

IS-5

1650

7.0 Machinery guards Signal red 537 - -

8.0 Piping (without insulation and cladding)

9.0 Water System Sea green 217 French blue 166

6.1 This colour code basically refers to IS:2379 for piping with necessary modifications

6.2 Base colour shall be applied throughout the entire length for un-insulated pipes and for a 2 Mtr. over the aluminium sheeting at places requiring colour bands for insulated pipes.

6.3 Colour bands shall be applied at battery limit points, intersection in pipe rack, near valves and junction points, mid-way of each piping system and at 30 metre intervals for yard piping and also adjacent to valves and junctions.

6.4 Flow direction shall be indicated by black or white arrow, in contrast to the colour on which they are superimposed.

7.0 SHOP PAINTING

7.1 All exposed fabricated steel materials except those galvanized shall receive protective paint coating as indicated below:

i) Two (2) coats of epoxy resin based zinc rich primer applied thoroughly and evenly to dry surfaces including duct work which have been cleaned by sand blasting conforming to Swedish Standards SA-2-½ grade minimum. The DFT of priming coat shall be 50 microns or as directed by the Engineer.

ii) Two (2) coats of finish paint epoxy based paint of approved colour having DFT min. 50 microns shall be applied for each type of paint.

iii) Painting shall not be done in frostly or foggy weather or when humidity shall be such as to cause condensation on the surfaces to be painted.

7.2 The structural steel work surfaces to be painted shall be thoroughly cleaned of all loose mill-scale, rust, grease, dirt and other foreign matter by sand/shot blasting only. Adequate care should be taken such that the surfaces does not possess a slick finish to which paint may not adhere properly.

7.3 Inaccessible parts

Surfaces not in contact but inaccessible after assembly shall receive two (2) coats of epoxy primer positively before assembly. This shall not apply to the interior of sealed hollow sections. The inaccessible parts shall also receive two (2) coats of epoxy paint before assembly.





BOILER

DOC. NO : 4 – 3678 – MECH – 001 (R2)

7.4 Contact Surfaces

The contact surfaces shall be cleaned by hand-wire brushing or by other methods of removing loose mill-scale, rust, weld slag or flux deposit, dirt and other foreign matter. Oil and grease deposits shall be removed by use of solvents.

7.5 Finished Surfaces

Machine finished surfaces shall be protected against corrosion by a rust inhibiting coating that can be easily removed prior to erection or which has characteristics that make removal unnecessary prior to erection.

8.0 PAINTING AFTER ERECTION

After erection touch-up painting, making good any damaged shop painting and completing any unfinished portion of the shop coat shall be carried out by the Tenderer free of cost to the Purchaser. The materials and specifications shall be in accordance with the requirements of good practice. All bolts, welds, and abrasions to the shop coat shall be painted with the same paint used for shop coat.

8.1 External Painting for Tanks

i) Primer: Two (2) coats of epoxy resin based Zincrich primer of adequate DFT.

ii) Finish: Two (2) coats of Bergerthane aluminium finish paint having adequate dry film thickness.

8.2 Touch-up and Repairs

Touch-up and repair shall be performed as follows:

iii) Defects in the painted surfaces shall be repaired in accordance with the touch-up and repair procedure laid down under the manufacturer's written recommendations.

iv) Damaged painting and un-primed areas shall be prepared to Purchaser’s approval. The touch-up painting shall be the same as the originally applied painting. The adjacent sound painting shall be featheredged and roughened up to 50 mm beyond the area requiring repair for overlapping.

9.0 GENERAL PAINTING PRACTICES

9.1 Paint application materials shall be mixed, thinned, applied, and cured in accordance with the manufacturer's latest printed instructions and approved procedures. Paint coat materials applied to any one surface shall be the product of a single manufacturer. A gray colour is provided on the water walls and convection surface walls.

9.2 Indoor mechanical and electrical equipment, surfaces requiring an insulation or lagging, or off-the-shelf items shall be painted with the painting system.

9.3 Interior surfaces painting application shall be performed in accordance with paint manufacturer's written recommendations and instructions.





BOILER

DOC. NO : 4 – 3678 – MECH – 001 (R2)

9.4 Auxiliary and local control panels shall be painted with the standard painting system.

Control panel colours shall be subject to Purchaser’s acceptance.

9.5 Machine surfaces shall be protected with rust-preventive compound.

9.6 All surfaces interior and exterior of the equipment parts, as applicable, shall be shot blasted to remove all rust, scale, grease and/or other adhering foreign matter as per Boiler Plant standards. Unless otherwise specified, all exposed surfaces of steel work, pipe work etc shall be applied with two (2) coats of approved high quality primers and finished with two (2) coats of finish paint in an approved colour to give a neat and clean finish.

9.7 All metal parts not accessible for painting shall be made of chemical corrosion resistant materials. All finished surfaces subject to rust shall be coated with a suitable rust preventive compound. Surfaces shall be putty filled and rubbed down to ensure first quality glossy finish.

9.8 Paints shall be carefully selected to withstand not only tropical heat and extremes of weather specified herein; but also acid and other chemical fumes. It shall not scale-off or crinkle or be removed by abrasion in handling. Epoxy resin based zinc rich primer paint shall be provided as per approved colour shades.

9.9 All exterior surfaces of uninsulated pipe work, structures, platforms & gratings, panels, instruments and equipment, wherever so directed shall be bonderised (or equivalent), given two (2) primer coats and finished with two (2) coats of lacquer (epoxy) of an approved colour to be specified at a later date. Interior surfaces shall be primed and finished with coats of light grey colour finish paints.

9.10 All equipment viz pipes, valves, soot blowers air heaters and fans etc. shall be tag numbered and painted at the appropriate places as approved by the Purchaser.

9.11 All underground pipe work shall be protected against corrosion as per latest AWWA Standards.

9.12 Paint shall be applied in accordance with paint manufacturer’s recommendations. The work shall generally follow relevant Indian Standards.

9.13 All fabricated steel structures, vessels, heat exchangers which have surface temperature less than 80 degree C shall have a minimum of two primer coats prior to despatch to site. The paint system shall be PVC Copolymer based primer or alkyd resin based primer paint of approved make. Two finish coat of PVC-Copolymer paint or synthetic enameling alkyd resin paint as applicable shall be applied at site. The dry film thickness of the four coats shall not be less than 120 microns.

9.14 All fabricated steel structures, vessels, heat exchangers which have surface temperature more than 80 degree C and less than 150 degree C shall have a minimum of two primer coat of Zinc ethyl silicate and one finish coat of high build epoxy polyamide enamel prior to dispatch to site. One finish coat of high build epoxy polyamide enamel paint shall be applied at site. The dry film thickness of the four coats shall not be less than 120 microns. All standard bought-out items and machines such as pumps, fans, motors, valves, cylinders, electrical and instrumentation panels etc. shall generally be painted as per the manufacturers’ standard and shall meet the requirement of the exposure condition and the specific system of painting thereof. These shall also have a minimum of two primer coats and one finish coat of paint with a total dry film thickness of not less than 105 microns.





BOILER

DOC. NO : 4 – 3678 – MECH – 001 (R2)

9.15 Over-ground pipe work inclusive of pipes, fittings, hangers, cable ducts etc., both insulated

and non-insulated, shall be painted with two coats of alkyd based red-oxide or zinc-phosphate pigments as primer paint before despatch. The minimum dry film thickness per coat shall be 40 microns.

9.16 Non-insulated pipes, having a maximum surface temperature of 60 degree C shall be applied with one intermediate coat of single pack high build oil alkyd based paint with micaceous iron oxide and two finish coats of single pack air drying high gloss oil alkyd modified synthetic enamel paint with suitable pigments over and above the primary coats. The minimum dry film thickness per coat shall be 70 microns and 25 microns for intermediate and finish coat respectively.

9.17 Painting specification shall include, but not limited to the following:

S.NO. DESCRIPTION SURFACE PREPARA

TION PAINT

NO.OF COATS

DFT / COAT (µm)

PAINTING AT

1.

All Steel Structure – Columns, Beams, Bracings, Staircases, Ladders, Hand railing, Grating, Trends, chequered plates, Trusses, Purlins, Cable tray supports etc (Temp. Limit below 60 Deg. C )

SA-2 ½

Primer Coat – Epoxy Based Zinc Phosphate

2 50 SHOP

Finish Coat – High Build epoxy polyamide Enamel paint.

2 50 SITE

2.

Coal, Bed material & Lime stone Bunkers, Chutes, Ducts (Uninsulated) (Temp. Limit below 60 Deg. C )

SA-2 ½


2 50 SHOP


2 50 SITE

3.

Steam Drum, CBD / IBD Tanks, Deaerator Storage & Vapour Tank (External Surface)

St-2 or

St-3

Primer Coat - (External Surface) High Build Zinc Phosphate

2 50 SHOP

4.

Steam Drum, CBD / IBD Tanks, Deaerator Storage & Vapour Tank (Internal Surface)

St-2 or

St-3

(Internal Surface) Light Grade Mineral Oil.

- Spray SHOP

5. Pressure Parts & Piping (Insulated)

St-2 or

St-3

Primer Coat – High Build Zinc Phosphate

2 50 SHOP

6. Piping (Water System) (Uninsulated)

SA-2 ½


2 70 SHOP

Finish Coat – High Build epoxy polyamide Enamel

2 50 SITE





BOILER

DOC. NO : 4 – 3678 – MECH – 001 (R2)

S.NO. DESCRIPTION SURFACE PREPARA

TION PAINT

NO.OF COATS

DFT / COAT (µm)

PAINTING AT

paint.

7. Ducts, Hoppers & Casing (Insulated)

St-2 or

St-3


2 50 SHOP

8.

Ducts, Hoppers & Casing (Uninsulated) (Temp. Limit below 60 Deg. C )

SA-2 ½


2 50 SHOP


2 50 SITE

9.

Pressure Part supports & Hanger Rods, Piping Supports & Hanger Supports (Uninsulated)

SA-2 ½


2 50 SHOP


2 50 SITE

10. Foundation Bolts St-2 or

St-3

Primer Coat - High Build Zinc Phosphate (Except Threaded Portion)

2 50 SHOP

Threaded Portion – Light Grade Mineral Oil

- Spray SHOP

11.

Standard Bought out Items and Machines (Fans, Pumps, Motors, Valves & cylinders, Dampers)

SA-2 ½


2 50 SHOP


2 50 SITE





BOILER

DOC. NO : 4 – 3678 – MECH – 001 (R2)

ERECTION, TESTING AND COMMISSIONING





BOILER

DOC. NO : 4 – 3678 – MECH – 001 (R2)

SECTION – 10

ERECTION, TESTING AND COMMISSIONING

1.0 SCOPE OF SERVICES

1.1 This scope covers transportation, unloading, storage, erection, testing and commissioning of One no. (1) Boilers and their Auxiliaries, De-aerator and feed water pumps being supplied under these specifications and also providing supervisory specialists.

1.2 It is not the intent to specify completely all details of the works. However, the complete work shall be performed in accordance with the recognised modern construction practices and shall meet all the requirement of equipment manufacturer and latest applicable codes, Factory Rules, Safety Codes, Fire and General Insurance Regulations and the like.

1.3 The work covered under this section is of a sophisticated nature requiring precision workmanship and competent construction management. The section calls for execution of work in the most expeditious manner to ensure successful and timely commercial operation of the equipment installed. Tenderer must have in his possession adequate quantity of precision tools, construction equipment and aids as well as adequate qualified and experienced craftsmen and supervisors in his direct rolls.

1.4 The successful Tenderer shall select and adopt methods and procedures for equipment erection to suit the nature of equipment and erection work involved according to the best modern practice and his own experience in such work. The successful Tenderer shall be solely responsible to provide competent and adequate supervision to ensure that assembly and erection work are in compliance with the Equipment Manufacturer’s drawings and or instructions. The successful Tenderer shall not make any alteration to equipment to facilitate assembly or erection work, without prior agreement of the Equipment Manufacturer’s drawings and/or instructions, and final approval of the Purchaser.

1.5 The Tenderer shall confine all his office, stores, fabrication yard, constructional plant and equipment etc., in the area as may be allotted for this purpose. On completion of works and/or termination of contract, the Tenderer shall dismantle and remove his office, stores and other temporary facilities and reinstate the area to the original conditions. Tenderer shall indicate his requirements of area for construction yard and fabrication yard for this purpose in his tender.

1.6 All assembly and erection procedures adopted by the successful Tenderer shall be open for inspection and approval by the Purchaser. Acceptance of assembly or erection procedures shall not in any way relieve the successful Tenderer of his responsibility for proper erection of the equipment.

2.0 SCOPE OF WORK

The Tenderer's scope of services shall include but not be limited to the following

2.1 Transportation, Handling, unloading from the carriers at site, of equipment and materials received from Tenderer’s/Sub-vendor's works, unpacking, inspection and inventory including checking against invoices, repacking where required, submitting shortages/damages reports, lodging insurance claims against losses/damages, transportation and storage at site.

2.2 Transportation of equipment and materials at site from storage yard/sheds to assembly yard/foundations/place of installation as required.

2.3 Transferring levels and coordinates from the master bench marks provided by the Purchaser.

2.4 Erection of all the plant / equipment /supporting structures, auxiliaries etc to be supplied under the scope of this specification.





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DOC. NO : 4 – 3678 – MECH – 001 (R2)

2.5 Supply of adequate quantity of consumables required for the work viz., welding electrodes,

scaffolding, welding gas, oil, kerosene, cotton waste, etc.

2.6 Furnishing all temporary piping, fittings, strainers, valves, pumps, tanks, instruments and accessories as required, dummy plates if any, spool pieces, target plates and other accessories, chemicals required for cleaning, degreasing, flushing, steam blow out and testing of the pipelines, valves and equipment.

2.7 Carrying out tests on all equipment erected including but not limited to radiography, hydro-test and air pressure tests and any other tests as directed by the Engineer within purview of the codes.

2.8 Erection, testing, calibration and commissioning of all electrical equipment supplied with boiler. Hardware required for erection of control equipment covered under this specification shall be supplied by the Tenderer.

2.9 Erection, testing, calibration and commissioning of all instruments and control equipment supplied with boiler. Hardware required for erection of all instruments and control equipment covered under this specification shall be supplied by the Tenderer.

2.10 Arranging for statutory inspections and clearances as required.

2.11 Necessary equipment for hydro test, chemical cleaning, steam blowout and temporary piping/valves, gaskets, tools and tackles, etc shall be furnished by the Tenderer. Any leaky joints noticed during hydro test shall be cut-out, repaired or re-welded as directed and test repeated until satisfactory results are obtained.

2.12 Deputing engineers, supervisors, workmen, skilled and unskilled workmen during erection, testing, commissioning and acceptance test, to carry out the job successfully.

2.13 Carry out necessary repairs/modifications on erected plant/equipment until Completion of job, which is due to the Tenderer’s own defects/faults.

2.14 Carryout the all the pre-commissioning activities like chemical cleaning of boiler, preservation till start of steam blowout, steam blowing.

2.15 Carry out the performance guarantee tests as stipulated. The measurement of performance parameters under guarantee shall be determined as per ASME PTC-4 test codes or any other International codes acceptable to Purchaser. The instruments required for carrying out Performance Test shall be arranged by Tenderer on loan basis. The standard calibration and accuracy of test instruments shall be subject to approval of the Engineer.

2.16 Submitting a detailed write-up on Performance test procedure along with sample calculations for Engineer's approval which shall be finalized prior to actual Performance Testing. The boiler shall be on commercial electrical load connected to the grid and the load shall be adjusted and maintained around the testing load point as far as practicable.

2.17 The auxiliary steam should be made available by the Tenderer for acid cleaning along with all the needed temporary piping including effluent discharge pipe up to neutralization pit, valves, tubes, cables, pumps, motors, gauges and switchgears at his own cost. Also for preservation, storage, erection, testing and commissioning all the chemicals, lubricants, gases and paints etc shall be provided by the Tenderer irrespective of anything to the contrary appearing in this section.

2.18 All the preservatives and lubricants required for the first filling shall be arranged by Tenderer at no extra cost till ‘Taking Over’ of the Plant by the Purchaser.





BOILER

DOC. NO : 4 – 3678 – MECH – 001 (R2)

Note: For acid cleaning, Tenderer shall arrange adequate number of pump sets and all

required chemicals, valves, piping, gauges, switchgear with cabling, SH plugs and orifices [for down comers] etc as per scheme.

3.0 ERECTION OF MECHANICAL EQUIPMENT

3.1 Preparing for Installation

3.2 The successful Tenderer shall satisfy himself that the centre line of foundations, individual bolt centres etc are in accordance with the drawings. Also the successful Tenderer shall ensure that the levels and sizes of each foundation bolt are as per the manufacturer’s drawings. Any discrepancy in this account shall be brought to the notice of the Purchaser well in advance of commencement of erection.

3.3 Alignment, Levelling and Grouting

3.4 All motors and driven equipment shall be accurately leveled and aligned to specific tolerances. Equipment shipped with motor mounted, aligned and coupled shall have the coupling disassembled and alignment rechecked.

3.5 The surfaces of foundations shall be dressed to bring the surface of the foundations to the required level prior to placement of equipment bases on the foundations. The concrete foundation surfaces shall be properly prepared by chipping/ grinding as required to bring the type of such foundation to provide the necessary roughness for bondage and to assure enough bearing strength.

3.6 All the equipment bases and structural steel base plates shall be grouted and finished as per the grout cement manufacturer’s instruction.

4.0 ERECTION OF PIPEWORK

4.1 The fabrication, erection, cleaning, testing, purging / flushing, insulation, painting and commissioning of pipe work and associated structures shall be carried out.

4.2 The pipe work covered herein will include internal pipe work for the plant and equipment including interconnecting pipe work between different units / systems of the plant offered as well as connection to Purchaser’s utility services and return water systems.

4.3 Welding

4.4 The successful Tenderer shall provide all tools, plant, instruments and consumable including welding electrodes for carrying out the welding at site.

4.5 The successful Tenderer shall arrange at his own cost for all tests outlined below and any other test indicated by the Equipment Manufacturer / Purchaser from time to time during the progress of work.

- Visual examination. - X-ray and Gamma-ray examination. - Ultrasonic test. - Liquid dye - penetrant test. - Test by blowing.

4.5.1 Welding procedures shall be prepared in line with IS:7307 and tests shall be carried out to quality procedures.

4.5.2 Welders employed shall be qualified as per IS:7310 after passing necessary tests witnessed by Purchaser.





BOILER

DOC. NO : 4 – 3678 – MECH – 001 (R2)

4.5.3 Welding consumable shall be of approved type. Such consumable are, however, subject to

qualifying initial check tests as per IS:814.

4.5.4 The successful Tenderer shall strictly follow approved welding procedures during actual welding.

5.0 ERECTION OF ELECTRICAL EQUIPMENT

5.1 Erection of electrical equipment shall include, but not be limited to, the following:

5.1.1 Laying of LT power and control signal and special cables on racks/trays along walls / conduits including HT termination for the XLPE cables and joining of HT cables, if any. Also, suitable glands/lugs for LT power and control cables.

5.1.2 Installation of cable racks / trays / conduits with supporting structures.

5.1.3 Installation of motors, local push button stations, MCC, VFD, lighting, special control equipment etc.

5.1.4 Laying and Installation of cables, GI cable racks/GI cable trays/conduits with supporting structures, consumables and hardwares.

5.1.5 Equipment earthing above ground till the risers for the boiler / ESP.

5.2 The installation is to be carried out by an Electrical Tenderer possessing valid license issued by the State Government.

5.3 The successful Tenderer shall obtain approval from the Electrical Inspector for the installation carried out by him including approval of drawings.

5.4 Modifications, if any, as demanded by the Electrical Inspector shall have to be carried out by the successful Tenderer to the satisfaction of the Inspector without extra cost to the Purchaser.

6.0 ERECTION OF INSTRUMENTATION AND CONTROL SYSTEMS

6.1 The erection of instruments and controls shall consist of installation of all site mounted and panel mounted instruments and control equipment, instrument piping, cabling etc complete in all respects up to the stage of commissioning in accordance with the contract and as per relevant drawings and erection instructions of the equipment manufacturers.

6.2 Testing

Testing shall be carried out after the installation of instrument with instrument piping and cabling complete in all respects and approved by Purchaser.

6.3 Calibrations

All the instruments included in successful Tenderer’s scope of supply shall be calibrated strictly as per manufacturer’s instructions and in-coordination with equipment supplier prior to installation.

7.0 TESTS AND PRE-COMMISSIONING ACTIVITIES

7.1 Pre-commissioning and commissioning activities of boiler & auxiliaries shall include but not limited to the following:

i) Cleaning and inspection of Boiler internals.

ii) Flushing with air and water as applicable.





BOILER

DOC. NO : 4 – 3678 – MECH – 001 (R2)

iii) Pneumatic or hydraulic tests.

iv) Leak check for internal leaks for valves, external leaks for equipment, inter-space leaks for heat exchangers.

v) Run tests of fans pumps and other drives.

vi) Chemical boiling and cleaning of pressure parts.

vii) Refractory dry air.

viii) Checks on electrics for completeness and simulation test.

ix) Checks on instrumentation and control.

x) Blowing out of steam system.

xi) Protection checks on boiler and its auxiliaries.

xii) Calibration of all instruments and control devices.

xiii) Verification of interlocks.

xiv) Operation of steam generation on combinations of fuel.

xv) Relief and safety valves floating.

xvi) Operation of valves and non-return valves.

7.2 However, any additional tests recommended shall also be carried out by the supplier as a part of this Contract.

8.0 SPECIAL TESTS

Following tests shall be conducted on all piping, equipment and on complete system wherever possible whether it is specified or not in the relevant sections:

- Pressure testing. - Steam blowing.

9.0 START-UP, COMMISSIONING AND ACCEPTANCE

9.1 The successful Tenderer shall provide necessary equipment, tools, tackles, instruments, labour supervision etc. for the following:

i) Prepare equipment for trial runs and start-up.

ii) Start-up and commissioning of equipment.

iii) Acceptance.

9.2 The successful Tenderer shall be required to clean up the equipment and prepare it for trial runs and operation. The successful Tenderer shall bring to site such equipment, tools, instruments, tackles, labour, chemicals, flushing oil etc. as deemed necessary to carry out this work.

9.3 The successful Tenderer shall provide adequate personnel as required for start-up and commissioning of equipment as well as adjustments, repair and rectification of defects in erection of the equipment, during commissioning of the equipment.

9.4 Till the equipment are finally accepted by the Purchaser and taken over after the successful commissioning, the Tenderer shall be responsible for any loss/damage/theft etc. for the equipment erected by him.





BOILER

DOC. NO : 4 – 3678 – MECH – 001 (R2)

9.5 The successful Tenderer shall maintain a skeleton staff at the site after commissioning for any

additional/ modification work as may be required by the Purchaser.





BOILER

DOC. NO : 4 – 3678 – MECH – 001 (R2)

PERFORMANCE GUARANTEES AND LIQUIDATED DAMAGES





BOILER

DOC. NO : 4 – 3678 – MECH – 001 (R2)

SECTION – 11


1.0 GENERAL

1.1 All plant, machinery and equipment shall be guaranteed for design, materials, workmanship and satisfactory performance as required in this specification.

1.2 The Tenderer shall be responsible for carrying out Performance tests on all equipment supplied by him in the presence of the Purchaser and the Engineer to demonstrate that the plant, machinery and equipment is capable of achieving the performance guarantees as specified in this specification. All Instruments and Electricals including VFD, controller, sensors, flow meters and any other associated instrument and Electrical system installed for normal operation of the plant, machinery and equipment shall be made use of during the Performance tests as far as practicable. The successful Tenderer shall also provide any additional instrument required.

1.3 The Purchaser shall schedule operation of steam generating unit for carrying out the Performance tests.

1.4 Performance guarantee test for Boiler shall be carried out as per PTC 4.0.

1.5 The Performance tests shall be carried out after ascertaining that the plant is commissioned as a whole and is capable of conducting performance guarantee tests. Before start of performance test, the Tenderer will ensure the availability of all the documents like layout drawings, maintenance manuals, test certificates of all tests conducted for successful erection and commissioning approval from Boiler inspector as built drawings. The successful Tenderer shall guarantee the Performance tests parameters given below:





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DOC. NO : 4 – 3678 – MECH – 001 (R2)


A) BOILER & AUXILIARIES

The following liquidated damages will be applicable in case of non performance even after rectification.

Sl.

No.

Guaranteed parameters

Guaranteed Value

Acceptable tolerance limit

Liquidated damages within tolerance limit

Remarks

1

Maximum continuous rating with feed water temperature of 155 degree C at 110 ata, 540 ± 5 degree C for performance fuel firing.

Rated capacity

No restriction on positive side

–1%

0.1% of the contract value for every 0.1% reduction in steam flow.

Tenderer to rectify beyond tolerance range

2 Boiler efficiency at MCR

Tenderer to indicate

No restriction on positive side

– 0.5%

0.1% of the contract value for every 0.1% deficiency or part thereof below guaranteed efficiency


3 Dust concentration at ESP outlet for worst fuel combination firing

20 mg/Nm3 (when all fields are in service)

Nil Nil Tenderer to rectify

4 Auxiliary power consumption for Boiler & its auxiliaries


+2%.

No restriction on negative tolerance

Rs.20.0 lakhs for every one(1) kW increase in power consumption or part thereof above guaranteed power consumption


5 Delay in supply of equipment


- 1.0% of the contract value for every one week delay beyond……. From the date of receipt of order





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DOC. NO : 4 – 3678 – MECH – 001 (R2)

B) BOILER & AUXILIARIES

The following shall be demonstrated in respect of steam generating unit.

Sl.

No.

Guaranteed parameters

Guaranteed Value

Acceptable tolerance

limit

Liquidated damages within tolerance limit

Remarks

1 Flue gas temperature at the outlet of air heater


- - Tenderer to rectify

2 Rated part load operation without fuel oil support



3 Deaerator vent loss

< 0.5 % Tenderer to rectify

4 Maximum oxygen content in de-aerated feed water

0.007 ppm Tenderer to rectify

5 Control range for superheated steam temperature of 540 +5 degree C

60-100% MCR

+5% Tenderer to rectify

6 Sulphur Dioxide (SO2)

100 mg/Nm3 With limestone addition

7 Oxides of Nitrogen

100 mg/Nm3

8 Steam purity

Conductivity 0.2 µS (max.)


Silica 0.02 ppm (max.)


2.0 TEST PROCEDURE, CONDITIONS, TIME PERIOD ETC

2.1 Preconditions for Performance tests

2.1.1 During the Performance tests the plant shall be operated under the supervision of the Tenderer. Purchaser shall provide necessary operating personnel, water, power, fuel, utilities etc.





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DOC. NO : 4 – 3678 – MECH – 001 (R2)

2.2 Other Conditions

2.2.1 Time lost by interruptions in Performance tests due to reasons attributable to the Tenderer shall be added to the test period. Maximum three (3) interruptions during the Performance tests shall be allowed.

2.2.2 Should the continuous operation of the plant during the Performance tests be interrupted due to difficulties either with the plant, machinery and equipment supplied by the successful Tenderer or the inadequacy of successful Tenderer 's supervision of erection, testing and start-up or due to defect in the erection work, as the case may be, then the Performance tests shall be re-started and run again for the whole of the specified period of Performance tests.

2.2.3 If the results of the Performance tests are not satisfactory, then the tests shall be repeated by the successful Tenderer after necessary rectification and adjustments within 15 days or any other period mutually agreed upon with the Purchaser from the date of the preceding tests. Maximum two (2) nos. repeat tests shall be allowed unless otherwise agreed to by the Purchaser.

2.2.4 Liquidated damages for shortfall in performance shall be payable by the supplier after availing reasonable opportunities to set right the equipment and for the reasons of shortfall attributable to the suppliers. If the total value of penalties for shortfall in performance exceed ten percent (%) of total Purchase Order price, and the SUPPLIER has expressed his inability to rectify the defect and bring the equipment performance to the guaranteed level, then the PURCHASER retains the option to reject the equipment, and in case of such option the SUPPLIERS shall, jointly and severally, replacement shall be done within a reasonable period mutually agreed and at no extra cost to the PURCHASER.

2.2.5 For those items for which shortfall in performance is not acceptable beyond a permissible tolerance, the SUPPLIER jointly and severally, shall carry out modification to obtain the guaranteed performance within the stipulated tolerance. It may be noted that as these are primary, they must be corrected even before the trial run is started, and further, these parameters must remain stable throughout the period of trial run.

3.0 BID EVALUATION FACTORS FOR GUARANTEED PARAMETERS

The following factors shall be considered for evaluation of the Bids.

i) Boiler efficiency

ii) Auxiliary Consumption.

iii) Combustible in fly ash and bottom ash.

iv) Schedule for implementation & completion.





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DOC. NO : 4 – 3678 – MECH – 001 (R2)

TECHNICAL DATA SHEETS TO BE FILLED BY THE TENDERER





BOILER

DOC. NO : 4 – 3678 – MECH – 001 (R2)

SECTION – 12

TECHNICAL DATA SHEET FOR BOILER

MECHANICAL

ATTACHED SEPARATELY IN EXCEL FORMAT ELECTRICAL

Sl. No. Description Tenderer’s to fill the data

MOTOR CONTROL CENTRE PANEL

1 General

2 Applicable Standards

2.1 Low voltage switchgear & control gear assemblies- requirements

2.2 LV switchgear and control gear

2.3

Guide for Marking of insulated conductors / Guide for Uniform system of marking and identification of conductor and apparatus terminals

2.4 Degree of protection

2.5 Bus bars Copper/Aluminium

2.6 Instrument transformers

2.7 LV Fuses

2.8 Meters and Instruments

2.9 Control Transformers

2.10 Safety

3 Environment

3.1 Voltage/System

3.2 Altitude/Temperature/RH

3.3 System short circuit level

3.4 Special requirements

3.5 Derating

4 Execution

4.1 Construction

4.2 Sections

4.3 Cable entry





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DOC. NO : 4 – 3678 – MECH – 001 (R2)


4.4 Incomer & bus coupler feeders

4.5 Outgoing module

4.6 Degree of protection

4.7 Bus bars

4.8 No. of poles in Incomers and Bus coupler

4.9 Interlocking between Incomers and Bus coupler

4.10 Bus bar material

4.11 Busbar rating

4.12 Bus bar covering

5 Construction details

5.1 Material

5.2 Base frame

5.3 Gaskets

5.4 Busbar supports

5.5 Paint shade

5.6 Cubicle doors

5.7 Bus bar covers

5.8 Cable chamber doors

5.9 Power Wiring

5.10 Control Wiring

5.11 Control wiring Duct

5.12 Components-Incomer / Outgoing modules

i) Incomer Modules

ii) Bus Section Module

iii) Outgoing Modules

5.13 Control Voltage Supply

5.14 Duty Classes

5.15 Motor protection

5.16 Ammeter

5.17 Motor heaters





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DOC. NO : 4 – 3678 – MECH – 001 (R2)


5.18 Indicating lamps

5.19 Panel lamps

5.20 Feeder identification

5.21 Operating height

5.22 Maintenance access

5.23 Extensibility

5.24 Cable Terminals and Glands

5.25 Tests

i) Routine Tests

ii) Type Tests

5.26 Spare feeders

5.27 Auxiliary power supply

5.28 Marshalling Panel

6 Safety features

6.1 Earth bus

6.2 Cubicle doors

6.3 Safety during maintenance

6.4 Bus bar connections

6.5 Terminals in cable chambers

6.6 Danger plates

7 Document to be referred for further reference

7.1 Typical single line diagram and control schemes for 415V MCC

VARIABLE FREQUENCY DRIVE

1 General

1.1 Type of Drive

1.2 Rating of the drive

1.3 Quadrants of operation

2 Quantity

3 Power supply

4 Variation in Frequency





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DOC. NO : 4 – 3678 – MECH – 001 (R2)


5 Combined voltage and frequency variation

6 Environmental Conditions

7 Location

7.1 Whether in air conditioned room

7.2 If No:

i) Average ambient temperature((degree C))

ii) Design ambient temperature((degree C))

iii) Relative humidity (%)

iv) Vibration

8 Type of cooling for drive panel

8.1 If water cooled, is DM water required

8.2 If yes, quantity of DM water

9 Cable

9.1 Size and type

9.2 Entry

10 Dimensions

11 Types of Protection

11.1 Instantaneous over current

11.2 Motor overload protection

11.3 Over voltage / under voltage

11.4 Momentary power loss

11.5 Stall prevention

12 Control characteristics for both AC/DC

12.1 Control Method

12.2 Freq. control range

12.3 Accelerate/decelerate time

13 Controls on Drive Panel

13.1 Start / Stop

13.2 Speed Raiser / Lower

13.3 Auto / Manual





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DOC. NO : 4 – 3678 – MECH – 001 (R2)


13.4 Local / Remote

13.5 DOL by-pass

13.6 Emergency Stop

13.7 Any other

14 DC DRIVE

15 Application

16 Quantity

18 Type of DC motor

19 No. of quadrant operation

20 Output Characteristics

20.1 Output Voltage

20.2 Output kW rating

21 Speed Control

21.1 Rated speed (RPM)

21.2 Speed range

21.3 Armature voltage/field weakening

21.4 Closed loop/open loop control

21.5 If closed loop, type of tachogenerator Analogue signal mV/mA

21.6 Whether control through

i) DCS system

ii) PLC system

21.7 Speed accuracy

21.8 Speed regulation

22 Control characteristics

22.1 Type of braking

22.2 Starting torque

22.3 Braking torque

23 Miscellaneous

23.1 Auto restart

23.2 Flying restart





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DOC. NO : 4 – 3678 – MECH – 001 (R2)


23.3 Soft start

23.4 I/O requirements

25 Degree of Protection

26 A.C. DRIVE

27 Application

28 Quantity

30 a) Starting/rated torque

b) Type of converters

c) Inverter capacity at specified pf

d) Rated Current

e) Load power factor

f) Max. continuous current

g) Rated voltage with number of phases

h) Rated frequency

i) Converter Bridge

j) Single Quadrant/Two quadrant/ Four Quadrant

31 Control Characteristics

31.1 Speed Control

i) Rated speed

ii) Speed ratio

iii) Constant torque/constant power

iv) Speed accuracy

v) Closed loop/open loop

vi) If tachogenerator used (for closed loop)

vii) Accel./Deccel. time

viii) Type of tacho-generator

- If analogue, then reference signal mA/mV

ix) Is remote operation required

- If yes, is it through

x) Type of control





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DOC. NO : 4 – 3678 – MECH – 001 (R2)


32 Braking

32.1 Type of braking

32.2 Braking Torque

33 Miscellaneous

34 Soft-start

35 Flying restart

36 Auto restart

37 Kinetic Buffering

38 Indication on Drive Panel (minimum)

38.1 Motor running

38.2 Motor stopped / trip

38.3 AC mains ‘ON’

38.4 System Ready to start

38.5 VSD system fault

39 Metering

40 Digital Display of the following Minimum parameters on the Drive Panels:-

40.1 a) Input AC Voltage

40.2 b) Input AC Frequency

40.3 c) Input AC Current

40.4 d) Output Voltage

40.5 e) Output Current VSD/Bypass

40.6 f) Output Frequency

40.7 g) Motor speed

41

Necessary transducers shall be Provided with 4-20mA output for indicating motor speed & current in DCS.

HT POWER CABLES

1 Name of the Manufacturer

2 Conductor (stranded/solid)

2.1 Form-circular/segmented





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DOC. NO : 4 – 3678 – MECH – 001 (R2)


2.2 Nominal diameter in mm

2.3 Effective cross sectional area sq.mm.

3 Whether cores identified by Numerals for cables with 5 cores and above

4 Whether incremental runninglengths are marked on cable at every 1m interval

5 Finished cable

5.1 Diameter under armour in mm

5.2 Diameter over armour in mm

5.3 Overall diameter in mm

6 Whether cables will carry ISI stamp

6.1 If not explain reasons

7 Cable drums

7.1 Length of cables in cable drum and tolerance

7.2 Weight of cable drum without cables

7.3 Type of end sealing

8 Conductor screen

9 Insulation

10 Insulation screen

11 Sheath

12 Armour

LT POWER & CONTROL CABLES

1 Name of the Manufacturer

2 Conductor (stranded/solid)

2.1 Form-circular/segmented

2.2 Nominal diameter in mm

2.3 Effective cross sectional area sq.mm.

3 Whether cores identified by Numerals for cables with 5 cores and above

4 Whether incremental runninglengths are marked on cable at every 1m interval

5 Finished cable

5.1 Diameter under armour in mm





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DOC. NO : 4 – 3678 – MECH – 001 (R2)


5.2 Diameter over armour in mm

5.3 Overall diameter in mm

6 Whether cables will carry ISI stamp

6.1 If not explain reasons

7 Cable drums

7.1 Length of cables in cable drum and tolerance

7.2 Weight of cable drum without cables

7.3 Type of end sealing

8 Conductor screen

9 Insulation

10 Insulation screen

11 Sheath

12 Armour

HT MOTORS

1 Name of Manufacturer,

2 Type and frame size :

2.1 Rated capacity of motor in KW

3 Starting time (Secs)

3.1 With 100% voltage at terminals

3.2 With minimum voltage at terminals (at Rated voltage)


4 Safe stall time at 100/110% rated voltage under hot/cold condition.

5 Type and size of cable for which gland is provided in the terminal box :

6 Type of bearings and expected life.

6.1 DE Bearing

i) Type, No. & make

ii) Lubricant

iii) Initial quantity

iv) Relubricating interval





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DOC. NO : 4 – 3678 – MECH – 001 (R2)


v) Relubricating quantity

vi) Anticipated life

6.2 NDE Bearing

i) Type, No. & make

ii) Lubricant





7 Motor bearing lubrication system – Self lubrication/Forced oil lubrication

7.1 Forced oil lubrication system (if provided)

a) Whether this is compatible with forced oil lubrication system of driven equipment. If NO, furnish the following details for motor bearing.

i) Type, make and specification of oil

ii) Flow rate (Ltrs/Sec)

iii) Pressure (Kg/cm2)

iv) Quantity of lube oil pump sets provided for each motor.

v) Local control panel provided forced oil lubrication system of each motor

vi) Make type and name plate particulars of lube oil pumps & 415V, 3 phase, 50Hz motors.

vii) Filters – Make & type

8 Air temperature detector (Internal) (CACA/CACW motor)

8.1 Type & make

8.2 Number

8.3 Number of contacts in each indicator

8.4 Contact rating at - 220V DC

240V AC

9 Terminal box

9.1 Location of main terminal box viewed from non drive end (Right/Left)

10 No load current of motor at rated voltage & frequency (for each type of motor)

11 Limiting rotor temperature for determining safe stall time





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DOC. NO : 4 – 3678 – MECH – 001 (R2)


12 Insulation

12.1 Material and treatment of insulation

13 Winding

13.1 Stator winding

i) Connection

ii) Resistance/phase

13.2 Rotor winding

i) Connection


14 Total weight of motor (kg)

14.1 Weight of Stator (kg)

14.2 Weight of Rotor (kg)

15 Motor GD2 :

16 Efficiency (%)

16.1 Full Load Efficiency

16.2 75% Load Efficiency



17 Power Factor

17.1 Full Load Power Factor

17.2 75% Load Power Factor



18 Torque (% FLT)

18.1 Starting

18.2 Maximum (Pullout torque)

18.3 Pull up torque

19 Type of Enclosure

20 Cooling designation

21 Space heaters





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DOC. NO : 4 – 3678 – MECH – 001 (R2)


21.1 Rated voltage/number

21.2 Rating total

21.3 Separate terminal box provided

22 Motor reactances (Pu)

22.1 Subtransient reactance

22.2 Transient reactance

22.3 Steady state reactance

23 Guaranteed losses (kW)

23.1 Iron loss

23.2 Copper loss

23.3 Friction, Windage & Stray losses.

24 Motor outline dimension drawing (Number of copies as per distribution schedule)

25 The following additional data/details should be shown on the motor drawing, when applicable.

25.1 Cooling water requirement for water cooled bearing (Lts/min).

25.2 Cooling water requirement for water cooled windings (Lts/min).

25.3 Required pressure of cooling water (kg/cm2).

25.4 Required maximum temperature of cooling water (degree C).

25.5 Weight of cooler if removable (kg).

25.6 Oil level sight gauges for oil lubricated bearings

25.7 Location and size of earthing terminals/holes in earthing pads.

26 Type test certificates (Number of copies as per distribution schedule)

27 Speed torque curve at rated & minimum starting voltage.

28 Current – speed curve.

29 Current – time curve.

30 Efficiency, power factor, slip, current against output curve.

31 Thermal withstand characteristic for motors of 100 kW & above – Hot & Cold.

32 Negative sequence current Vs time curve for motor of 100 kW & above.

33 Rotor voltage/Rotor current (for wound motors).





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DOC. NO : 4 – 3678 – MECH – 001 (R2)


34 Instruction Manual (Number of copies as per distribution schedule)

LT MOTORS

1 Name of Manufacturer,

2 Type and frame size :

2.1 Rated capacity of motor in KW

3 Starting time (Secs)


3.2 With minimum voltage at terminals (at Rated voltage)


4 Safe stall time at 100/110% rated voltage under hot/cold condition.

5 Type and size of cable for which gland is provided in the terminal box :

6 Type of bearings and expected life.

6.1 DE Bearing

i) Type, No. & make

ii) Lubricant





6.2 NDE Bearing

i) Type, No. & make

ii) Lubricant





7 Motor bearing lubrication system - Self lubrication/Forced oil lubrication

7.1 Forced oil lubrication system (if provided)

a) Whether this is compatible with forced oil lubrication system of driven equipment. If NO,





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DOC. NO : 4 – 3678 – MECH – 001 (R2)


furnish the following details for motor bearing.

i) Type, make and specification of oil

ii) Flow rate (Ltrs/Sec)

iii) Pressure (Kg/cm2)

iv) Quantity of lube oil pump sets provided for each motor.

v) Local control panel provided forced oil lubrication system of each motor

vi) Make type and name plate particulars of lube oil pumps & 415V, 3 phase, 50Hz motors.

vii) Filters - Make & type

8 Air temperature detector (Internal) (CACA/CACW motor)

8.1 Type & make

8.2 Number

8.3 Number of contacts in each indicator

8.4 Contact rating at - 220V DC

240V AC

9 Terminal box

9.1 Location of main terminal box viewed from non drive end (Right/Left)

10 No load current of motor at rated voltage & frequency (for each type of motor)

11 Limiting rotor temperature for determining safe stall time

12 Insulation

12.1 Material and treatment of insulation

13 Winding

13.1 Stator winding

i) Connection


13.2 Rotor winding

i) Connection


14 Total weight of motor (kg)

14.1 Weight of Stator (kg)

14.2 Weight of Rotor (kg)





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DOC. NO : 4 – 3678 – MECH – 001 (R2)


15 Motor GD2 :

16 Efficiency (%)

16.1 Full Load Efficiency




17 Power Factor

17.1 Full Load Power Factor




18 Torque (% FLT)

18.1 Starting

18.2 Maximum (Pullout torque)

18.3 Pull up torque

19 Type of Enclosure

20 Cooling designation

21 Space heaters

21.1 Rated voltage/number

21.2 Rating total

21.3 Separate terminal box provided

22 Motor reactances (Pu)

22.1 Subtransient reactance

22.2 Transient reactance

22.3 Steady state reactance

23 Guaranteed losses (kW)

23.1 Iron loss

23.2 Copper loss

23.3 Friction, Windage & Stray losses.

24 Motor outline dimension drawing (Number of copies as per distribution schedule)





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DOC. NO : 4 – 3678 – MECH – 001 (R2)


25 The following additional data/details should be shown on the motor drawing, when applicable.

25.1 Cooling water requirement for water cooled bearing (Lts/min).

25.2 Cooling water requirement for water cooled windings (Lts/min).

25.3 Required pressure of cooling water (kg/cm2).

25.4 Required maximum temperature of cooling water (degree C).

25.5 Weight of cooler if removable (kg).

25.6 Oil level sight gauges for oil lubricated bearings

25.7 Location and size of earthing terminals/holes in earthing pads.

26 Type test certificates (Number of copies as per distribution schedule)

27 Speed torque curve at rated & minimum starting voltage.

28 Current - speed curve.

29 Current - time curve.

30 Efficiency, power factor, slip, current against output curve.

31 Thermal withstand characteristic for motors of 100 kW & above - Hot & Cold.

32 Negative sequence current Vs time curve for motor of 100 kW & above.

33 Rotor voltage/Rotor current (for wound motors).

34 Instruction Manual (Number of copies as per distribution schedule)





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DOC. NO : 4 – 3678 – MECH – 001 (R2)

DRAWINGS AND DOCUMENTS TO BE SUBMITTED BY THE TENDERER





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DOC. NO : 4 – 3678 – MECH – 001 (R2)

SECTION – 13

DRAWINGS AND DOCUMENTS TO BE SUBMITTED

1.0 Along with the Bid :

1.1 The Tenderer shall submit in his Technical bid the drawings, diagrams, graphs curves and all such information which are necessary to fully understand the offer both technically and commercially.

1.2 As a minimum requirement the following information shall be supplied with technical bid of the Bid in sufficient detail to fully describe the scope of work and the services offered.

i) Duly filled-in Data sheets and the schedules

ii) List of all equipment under scope of supply

iii) Terminal point details

iv) Time schedule for the design, manufacture, delivery, erection, testing, commissioning and trial operation indicating important milestone activities

v) A tentative Engineering drawing and document submission schedule.

vi) Proposed detailed training program of PURCHASER’s operating personnel for operation and maintenance of various equipment / systems indicating clearly the man-months considered for each category of personnel.

vii) A tentative layout of the plant and equipment with Section

viii) The Process and Instrumentation Diagrams of the systems like steam and feed water, air, flue gas, fuel etc.

ix) Preliminary arrangement drawings of the main equipment with overall dimensions.

x) Details of critical equipment and instruments including capacity, make, design parameters, codes and standards followed.

xi) A detailed write-up on the fuel firing system proposed to be adopted for coal giving specific details about the feeders, combustors etc.,

xii) Detailed write up on the arrangement and functioning of the steam separation system in the drum.

xiii) Details of refractory materials and a brief description of the refractory work of the boiler.

xiv) For Electrical requirements please refer electrical SECTION 5.0 – SL.NO.:9.0 & 10.0

xv) Motor list and the preliminary electrical load list of AC and DC power consumers including power demand.





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DOC. NO : 4 – 3678 – MECH – 001 (R2)

xvi) Write-up on the control and safety aspects of the plant with logic diagrams including

alarm and shutdown facilities.

xvii) List of items manufactured in the Tenderers own works and the list of bought out items with the name of the Tenderers with their experience details.

xviii) All instrument Specifications.

xix) Organization charts.

xx) Illustrative catalogues and literature for the various plant and equipment.

xxi) Any other information relevant to the subject tender.

2.0 Drawings and Information required from Successful Tenderer during Contract Stage

2.1 The drawings and documents to be furnished by the successful Tenderer after the award of the contract shall include but not limited to the following. A drawing/document submission schedule clearly identifying the documents to be submitted and the purpose of the submission (for information / approval etc.) shall be furnished after discussions and in consultation with the Consultant and Purchaser. The drawings which require approval from the consultant / Purchaser shall be submitted in 3 sets. One set will be returned to the Tenderer.

2.2 General

i) Detailed time schedule in the form of Network or bar chart for the design, manufacture, delivery, erection testing and commissioning period with critical milestone activities and other important intermediate dates for uninterrupted progress of the project.

ii) Technical Specifications and data sheets for the Boughtout items.

iii) Test certificates & inspection reports.

iv) Operation and maintenance manual including catalogues, bought out items, start up procedures and O & M manuals of bought out items.

v) All drawings / documents shall have a title block indicating, Project Customer, Consultant, Title, Drawing Number, Revision Index and details etc.,

vi) Quality Assurance Plans.

vii) Tie-in data

viii) List of approved vendors. They should be preferably as per the list included in the tender.

ix) Erection manuals and installation procedures for all equipment and systems.

x) As Built drawings.

xi) Any other drawings and documents as required for statutory approval.





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DOC. NO : 4 – 3678 – MECH – 001 (R2)

xii) Other drawings, calculations and documents as indicated in the various sections of

this bid documents.

xiii) Proposed detailed training program of Purchaser’s operating personnel for operation and maintenance of various equipment/ systems.

2.3 Process and Mechanical

i) Technical Specifications and data sheets for the boughtout items.

ii) Piping and instrument diagrams for Steam & Feed Water System, Air & Flue Gas System, Fuel System, Cooling Water System, Fuel feeding system, Start-up oil firing system, Instrument Air system, SWAS, ESP, DM water/initial filling/Makeup water, dozing system etc.

iii) Complete boiler performance data including predicted performance at various loads, heat transfer areas, pressure drops, temperature profiles etc.

iv) Start-up and shut-down curves for the boiler.

v) Boiler plant equipment layout plan and elevation.

vi) Foundation loading data for the boiler and auxiliaries and other equipment and supports.

vii) Boiler sectional plan at various levels and elevation.

viii) Boiler pressure part arrangement drawings.

ix) GA of Superheaters, Evaporators, Water walls, Wing walls, Drum, Economisers, Attemperator, Cyclone separator, Air preheaters etc.,

x) Metal temperature calculations.

xi) Boiler Expansion Movement Diagram

xii) Layout of Gas Ducting.

xiii) Layout of Air Ducting.

xiv) Furnace Openings & Buckstays.

xv) IBR approved drawings and documents.

xvi) G.A. of fuel firing system inclusive of the feeding, distribution and fuel feed control.

xvii) Chemical dosing system arrangement and piping layout drawings.

xviii) G.A of all fans and cross sectional view showing parts and materials for all Fans.

xix) Calculation for determining capacity and head of fans and all the characteristic curves of the fans.

xx) G.A of boiler feed pump and cross section view showing parts, materials and fittings and the characteristic curves.





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DOC. NO : 4 – 3678 – MECH – 001 (R2)

xxi) Fans & pumps performance curves and test reports.

xxii) Completed data sheets for pumps/motors/fans.

xxiii) Calculation for determining capacity and head of pumps.

xxiv) General Arrangement of ESP and its technical particulars.

xxv) General Arrangement of Soot Blowers and Wall Blowers

xxvi) G.A. of Deaerator Assembly.

xxvii) G.A of CBD, IBD, SWAS, Bed ash coolers, Blow Down Tanks.

xxviii) Allowable Forces & Moments, Displacements at piping connecting points.

xxix) Piping Line list and schedule.

xxx) Valve schedule & Data sheets for control valves, safety valves.

xxxi) Piping Layout and Isometric Drawings with supports, hangers and the flexibility analysis results for the critical piping.

xxxii) Insert plate drawing for pipes & equipment supports.

xxxiii) G.A drawings of Control valves, Isolation valves, Non-Return valves, Safety Valves etc.

xxxiv) Thermal Insulation schedule

xxxv) Expansion Bellow data sheets and drawings.

xxxvi) Details of safety valves including manufacturer’s catalogues and service instructions, data sheet, GA drawings and capacity calculations.

xxxvii) Boiler operation and maintenance manual including catalogues, bought out items, start up procedures and O&M manuals of bought out items.

xxxviii) Utility list

xxxix) Input details for Ash handling system and chimney design

xl) Boiler performance data sheet and Boiler thermal calculation

xli) Burner arrangement drawings

xlii) Process valve and control valve schedule

xliii) GA of fuel bunkers, bed material bunker, drag chain feeders, Variable speed Fluid couplings, etc.,

xliv) Duct, BEP and Fan sizing calculation

xlv) Bed material requirement calculation





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DOC. NO : 4 – 3678 – MECH – 001 (R2)

xlvi) Fuel consumption details for each fuel firing combinations

xlvii) Data sheets for Feed control station valves, Temperature control valves, deaerator pressure and level control stations, PRDS, Fluid coupling etc.,

xlviii) Sizing calculations for HP dosing system, LP dosing system, Deaerator thickness and storage sizing, CBD tank size, IBD tank size, Common blow down tank sizing etc.,

xlix) Erection manual of ESP and Boiler

l) Welding procedure specification

li) Hydrotest procedure

lii) Boiler start-up procedure

liii) Refractory dry-out procedure

liv) Alkali boil-out procedure

lv) Safety valve floating procedure

lvi) Steam blowing procedure

lvii) Performance test procedure

lviii) Detailed Erection and commissioning schedule, Erection drawing, Erection procedures, Field quality assurance plan, Site safety management plan, Safety procedures, as-built drawings and O & M manual

2.4 Electrical (The following in addition to those indicated under SECTION 5 – SL.NO. 9.0 and 10.0)

2.4.1 Motors

i) Dimensional general arrangement drawing.

ii) Power & Control schematic drawing for each motor/drive.

iii) Foundation plan and loading details.

iv) Complete motor data.

v) Erection and maintenance manual

vi) Thermal withstand hot & cold curves

vii) Speed-torque and time curves

viii) The load torque curves and characteristics of motors shall be well coordinated with driven equipment requirements. The motor torque and other characteristic curves shall be drawn on the basis of starters (VFD/ASD/DOL) and also shall have driven equipment torque and other parameters wherever required.





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DOC. NO : 4 – 3678 – MECH – 001 (R2)

ix) Current and speed curves,

x) Negative sequence withstand curve,

xi) Eff / pf curves,

xii) Final AC/DC load list.

xiii) MCC arrangement drawing along with Power & control wiring diagram..

xiv) Lightning protection layout with cross section of boiler houses / ESP & BOQ.

xv) Physical layout of electrical system showing all panels, motors, etc.

xvi) Cable tray & trench layout

xvii) Cable schedule & interconnection charts

xviii) Earthling schedule and layouts.

xix) Lighting Layout with Lighting fixtures & support details and BOQ

xx) Test certificates for panels, critical components and electric motors.

xxi) Power and earthing layout showing physical location of the equipment with earthling details.

xxii) Relay setting and co-ordination charts for all the relays and releases of feeders in the scope of Tenderer.

The following details for the actuators

xxiii) Mounting arrangement with dimensions.

xxiv) Dimensional drawing of blank adapter bush

xxv) Operating and maintenance instruction manual

xxvi) Actuator motor data sheet

xxvii) Control schematic diagram of each type of actuator.

xxviii) Boiler platform drawing for illumination design

2.5 Control & Instrumentation

i) PLC I/O list

ii) PLC system configuration Technical specification / catalogs for instruments.

iii) Preparation of technical details for all hard wares pertaining to PLC system Sizing calculation for flow elements and control valve.

iv) Preparation of GA, foundation details for system cabinet, HMI console, etc

v) Preparation of power distribution scheme





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DOC. NO : 4 – 3678 – MECH – 001 (R2)

vi) Preparation of Nest loading document based on the I/O list

vii) Preparation of I/O loading details

viii) Preparation of earthing arrangement drawings (On ground & underground) with BOM

ix) Preparation of Alarm with set points

x) Preparation of process MIMIC diagrams graphic with parameters to be monitored in PLC system

xi) Preparation of format for various displays

xii) Preparation of format for various log functions, reports

xiii) Preparation of terminal plan of marshalling racks for AI/AO signals, DI/DO signals of PLC

xiv) Preparation of loop interconnection diagram (Schematics)

xv) Preparation of FAT & SAT procedure shall include demonstration of third parties device through MODBUS

xvi) Preparation of datatsheet for bought out items Eg. PC, cable, Ethernet switch

xvii) Preparation of UPS sizing calculation

xviii) Preparation of AH calculation for UPS battery

xix) Technical data sheet for field instruments & cables

xx) Instrument schedule

xxi) Sizing calculation sheets, G.A, specification sheets for flow elements, control valves

xxii) Loop schematic diagram for measurement and control loops

xxiii) Protection & interlock logic diagram

xxiv) I/O list

xxv) Installation and hookup diagram along with bill of quantities for each instrument

xxvi) G.A of Junction boxes

xxvii) Interconnection wiring diagram for the instruments and controls from field to control panel

xxviii) Instrument cable schedule

xxix) Junction box schedule (as per the format below:

• From field to JB





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DOC. NO : 4 – 3678 – MECH – 001 (R2)

• From JB to PLC & vice versa

xxx) Control schematic write up

xxxi) JB wiring diagram

xxxii) Cable routing diagram

xxxiii) Air calculation for all control valves

xxxiv) Tray routing & insert plate detail drawing

xxxv) Control scheme for MCC

xxxvi) Interface diagram from MCC to PLC

xxxvii) JB location diagram

2.6 Civil & Structural

Drawings showing the outline of foundation in plan and section and loading details, pocket sizes etc.

Point of action of static and dynamic loads in plan and elevation.

i) Layout of Floor Plans.

For foundations subjected to vibrations, in addition to the above, the following shall be furnished.

ii) Weight of rotating parts.

iii) Unbalanced force to be considered for dynamic design along with its direction and points of application.

iv) Max. allowable amplitude of vibrations in the vertical and horizontal direction.

3.0 Final submission of drawings and documents

After the completion erection and commissioning, the Tenderer shall submit 6 sets of hard copies and one soft copy of final GA drawings, fabrication drawings of all the components of the boiler and its auxiliaries and mountings





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DOC. NO : 4 – 3678 – MECH – 001 (R2)

LIST OF APPROVED SUB-VENDORS FOR MAJOR BOUGHTOUT ITEMS





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DOC. NO : 4 – 3678 – MECH – 001 (R2)

SECTION – 14

LIST OF APPROVED SUB VENDORS FOR MAJOR BOUGHTOUT ITEMS

SL. NO.

ITEM MAKE

A MECHANICAL

1 FANS AND ACCESSORIES ANDREW YULE / BHEL / BATLIBOI / TLT / FLAKT

2 ELECTROSTATIC PRECIPITATOR ACC/ALSTOM/BHEL/THERMAX / ETS

3 CHEMICAL DOSING SYSTEM / PUMPS ENPRO/FLUID CONTROLS/ V.K.PUMPS INDUSTRIAL PVT LTD

4 SOOT BLOWERS (STEAM) BHEL / INDIANA / SITSON / RR TECHNO

5 REFRACTORY ACC / BHILAI REFRACTORY/ FURNACE FABRICA / KFS / TATA REFRACTORIES

6 INSULATION LLOYDS/MINWOOL/ MURUGAPPA/ ROCKWOOL INDUSTRIES

7 SAMPLE COOLERS JNM /THERMAX LTD

8 BELLOWS ANUP ENGG./LONESTAR / FLEXICAN BELLOWS & HOSES PVT LTD.

9 AIR AND FLUE GAS DAMPERS BACHMANN INDIA / DEVIKRIPA ENGG, TRICHY (EFFOX, USA) / FOURESS-METROVICKS, USA

10 DEAERATOR BHEL / GEA ENERGY / ALLIED ENERGY STERLING /WALCHANDNAGAR

11 FEED WATER PUMPS KSB/SULZER

B PIPE WORK, VALVES AND FITTINGS

1 SEAMLESS & ERW PIPES, PLATE FORMED PIPES

MAHARASHTRA SEAMLESS, KALYANI, SAIL, TATA, JINDAL, INDIAN SEAMLESS, SAW PIPES, SURYA ROSHINI

2 PIPE FITTINGS GUJARAT ENGG. CO, M.S FITTINGS MANUFACTURING COMPANY, S & L, TRUE FORGE, DEE DEVELOPMENT/ TUBE TURN/SWASTIK/LLOYDS

3 GM GATE, GLOBE, CHECK LEADER, NECO





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SL. NO.

ITEM MAKE

4 SLUICE VALVE (CI) AUDCO, BDK

5 GATE, GLOBE & REGULATION VALVES

AUDCO, BHEL, KSB, BDK, NECO

6 BLOW DOWN VALVE BHEL, LEVCON, SEMPELL, UNITED ENGINEERS

7 BALL VALVES AUDCO, VALTEC

8 RELIEF & SAFETY VALVES AUDCO, JNM, MAZDA, MOORCO, FAINGER LESEN, TYCO SANMAR

9 DESUPERHEATERS DEMBLA VALVES, SAMSON, MAZDA

10 CONTROL VALVES IL, MIL, FISHER XOMOX, FOURESS

11 BUTTERFLY VALVES FOURESS, INTERVALVE, AUDCO, BDK,

12 THERMAL INSULATIONS LLOYDS, ROCKWOOL INDUSTRIES/ MINWOOL

13 AUTOMATIC DRAIN VALVE TRIDENT

14 STEAM TRAPS/STRAINERS UNI KLINGER, SPIRAX MARSHALL, ARMSTRONG

15 BFP-ARV SCHRODEL (IMPORTED)

16 SPRING HANGERS SARATHY/ PIPE SUPPORTS INDIA PVT LTD.

C ELECTRICAL

1 CABLES CCI / UNIVERSAL / NICCO / ASIAN

2 LT MOTORS SIEMENS / NGEF / CGL / KIRLOSKAR/ABB

3 ACB L&T / SIEMENS / ALSTOM /SHNEIDER/ GE

4 FSU L&T / SIEMENS / ALSTOM /SHNEIDER

5 STARTERS & CONTACTORS SIEMENS / L&T /SHNEIDER / GE

6 ANALOG METERS AE / IMP / RISHAB

7 PUSH BUTTONS SIEMENS / L&T / TECHNIC

8 LIGHTING FIXTURE PHILIPS / BAJAJ / CGL / WIPRO

9 MCB’S FOR CONTROL CIRCUITS S&S / MDS / HAVELS

10 SELECTOR SWITCHES KAYCEE / ALSTOM / SIEMENS

11 INDICATING LAMPS ALSTOM / SIEMENS / L&T





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SL. NO.

ITEM MAKE

12 SOCKETS BEST & CROMPTON /CGL

13 CONTROL WIRES FINOLEX / CCI / INCAB

14 CONTROL TERMINALS ELMEX / CONNECTWELL

15 ANNUNCIATION MINILEC

16 VFD ABB/SIEMENS/DANFOSS

D INSTRUMENTATION

1 AIR FILTER REGULATORS

SCHVADER, PLACKA, SHAVONORGEN

2 COMPENSATING CABLE INDUSTRIAL INSTRUMENTATION CONSORTIUM (BOMBAY), GENERAL INSTRUMENTS, TOSHINIWAL INDUSTRIES PVT. LTD.

3 CONDUCTIVITY MEASUREMENT ROSEMOUNT (BECKMAN) SMART 3051C/1151S, HONEYWELL

4 DIFFERENTIAL PRESSURE INDICATORS/SWITCHES

INFOSS, H.GURU INSTRUMENTS (P) LTD. SHOR, SWITZER INSTRUMENTS LTD.

5 PRESSURE/DIFFERENTIAL PRESSURE TRANSMITTER

TATA HONEYWELL (SMART), ROSEMOUNT (SMART)

6 DISPLACEMENT TYPE LEVEL TRANSMITTERS

MAGNETROL, YAMATAKE HONEYWELL

7 DISSOLVED OXYGEN MEASUREMENT

HONEYWELL, POLYMETRON, ROSEMOUNT

8 ELECTRIC METERS AE, MECO

9 ELECTRONIC WATER LEVEL INDICATOR

SOLATRON, YARWAY

10 FLOW ELEMENT MECH, MICROPRECISION PRODUCTS, TECHNOMATIC (INDIA) PVT. LTD.

11 FLOW GLASSES

EUREKA, GENERAL INSTRUMENTS, LEVCON V.AUTOMAT & INSTRUMENT (P) LTD.

12 FLOW INTEGRATORS LECTROTEK, NISHKO, H & B

13 ILLUMINATED PUSH BUTTONS EAO, H & B

14 INSTRUMENT IMPULSE TUBES/& FITTINGS

CHAMP INSTRUMENTS & ENGINEERS

15 INSTRUMENT CABLES INCAB, DELTON, FORT GLOBSTER INDUSTRIES, UNIVERSAL CABLES LTD





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DOC. NO : 4 – 3678 – MECH – 001 (R2)

SL. NO.

ITEM MAKE

16 FITTINGS MICROPRECISION, H. GURU

17 LEVEL GAUGES CHEMTROLS ENGG., LEVCON, TECHNOMATIC (INDIA) PVT. LTD.

18 LEVEL SWITCHES LEVCON, MAGNETROL

19 LOCAL CONTROL PANELS

INDUSTRIAL CONTROLS & APPLIANCES (P) LTD., J & H, PYROTECH

20 PRESSURE INDICATORS

GENERAL INSTRUMENTS, H.GURU INSTRUMENTS (P) LTD, WAREE

21 PRESSURE SWITCHES INDFOSS (INDIA) LTD., SWITZER INSTRUMENTS LTD., VARMA TRAFAG

22 PUSH BUTTONS HONEYWELL, LARSEN & TOUBRO LTD., SIEMENS LTD., ELECON

23 RECEIVER INDICATOR (BAR GRAPH)

LAXONS, MASIBUS, INDUSTRIAL INSTRUMENTATION

24 RELAYS

OEN INDIA LTD. (COCHIN), JYOTHI, ABB

25 RTD

INDUSTRIAL INSTRUMENTATION, NAGMAN SENSORS (P) LTD., TOSHNIWAL INDUSTRIES PVE LTD, PYRO ELECTRIC INSTRUMENTS

26 SAMPLING RACK ROSEMOUNT (INDIA), POLYMETRON

27 SILICA HACH, POLYMETRON, BRAUN & LEUBE

28 SOLENOID VALVES ASCO, AVCON, ROTEX, SCHVADER

29 TEMPERATURE INDICATORS G.I.CONSORTIUM, H.GURU INSTRUMENTS (P) LTD., BELLS CONTROLS

30 TEMPERATURE SWITCH

ASHCROFT, SWITZER INSTRUMENTS LTD.

31 TEMPERATURE TRANSMITTERS H & B, ROSEMOUNT

32 THERMO COUPLE ASSEMBLY

INDUSTRIAL INSTRUMENTATION, GENERAL INSTRUMENTS, NAGMAN SENSORS (P) LTD, PYRO ELECTRIC INSTRUMENTS, TOSHNIWAL INDUSTRIES PVT. LTD.





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DOC. NO : 4 – 3678 – MECH – 001 (R2)

SL. NO.

ITEM MAKE

33 THERMOWELL

GENERAL INSTRUMENTS, NAGMAN SENSORS (P) LTD., PYRO ELECTRIC INSTRUMENTS, DETRIV INSTRUMENTATION, TOSHNIWAL INDUSTRIES LTD

34 UNIT CONTROL PANELS INDUSTRIAL CONTROLS & APPLIANCES (P) LTD., PYROTECH

35 VARIABLE AREA FLOWMETERS EUREKA, KRONE - MARSHALL

36 VIBRATION MONITORING SYSTEM / TURBINE SUPERVISORY INSTRUMENTS

BENTLY NEVADA / SHINKAWA





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DOC. NO : 4 – 3678 – MECH – 001 (R2)

SPECIFICATION DRAWINGS





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DOC. NO : 4 – 3678 – MECH – 001 (R2)

SECTION – 15

SPECIFICATION DRAWINGS

DRAWING NO. DESCRIPTION

1-3678-100-001 PLANT GENERAL LAYOUT

1-3678-100-012 TG BUILDING EQUIPMENT LAYOUT (Sheet 1 of 2)

1-3678-100-012 TG BUILDING EQUIPMENT LAYOUT (Sheet 2 of 2)

2-3678-100-008 P&ID FOR STEAM AND WATER SYSTEM (Sheet 1 of 5)





2-3678-100-013 P&ID FOR AIR AND FLUE GAS SYSTEM

2-3678-100-014 P&ID FOR STEAM DISTRIBUTION SYSTEM AND PRDS (Sheet 1 of 2)

2-3678-100-014 P&ID FOR STEAM DISTRIBUTION SYSTEM AND PRDS (Sheet 2 of 2)

2-3678-100-015 P&ID FOR FUEL FEEDING SYSTEM (Sheet 1 of 2)

2-3678-100-015 P&ID FOR FUEL FEEDING SYSTEM (Sheet 2 of 2)

2-3678-100-016 P&ID FOR START-UP OIL FIRING SYSTEM

3-3678-400-002 TYPICAL SINGLE LINE DIAGRAM FOR AC VFD & INTEGRAL STARTERS

3-3678-400-003 TYPICAL SCHEMATIC DIAGRAM FOR DOL STARTER FEEDER

3-3678-400-004 TYPICAL SCHEMATIC DIAGRAM FOR STAR-DELTA STARTER FEEDER

3-3678-400-005 SALIENT POINTS ON 415 MCCs

2-3678-400-006 KEY SINGLE LINE DIAGRAM FOR BOILER PACKAGE





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DOC. NO : 4 – 3678 – MECH – 001 (R2)


ANNEXURE




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DOC. NO : 4 – 3678 – MECH – 001 (R2)

ANNEXURE

UTILITY REQUIREMENT

1.0 The Tenderer shall furnish hereunder the following utilities requirements for Steam generator and auxiliaries.

1.1 Auxiliary Cooling Water Requirement 1.1.1 Tenderer shall furnish the break-up of auxiliary cooling water requirements as below : Sl. No.

Equipment Requiring Aux. Cooling Water

Number of Coolers Maximum heat load for each

Auxiliary cooling water flow through

Total aux. cooling water flow

Remarks

Operating Standby cooler kcal/hr

each cooler m³/hr

m³/hr

1.1.2 Guaranteed pressure drop across Tenderer’s terminal point (maximum) = ---------------- kg/cm² (a) 1.2 Instrument / Service Air Requirement 1.2.1 Tenderer shall furnish the break-up of instrument / service air requirements as below: Sl. No.

Item Requiring Compressed Air

Instrument Air flow, Nm³/hr

Service Air Flow, Nm³/hr Remarks

Continuous Intermittent Continuous Intermittent

1.2.2 Service air pressure which will be provided

at interface terminal points indicated in Section C3:--------kg/cm² (a)

1.2.3 Instrument air pressure provided at interface terminal points indicated in Section C3: ----- kg/cm² (a)

Consultant: Snyder Energo Private Limited Annexure 1 of 2 Bangalore




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DOC. NO : 4 – 3678 – MECH – 001 (R2)

1.2.4 Maximum temperature of service/ Instrument air at interface terminal points : -------------------- degree C

1.3 Auxiliary Steam Requirement

1.3.1 Tenderer shall furnish the break-up of auxiliary steam requirements as below :

Sl. No.

Items requiring Aux. Steam

Steam Parameters Steam Quantity required and Tenderer’s Terminal Point, tph

Remarks

Pressure kg/cm²(a)

Temperature degree C

Continuous Intermittent

1.3.2 Auxiliary steam parameters

at Tenderer’s terminal point : ---------------- ata/ --------------------ºC 1.3.3 Total auxiliary steam requirement : -------------------- t/h

1.4 Auxiliary power requirement

Sl. No.

Equipment HT power 6.6 kV 415V, 3 phase, 50

Hz, 3 wire power 240 V AC, single phase, 2 wire,

UPS power kVA kVA kVA

Consultant: Snyder Energo Private Limited Annexure 2 of 2 Bangalore