Technical Specifications For Sugauli Cogen

Doc No. Date Assign No.
Date
: : : :
GDP/EPC-BID/09-10/025, R1 June 8, 2009 GPD/SDE/HPCL/08-09/045 September 12, 2008
ENGINEERING, PROCUREMENT & CONSTRUCTION (EPC) BID DOCUMENT
20 MW Cogeneration Power Plant Village Sugauli, District East Champaran, Bihar
Technical Basis And Specifications

Prepared For
Hindustan Petroleum Corporation Ltd. (HPCL)

(A Govt. of India Enterprise) Petroleum House, 17, Jamshedji Tata Road, Mumbai 400 022 Prepared By
MITCON Consultancy Services Ltd. (MITCON)

Kubera Chambers, Shivajinagar Pune - 411 005
June, 2009
Doc No. Date Assign No. Date
: : : :
GDP/EPC-BID/09-10/025, R1 June 8, 2009 GPD/SDE/HPCL/08-09/045 September 12, 2008
EPC BID DOCUMENT

20 MW Cogeneration Power Plant Village Sugauli, District East Champaran, Bihar TABLE OF CONTENTS
Chapter Chapter No. No. DESIGN BASIS, SCOPE OF WORK, TERMINAL POINTS, 1 1.1 1.2 1.3 1.4 2 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11 2.12 2.13 2.14 2.15
PERFORMANCE GUARANTEE Design Basis Scope Of Work Terminal Points Building Dimensions TECHNICAL SPECIFICATIONS FOR MECHANICAL & ELECTRICAL EQUIPMENTS, INSTRUMENTATION & CONTROL AND ERECTION AND COMMISSIONING Steam Generator &Auxiliaries Steam Turbine Generator & Auxiliaries EOT Crane & Hoists Water Treatment Plant Air Compressor & Air Dryer Fuel And Ash Handling System Cooling Tower & Auxiliaries Fire Fighting System Piping & Fittings Painting Electrical Evacuation System Cabling DCS Based Instrumentation And Control Uninterrupted Power Supply Erection & Commissioning Page No. 1 174 1 172 173 174 175 - 464 175 220 280 291 299 302 314 322 326 333 335 386 398 438 445
TABLE OF CONTENTS (contd..)

Chapter No. 3 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 4 4.1 4.2 4.3 5 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 5.10 5.11 Chapter No.
CIVIL WORKS Major Civil Works Design Data System Description & Specifications Design Criteria Foundations Machine Foundations General Design Considerations Design Of Miscellaneous Items Architectural Concepts And Design Construction APPROVED LIST OF VENDORS, LIST OF SPARES AND LIST OF DRAWINGS / DOCUMENTS Approved List Of Vendors List Of Spares List Of Drawings & Documents DATA SHEETS Steam Generator & Auxiliaries Steam Turbine Generator & Auxiliaries Water Treatment Plant Cooling Tower Fuel & Ash Handling EOT Crane Electrical Evacuation DCS Building Dimensions Performance Guarantee List of Technical Deviations Page No. 465 - 488 465 466 466 467 468 469 472 477 478 482 489 - 514 489 495 503 515 - 554 515 518 521 524 525 533 535 551 552 552 554
TABLE OF CONTENTS (contd..) LIST OF APPENDICES

APPENDIX NO. I II III IV SITE LOCATION MAP PROXIMATE & ULTIMATE ANALYSIS OF BIOMASS FUELS TYPICAL TG HALL LAYOUT PROPOSED MASTER PLAN DEMARCATING COGEN AREA AND PROVIDING SCHEMATIC OF FUEL HANDLING SYSTEM V VI VII VIII IX X XI TYPICAL SCHEMATIC PLANT STEAM SYSTEM TYPICAL SCHEMATIC FOR HP HEATER TYPICAL SCHEMATICS COOLING WATER SYSTEM TYPICAL SCHEMATICS PLANT WATER SYSTEM TYPICAL BOM, FIRE FIGHTING TYPICAL SCHEMATICS SYSTEM CONFIGURATION, PLANT DCS TYPICAL SINGLE LINE DIAGRAM, ELECTRICAL EVACUATION & DISTRIBUTION SYSTEM XII XIII XIV XV PIPING MATERIAL SPECIFICATIONS CODES & STANDARDS TYPICAL PAINTING SUMMARY ELECTRICAL SYSTEM REQUIREMENTS FOR MOTOR SELECTION XVI XVII XVIII RAW WATER ANALYSIS HEAT & MASS BALANCE DIAGRAM TERMS & CONDITIONS FOR ERECTION & COMMISSIONING APPENDICES
CHAPTER 1
DESIGN BASIS, SCOPE OF WORK, TERMINAL POINTS AND PERFORMANCE GUARANTEE
1.1
DESIGN BASIS 1.1.1 General The cogen power plant will have installed capacity of 20 MW and will Employ 110 kg/cm2 and 540C configurations. Bagasse generated from cane crushing, excluding handling losses and bagacillo requirements will be available for operation of the high-pressure boiler during season of 130 days. Saved bagasse, cane trash, rice husk will be used during the offseason period of about 170 days. The auxiliary steam consumption for the cogen power plant will be for soot blowing and other auxiliary consumptions like Steam Jet Air Ejector (SJAE) & Gland Steam Condenser (GSC) at high pressure, for twin type HP heater at medium pressure and for de-aerator at low pressure. The auxiliary power consumption for the power plant will be about 8.5% of generation during season and 9% of generation during off-season periods. The process steam required for sugar @ 22% on cane or 32.08 TPH during season, 20 TPH for ethanol plant during season & 10.25 TPH during offseason will be provided from the cogen power plant. Also, power requirement of 2.92 MW for sugar process during season & 0.15 MW during off-season, 1 MW during season & 0.9 MW during off-season periods for ethanol plant & 0.15 MW both during season and off season periods for the colony will be provided from the cogen power plant.
Technical EPC Bid Document for Cogen Power Plant at Sugauli, Dist. East Champaran, Bihar
The brief design parameters for the cogen power plant will be as follows: Boiler capacity, TPH Pressure, kg/cm2 Temperature, C Turbine capacity, MW Turbine type Season operation, days Off season operation, days Fuels used for season operation Fuels used for off season operation Boiler efficiency, % - On bagasse / bio-mass / cane : 70.00, 2 trash Feed water temperature, C : 210 Captive power consumption, % of : 8.5 during season & 9 generation during off-season : 1 x 100 110.00 540 20.00 Bleed cum double extraction cum condensing 130 : 170 : Mill bagasse : Saved bagasse, Cane Trash, Biomass
1.1.2
Key performance parameters The key performance parameters for the cogen power plant are given below: Sr. No. 1 2 Description Steam Generator efficiency, % Steam to Fuel bagasse / kg Ratio, Value : 702 on bagasse / biomass / cane trash
kg : 2.65
Average Steam Ratio, kg / kW Season Off-Season
to
Power : 5.08 : 3.80
Auxiliary Power consumption, MW (%) Season : 1.70 (8.5) Off-Season : 1.80 (9)
Note: The estimated HMBD is provided in Appendix XVII. However, the Tenderer can optimise the same to maximise power generation at the required steam flows to process. 1.1.3 Ambient Conditions Plant Elevation above Mean Sea Level (MSL) : 61 meters
Temperatures: (a) Maximum Temperature : 46 Deg. C (b) Minimum Temperature : 5 Deg. C (c) Plant Design Temperature : 36 Deg. C (Performance design) (d) Plant Design Wet Bulb Temperature : 27.0 Deg. C (e) Plant Design Temperature for Electrical : 50 Deg. C Equipment
Precipitation: (a) Average Annual Rainfall Wind: (a) Wind Direction (b) Design Wind Velocity
: 1241 mm : South - West (May Sept) North - East (Oct - Apr) : As per IS 875 : As per IS: 1893-2002 : Zone 4
Seismic Coefficient Seismic Zone
: 12 ton/m at 2 m from NGL * Tenderer will need to carry out required trial pits and other tests to affirm the SBC and other required soil characteristics Soil Bearing Capacity* 1.1.4 Fuels a) Design & Guarantee Fuels During sugar season, the principle fuel will be bagasse and the steam generator will be designed for 100% MCR on bagasse. During sugar off-season, the boiler will operate on stored / procured bagasse and other biomass. The estimated fuel balance will be as follows : Sr. Item No. 1. Crushing rate, TCH 2. Bagasse generation at 34% on cane, TPH 3. Bagacillo / handling loss at 1.0% on cane, TPH 4. Bagasse available as fuel at 33% on cane, TPH 5. Biogas available from distillery (equivalent to bagasse), TPH 6. Total equivalent bagasse available, TPH (MT) 6. Bagasse consumed by new boilers, TPH (MT) 7. Bagasse saved / available for off season operation, TPH (MT) 8. Biomass requirement, equivalent bagasse, TPH (MT) Value Season Off season 146 49.58 1.46 48.13 2.08 50.21 (156655) 37.74 (117748) 12.47 (38904) 2.08 0.00 26.60 9.54 (38904) 17.43 (71114)
The following will be the analysis and the Gross Calorific Value (GCV) of the design fuel (Bagasse). Ultimate Analysis: Carbon Hydrogen Oxygen Moisture Ash GCV with 50% moisture
: : : : : :
23.5% 3.25% 21.75% 50% 1.5% 2270 Kcal/Kg
The Following gives the Ash Analysis for Bagasse: SiO2 : 50-60% Al2O3 : 10-13% Fe2O3 : 10-12% CaO : 3-5% MgO : 3-4% TiO2 : 2-4% P2O5 : 1-2% Na2O : 0.5-1.5% K2O : 4.5-6.0% SO3 : Nil b) Other Fuels The Cogeneration plant will also be designed to operate with other fuels like sugarcane trash, rice husk and maize cobs in combination with bagasse. The operation of the plant during the seasonal operation will be basically with bagasse and during off season with saved bagasse and biomass. However during off season bio-mass fuel sugarcane trash, rice husk and maize cobs are envisaged to be used depending upon the availability. Ultimate and Proximate analysis of the other fuels like sugarcane trash, , rice husk and maize cobs are given in Appendix II
1.1.5
Plant Design Criteria The estimated cogen plant design criteria is as follows : Sr. No. 1. 2. 3. 4. 5. 6. 7. 8. 8. 9. 10. 11. 12. 13. 13.1 Item Season Operation (130 days) Cane crushing, TCH No. of season days, nos. No. of hrs / day Cane crushing / season, lakh MT / season. Bagasse generation, % cane (TPH) Bagacillo / handling loss,% cane (TPH) Bagasse available for boiler, % cane (TPH) Bio-gas available from distillery as fuel (equivalent bagasse) Total equivalent bagasse available for boiler, TPH Total fuel available as fuel, (MT) Bagasse consumption during season, TPH (MT) @ 2.65 T/MT of bagasse Bagasse saved for off season operation TPH (MT) (9-10) Steam generation, TPH (@ 2.65kg steam / kg bagasse Steam consumption, TPH HP steam @ 110 & 25 kg/cm2 - Gland Steam Condenser & Steam Jet Air Ejector (SJAE) - HP heater I MP steam @ 8 kg/cm2 - Ethanol process - HP heater II - De-superheating water addition - Total MP steam LP steam @ 2.5 kg/cm2 - Sugar process @ 22% on cane - De-aerator Value
146 130 24 4.55 34.00 (49.58) 1.0 (1.46) 48.13 (98.60) 2.08 50.21 156655 37.74 (117749) 12.47 (38904) 100.00
1.00 7.00 20.00 8.00 (0.56) 27.44 32.08 4.60
13.2
13.3
Sr. No.
Item - De-superheating water addition - Total LP steam Condensing steam @ 0.1 kg/cm2 Total steam consumption Power generation, MW (@ 5.08 kg/kW avg.) Power consumption, MW - Sugar process @ 20 kWh/TCH - Ethanol - Cogen auxiliaries - Colony - Total Power export, MW (14-15) Power export, MUs Off Season Operation (170 days) No. of off season days Steam generation, TPH Steam consumption, TPH HP steam @ 110 kg/cm2 for GSC HP steam @ 25 kg/cm2 for HP Heater I MP steam @ 8 kg/cm2 - HP heater II - Ethanol Plant - De-superheating water addition - Net MP steam LP steam @ 2.5 kg/cm2 - De-aerator - De-superheating water addition - Total LP steam Condensing steam @ 0.1 kg/cm2 Total steam consumption Power generation, MW (@ 3.80 kg/KW avg.) Power consumption, MW - Colony & Sugar Complex - Ethanol Plant - Cogen auxiliaries - Total
Value (0.73) 35.95 28.61 100.00 19.69 2.92 1.00 1.70 0.15 5.77 13.92 43.43 170 76.00 0.76 5.32 6.08 10.25 (0.33) 16.00 5.70 (0.11) 5.59 48.33 76.00 20.00 0.30 0.90 1.80 3.00
13.4 13.5 14. 15.
16. 17. 18. 19. 20. 20.1 20.2
20.3
20.4 20.5 21. 22.
Sr. No. 23. 24. 25. 26. 27. 28. 29. 30. 31 32
Item
Value
Power export, MW 17.00 Power export, MUs 69.36 Total power export, MUs 112.79 Fuel consumption Equivalent bagasse 28.68 requirement for off-season, TPH (MT) (117014) Biogas available from distillery for off-season 2.08 (equivalent bagasse), TPH Net off-season biomass fuel requirement 26.60 (equivalent to bagasse), TPH (MT) (110023) Bagasse saved during off season , MT 38904 Net biomass required, for off-season 50005 operation, MT Boiler size & configuration 1 x 110 TPH, 110 kg/cm, 540C Turbine size & configuration 1x20 MW, 105 kg/cm, 535C
1.1.6
Main Plant And Equipments 1.1.6.1 Steam Generator & Auxiliaries The steam generating system for the Cogeneration plant will consist of one bagasse and biomass fired boiler with a Maximum Continuous Rating (MCR) of 110 TPH. The outlet steam parameters of the boiler shall be 110 kg/cm2 and 540 deg C. The tolerance on the super-heater outlet temperature shall be a + 5 Deg. C. The combustion system of the boiler shall be travelling grate with spreader stoker. The boiler efficiency, firing 100 % bagasse, shall be a minimum of 70 % on the GCV basis. The flue gas temperature leaving the boiler to stack shall be chosen such that maximum economically possible efficiency is achieved but the temperature shall be sufficiently higher than the dew point considering the fuel characteristics. However, at 100% MCR the same shall not be higher than 140 deg C. An ESP is envisaged to control outlet emission to 100 mg/Nm3.
1.1.6.2
Turbo-generator & Auxiliaries Triple extraction cum condensing steam turbine generator & auxiliaries is envisaged. The high pressure bleed will be at about 25 kg/cm, medium pressure bleed at 8 kg/cm and low pressure controlled extraction at 2.5 kg/cm will cater to the sugar mill process needs and cogeneration power plant auxiliaries. Balance of steam will be passed through condenser to generate the rated capacity. Feed water will be de-aerated in a pressurized de-aerator and further heated in HP heaters. The Turbo - Generator and the Auxiliary Equipment covered under this specification shall be designed to achieve maximum power generation as per normal steam flow rates from the triple extraction cum condensing set. Part of the generated power will be supplied to the sugar factory complex and the rest will be exported to the grid, after stepping up the voltage to EHV and transporting the power through transmission lines to the nearby sub-station of the BSEB. The extractions from the turbine provide the sources for the medium and low pressure steam for the use in the sugar complex & power plant auxiliaries. The turbo alternator shall be designed taking into consideration all possible electrical parameters affecting the choice of the machine, assuring stable and reliable operation in a rural network. Tenderer shall offer his standard micro-processor based controls and instrumentation system with panels etc, for the start up, shut down and operation with all standard features. Basic Design Parameters for the design: Water Cooled Condenser 0.1 (in off-season) Operating Pressure (ata) Temperature rise for cooling 8 water (Deg. C) Power Factor (lagging) 0.8
Generation Voltage (kV) Ambient Temperature for Electrical Equipment Design (Deg. C) Parallel operation with grid Grid Voltage Duty Requirements System Frequency Turbine Type Inlet Steam Parameters - Pressure (Kg/Sq. Cm(a)) - Temperature (C) - Flow (Kg/Hr) Extraction parameters, No of Extractions, Steam Flow
11.0, 3 phase 50
Required with BSEB grid 132 kV, 3 phase Continuous 8000 hours 50 + 5% Triple Extraction cum Condensing 105 535 99000 in season & 75250 in off-season 3 extractions at 25 kg/cm, 8 kg/cm and at 2.5 kg/cm. Bleed at about 25 kg/cm is only for HP heater no. 2. Bleed at 8 kg/cm is for HP heater no.1 and to supply 20 TPH to ethanol in season. Extraction at 2.5 kg/cm is for deaerator and supply of 32 TPH steam to sugar process in season. Appendix XVII provides the HBDs
The turbo-generator system should be designed in such a way that the TG set does not trip during the Grid load- throw off condition, when the plant is operating at 100% rated capacity.
10
The prime mover control system shall be selected and programmed to satisfy the following conditions under parallel mode of operation with the grid: a. Load set point shall remain unaffected for the variation of frequency between 47.5 Hz and 52.5 Hz. The turbine inlet steam pressure shall be maintained at the set value by controlling the power export to the grid.
b.
The Turbine extraction which provides the Medium Pressure Process Steam shall be selected such that the pressure at the battery limit will be maintained between the turbine inlet steam flows of 60% to 100% of the MCR flow. This is required mainly from the point of view of energy efficiency, where in even under less than the capacity crushing of the sugar plant, the MP process steam is taken through the turbine instead of taking the steam through the PRDS. 1.1.6.3 Fuel & Ash Handling The project will have common bagasse and biomass handling systems. The bagasse handling system will take-off the mill bagasse from the take-off point in the sugar mill to the boiler, return the excess bagasse to the yard and supply bagasse from the yard to the boiler. Other biomass will be mixed in the bagasse storage yard. All ash will be mechanically handled and conveyed to ash silos and will be transported from the site by trucks / trolleys.
11
The fuel & ash handling system covered under this specification shall be designed to achieve the following objectives. 1 Bagasse from sugar mill elevator & yard, biomass from yard Ash from Boiler bed, Economiser, ESP Hoppers of Boiler & Bagasse from yard & mill Ash from furnace through submerged ash conveyor will be normally wet when it is discharged on to the belt. Bulk Density Bagasse : 150 Kg/ Cu M Bagasse Ash: 180 Kg/ Cu. M Material 180 Deg. C for the fly ash and Temperature 40 Deg .C for the bagasse Nature of Ash The ash collected will Contain un-burnt carbon Material Particles & also occasionally un-burnt Bagasse Bagasse Ash analysis (% ) SiO2 50 - 60 Al2O3 10 - 13 Fe2O3 10 - 12 CaO 3 -5 MgO 3 -4 TiO2 2 -4 P2 O5 1 -2 Na2O 0.5 -1.5 K2O 4.5 - 6.0 Material Handled Cooling Tower & Pumps A closed circuit cooling water system to provide cooling water for condenser and power plant auxiliaries will be constructed. Pumps and piping circuits will be provided for auxiliary cooling. The cooling tower to be designed for continuous duty. The design of the tower shall be as per the enclosed specification and Data Sheet.
2 3 4 5
1.1.6.4
12
The equipment offered shall be capable of cooling the rated capacity of water through the specified range at the design wet bulb temperature. The specified design wet bulb temperature of 27.50C includes the necessary recirculation allowance. Hence, Tenderer shall design his cooling tower based on this design wet bulb temperature without considering further recirculation allowance. While arriving at the air flow through the tower, due consideration shall be given to heat carried away by evaporation and enthalpy correction of altitudes. Tenderer shall furnish detailed heat balance calculation in support of the air flow through the tower. Tenderer shall also furnish the basis of the enthalpy values indicated. The motor rating of the cooling tower fans shall be at least 125% of the fan power requirement at the motor output shaft to take care of any changes in tower loading or fan performance at a later date, Tenderer shall furnish calculations for arriving at the motor rating.
1.1.6.5
Water Treatment System Raw water will be drawn by the Tenderer from the delivery header of the raw water transfer pumps at the ground water reservoir. Appendix IV provides the plant layout. Tenderer will also provide borewells at locations provided by the Owner / Consultant and connect the same to the day reservoir before the water treatment plant. The total capacity of the borewells should be 3000 m3/day. Schematic of plant water system is given in Appendix VIII Primary package consists of the treatment plant consisting of alum, polyelectrolyte, sodium hypo chlorite, and lime dosing systems, clarifloculator with bridge or tube settler, flash mixer, raw water pumps, auxiliary equipments for clarifier / tube settler, clarifier sludge pipes, related sludge discharge pumps, clarified water pumps etc., sampling devices, plant instrumentation, metering / measuring devices, pressure gauges, basket strainers, all piping etc.
13
Secondary system comprises of Multi grade Filters, Activated Carbon Filters, Filter Water pumps, Chlorine dosing and acid dosing, anti-scalant dosing systems, SMBS system related tanks and pumps, ultra-filtration unit, DM plant, Degasser, Degasser Tank, Blowers, degassed water pumps, mixed bed units, related acid and alkali dosing tanks, ejectors, morpholine dosing systems, all auxiliaries, including pumps and piping. Plant instrumentation including pH, conductivity meters, flow metering devices and totalliser. Basis for Design Water Treatment Plant Source of water
Gandak River. In case of exigencies, borewell water will be required to be used for process and boiler. Hence the water treatment plant should be designed accordingly. Total outflow of water DM plant : 1000 m/day, OBR Pre-treatment plant : 1250 m/day. OBR No. of Regeneration per day One per stream
1.1.6.6
Compressed Air System Two (2) instrument air compressors will supply the requirement of compressed air for instruments and the control systems of the proposed cogeneration plant with one (1) working and the other standby. Each of the compressors shall be of 7 kg/cm pressure. The air compressor shall be provided with accessories like Intercooler, after cooler, Moisture separators, Air driers, Air receivers and control panel.
14
The air compressor shall be oil free two (2) stage reciprocating nonlubricating type with belt drive. The design of the reciprocating compressor will be opposed piston dynamically balanced according to the standard. The heat exchangers (inter and after coolers) shall be designed as per TEMA-C and coolers shall be mounted horizontally. The cooling water flow shall be through tubes and the tubes shall be of copper. The internal surfaces of the cooler shall be galvanized. The coolers shall be fitted with moisture separators and all necessary accessories. The air drier unit shall comprise of 2 x 100% absorber towers with one of the towers in operation and the other one in regeneration mode. The towers shall be fabricated from SA 515Gr. 70 or IS:2002 material and filled with alumina. The air drier shall be provided with sequence timer for automatic change over valves. He entire drying system shall be skid mounted. The air receiver capacity shall be fabricated from SA 515 Gr. 70 or IS:2002 material. The internal surface shall be galvanized. The air receiver shall be fitted with all accessories including safety valves, moisture separators etc. The control system of pressure switches, solenoid valves, regulators for automatic loading of compressors shall be mounted on a local control panel. All air piping shall be internally galvanized. The service air requirement of the Cogeneration plant, being very low will also be met by the instrument air compressors. However the service air will be directly tapped off from the air receiver by passing the dryer units.
15
The compressors are to be opposed, belt pulley driven, nonlubricating type reciprocating air compressors complete with drive guards, AC electric motors, LPBS, air receiver, intercooler, after cooler, moisture separators, air dryer, moisture traps, all interconnecting pipe work & fittings, control panel, etc. The heat exchangers shall be designed as per TEMA-C and coolers shall be mounted horizontally. The air receiver shall be fabricated from SA 515 Gr. 70 or IS : 2002 material. The internal surface shall be galvanised. Control air will be supplied to boiler and its auxiliaries, turbo generator and its auxiliaries and common plant auxiliaries like water treatment plant, fuel handling plant, ash, pump house etc. Compressed air will meet the requirements as stated below : Capacity : 200 m3/hr or higher as per plant needs : 2 nos. (1 operating & 1 standby)
Nos.:
Pressure at receiver outlet : 7 kg/cm2 (g) Dew point temperature at Atmospheric conditions : (-) 400C Particulate material size (max.) Contaminants : 1 micron
: No corrosive, hazardous, toxic Or flammable material : 100% Oil Free
Oil Content
It is proposed to interconnect the service air system with the instrument air system before the instrument air dryers. A nonreturn valve and a manual isolating valve will be provided in this line so that instrument air cannot be supplied to the service air system.
16
1.1.6.7
Tanks & Vessels The tanks shall be designed, manufactured and tested in accordance with the requirements of the ASME Boiler and Pressure vessel Code Section VIII. Other equivalent standards are also acceptable. All vessels for steam application shall be designed for full vacuum. The cogeneration plant tanks will have storage capacities as required by design of the systems. Tanks will be of the closed top type. Tanks will be fabricated in accordance with guidelines established by API or AWWA, as determined by the service. A corrosion allowance of 3 mm shall be provided. Overflow connections and lines shall be provided where required and will be at least one pipe size larger than the largest input line or combination of inputs that can discharge simultaneously. Maintenance drain connections shall be provided of an adequate size to facilitate drainage of tanks is within a reasonable time. Manholes where provided on tanks and pressure vessels shall be of size NB 500. The manhole covers shall be provided with davits. Ladders and cleanout doors will be provided on large tanks. DM water tank shall be internally lined with natural rubber or painted with three coats of Epoxy Coating. DM water and make up water tank shall be provided with interconnection platforms and staircase. The saddles and reinforcement pads welded on to the vessels and tanks shall be of the same material as that of the vessel/tank shell or head. Insulated vessels shall be provided with insulation cleats for applying the insulation.
17
1.1.6.8
Piping All cogeneration plant piping will be as per applicable IBR / IS standards. All piping will be aesthetically and neatly laid on pipe racks with approved colour coding. The cogeneration plant piping will inter-alia include raw water intake, water treatment plant, cooling water circulation, auxiliary cooling water circulation, plant service water, plant potable water, plant sanitation, compressed air ring, drain piping, treated effluent piping, steam piping from boiler to turbine, steam piping from HP line via PRDSH stations to LP & MP headers, HP / MP / LP steam piping to all cogeneration auxiliaries, steam piping from LP & MP headers to sugar plant headers. HP piping to be sized for highest safety valve pressure at 110% MCR with maximum pr. drop of 2 kg/cm for the entire piping. The pipeline will be duly approved by IBR by the Tenderer on the buyers behalf. Standard fittings like expansion loops, stream traps, supports etc. are to be provided. The line should be insulated to suit weather conditions and preferably of LRB mattress with multilayer mineral wool and aluminium cladding (22 g), to achieve skin temperature of not higher than 65C. Stress analysis for the HP piping to be submitted by the Tenderer along with IBR approved steam pipe drawing. All piping required for effectively connecting the steam generator with the steam, feed water, and other systems shall be provided. The piping provided shall be complete in all respects including valves, fittings, supports etc. as required. Necessary supporting materials, towers and trestles to support and anchor the pipelines at regular intervals shall be supplied. Suitable expansion loops and hangers shall be provided wherever necessary. Suitable expansion loops restraints and anchors shall be provided so as to ensure compliance with the applicable codes and to limit the stress and reactions to within the allowable values.
18
a) The flow velocities in pipes shall be limited to the following values: Super-heated Steam. 30-60m/sec depending on pipe size Saturated Steam. 20 to 35 m/sec Cooling Water. Up to 3 m/sec b) Drains at all low points and vents at all high point shall be provided. c) Al local instruments shall be located on pipelines so as to render them observable from the nearest available platform. d) Oil drains shall be sized to run no more than half full when flowing at a velocity of 0.3 m / sec, and shall be arranged to ensure good drainage. Material Of Fabrication Of Equipments And Piping Wherever Applicable 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 Clarifloculator Inlet well Alum Dosing Tank NaOCl dosing tank Polymer Dosing Tank Lime Dosing Tank Mixing channels Clarifier Clarified water storage tank Multi grade filter ACF Acid Measuring Tank Caustic Measuring Tank Anti Scalant Tank Fast Flush Tank Backwash Tank Degasser Tower Degassed Water Tank Rotating Bridge Type RCC HDPE / FRP / MSRL HDPE / FRP / MSRL HDPE / FRP / MSRL HDPE / FRP / MSRL RCC (Through flow pipe) RCC RCC MSEP MSEP HDPE / MSRL MS / MSRL HDPE HDPE HDPE / FRP MSRL MSRL
19
19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39
Degassed Blower Degassed water pumps MB Unit ETP Pump Acid and Caustic Lye Pumps Neutralisation pit
SS 316 internals SS 316 MSRL SS 316 PP RCC with acid proof tile lining Softener MSEP Brine Preparation Tank RCC Bitumen Brine Dosing Tank MSEP / Bitumen Sludge Sump RCC Sludge Pumps SS 304 DM water piping MSRL Soft water piping MS UFRO Unit SS / PVC / MSRR Effluent / Sludge Slurry PVC DM water tank MSRL Soft water tank MSEP Filtered water storage tank MSEP All dosing pumps SS 316 internals Raw water pumps CI Filtered water and clarified CI with SS 316 internals water pumps
1.1.6.9
Insulation High grade insulation materials suitable for out door Steam generators shall be supplied with LRB mattress with mineral wool of multilayer with aluminium cladding, water proof lagging and protected from rain water, wind and Dust etc. for the exposed portion of the steam and mud drums, steam generator furnaces, integral pipe work from the feed pumps to the steam generators, steam & exhaust piping, hot air & gas dusting, condensates pipes, valves having high temperature fluids & hot water / condensates feed water tank, de-aerated water tanks, and other steam generator accessories to be provided.
20
Glass wool materials is used should confirm to I.S. 3690 - 1974 type 2 mineral wool shall confirm to I.S. 5696 - 1970. The thickness should be to suit the diameter and temperature of pipes. The wire mesh should be of galvanized wire and lugs/pins used should be galvanized. 1.1.6.10 Fire Fighting System Fire fighting scheme meeting TAC recommendations and ensuring plant & personal safety will be constructed. Pressurized fire hydrant system will consist of a pipe network and hydrants positioned around the station in sufficient numbers and so located that all buildings and risks are readily protected. Necessary number of loops will be formed around various risks. The loops will be interconnected for better reliability of the system. To isolate a portion of the ring main because of damage/repair, suitable nos. of valves will be provided. The hydrant network will be sized and analysed to ensure that about 3.5 kg/cm2 pressure is available at the hydraulically remotest point in the system with the hydrant pump discharging at rated head and capacity. The velocity in the hydrant main will not exceed 2 m/sec. The fire alarm system shall consist of smoke detectors, heat detectors, fire alarm panel, hooter, manual call point etc. The detectors shall be located in all the electrical panel rooms, control room and battery room. The manual call point and hooters shall be located throughout the entire TG building. The detectors will sense the fire automatically and will generate fire alarm through Fire alarm panel. The portable fire extinguishers shall consists of dry chemical powder type, carbon-di-oxide type, foam type fire extinguishers. The extinguishers shall be located strategically inside the TG building.
21
Raw water will be will be taken from the raw water pumps header at ground water reservoir to the fire water reservoir in the cogen plant. Raw water will be used for fire fighting. Typical BOM for fire fighting is provided in Appendix IX 1.1.6.11 Crane for the Turbo-generator Building An Electrically operated overhead travelling (EOT) crane with the main hook lifting capacity suitable for maintenance requirement of turbo-generator and an auxiliary hook lifting capacity of 5 Tons shall be provided to facilitate maintenance of the Turbo-generators and their auxiliaries. The crane travel will cover the entire length of the Turbo-generator building. The crane shall be electrically operated, bridge type and shall be designed and equipped for indoor operation complete with all accessories. The crane bridge shall consist of bridge girders each one carrying a rail on which a wheeled trolley is to run. The bridge trucks and trolley frames shall be fabricated from structural steel. Access walkways with safe hand railing are required along the full span length on either side of the bridge girders. Bridge and trolley trucks shall be of cast steel or fabricated structural steel sections. Wheel trucks of cast or welded construction shall be stress relieved as per accepted standards. Spring buffers shall be provided on the trolley and bridge structural frames at suitable places to absorb the shock of impact without transferring to the structural frame. 1.1.6.12 Electrical System The power generated will be evacuated to the sugar mill at the given terminal points. All the cogeneration power plant auxiliaries will operate on the power supplied from the cogeneration power plant. Balance of power generated after meeting the sugar and auxiliary load will be exported to the grid after stepping up to 132 kV. DG set will be provided for emergency power. All other power sources including DC power, UPS, control power, lighting, etc. will be derived from the cogeneration panels. Required earthing will be provided to ensure safety.
22
Proposed synchronous alternator shall be of 20 MW rating with generation at 11 kV. Surplus power, after meeting the cogeneration plant auxiliary requirement and power requirement of the sugar plant, shall be exported to the grid through 11/132 kV, ONAN/ONAF, generator transformer. The generator transformer shall be suitable for exporting the maximum power at 132 kV, without any limitation in the plant operation and power export. All equipment shall be designed to withstand the maximum fault levels provided in this tender document. The successful tenderer shall carry out complete system study for the electrical systems to ascertain the selection of fault levels of the switchgears are within limit, power (active and reactive) flow, system losses and power factor at various MCCs, voltage level in various level of voltage, motor starting analysis and stability study of the plant with BSEB grid. Power system shall be designed so as to export the entire power from cogeneration plant (total generation less auxiliary power consumption), when the sugar plant is not in operation. Following lighting sources are considered, Plant areas HPMV Lamp in Industrial type High Bay fixtures or in integrated Well Glass luminaries, Industrial type Fl. Lamp fixtures with Vitreous enamelled reflectors Mirror Optic Fl. Lamps or CFL
Electrical Room
Outdoor Lighting in transformer yard HPMV flood light fittings Battery operated Critical Lighting provided at strategic locations such as stair cases, control rooms and escape routes in the plant area - CFL lamps
23
Earthing arrangement in 132 KV switchyards shall be strictly as per the statutory regulations. The earthing shall include: a. Provision of earth electrodes for LAs, switchyard equipments body earthing, T.G. set Alternator , D.G. set Alternator Neutral and Body earthing, Transformer neutral earthing, earthing of structures etc. b. Provision of earth mat as per IEEE 80. c. Provision of lightning conductor over 33KV switchyard. d. Provision of earthing grid conductor as per fault level considered. e. Chimney Lightning protection and Lightning protection of other buildings The switchgear shall be free floor standing, totally enclosed, dust and vermin proof with draw out type circuit breakers. Vertical units shall be assembled to form a continuous line Up of uniform height and depth The panel structure shall house the components contributing to the major weight of the equipment such as circuit breaker, main horizontal bus bars and other components are adequately supported without deformation or loss of alignment during transit or during operation. Each unit of the switchgear shall have necessary internal sheet metal barrier to form separate compartments for buses, instruments, relays, cable connections etc. Adequate barriers shall permit personnel work safely within an empty compartment with the bus bars energised. Checking and removal of components shall be possible without disturbing the feeder. All auxiliary equipment shall be easily accessible to facilitate their operation and maintenance. It shall be possible to set all relays and measuring instruments without de-energising the switchgear.
24
All doors and opening shall be fitted with dust excluding neoprene gaskets with fasteners designed to ensure proper compression of the gaskets. When covers are provided in place of doors, generous overlap shall be assured between sheet steel surfaces with closely spaced fasteners to preclude the entry of dust. The panels shall have a rear cable chamber housing the cable and connections. The design shall ensure generous availability of space for easy installation and maintenance. System Fault Level : : : : 40 kA for 1 Sec. for 132kV system 40 kA for 1 Sec. for 11kV system 50 kA for 1 Sec. for 415V System 9 kA for 1 Sec. for Lighting Circuits
a)
Power Supply: 132 kV + 10%, 50Hz + 5 %, 3 Phase for Grid Connection 11 kV + 10%, 50Hz + 5 %, 3 Phase for Generation and Power Supply to 11KV Eqpts. 415 V + 10% , 50Hz + 5 % , TPN for plant load operating at 415V supply Control Voltage 110V AC, 50Hz for MCCs and PCCs Power Supply for Space Heaters, Plug Sockets, Lighting : 230 V,50 Hz, 1Ph. Power Supply for Tripping and Closing Circuits of Circuit breakers : 110 V, D.C.
25
b)
Power Distribution : a) Power will be generated at 11KV, 3Ph, 50Hz with Steam Turbine. Power will be stepped up to 132KV for Grid Connection and Evacuation to BSEB. 11kV Power Supply will be given to Sugar Plant Switchboard. Further downstream power distribution will be done in Sugar Plant. 11kV/433V distribution transformers are provided to cater power to 415V rated equipments in plant. 230 V Single phase power supply shall be derived through Phase & Neutral for single phase power consumer.
b)
c) d)
c)
Design Criteria In Equipments / Power Distribution : All Busbars shall be Air insulated and of Aluminium. Busbar size shall be selected based on Temperature limit of 85 C at Busbar for the rated current. Power Cables (HV & LV) shall be XLPE armoured ALUMINIUM conductors above and including 6 sq. mm. size. Power cables including and less than 4 sq. mm. shall be copper conductor. Squirrel Cage Motors up to 15 KW shall have automatic DOL Starter suitable for operating from MCC, DCS and PB Station near Motors. Motor rating above 15 KW up to 200KW shall be with Automatic Star Delta - Starter suitable for operating from MCC, DCS and PB Station near Motors. Motor rating above 200KW shall be operated with Soft Starter suitable for operating from starter, DCS and PB Station near Motors. Starter Shall have bypass contactor with AC3 rating. VFD shall be provided as per the functional requirement. Following spare feeders shall be considered in Power Distribution o In 11KV Switchboard - 1 No. Transformer feeder
26
o Panels in other areas including PCC / MCC / DB 1 No. of Each Rating MCC shall be floor mounted self supporting, dust and vermin proof , fixed type construction. Power Control Center (PCC) shall have Switch Disconnector Fuse up to 630A and above 800A these shall have Manually operated Draw Out (MDO) type ACB.ON indication shall be provided on outgoing feeders. Motor Control Center (MCC) shall have Switch Disconnector Fuse unit, Contactor and Bimetallic Over Load (O/L) relay for starters. Starters on MCCs shall have ON & TRIP indication. The selection of switchgear components shall be minimum with one stage higher than Type II co ordination as per IS 13947 Motor protection shall be provided in ACVF Drives & Soft Starters, as inbuilt protection functions. Rating of Switchboard incomer ACB/SDF shall be 1.2 times the operating load current.Protection & Indication Flameproof equipments such as Push Button Stations, junction boxes, Lighting Switches, L lighting Fixtures etc shall be considered with hazardous area classification in Ethanol plant. Push Button Station with Shrouded type actuator for ON push button, Lockable Mushroom type actuator for OFF Push button with Aluminum die cast enclosure shall be provided. Push Button Station for Motors above 15KW rating shall be provided with suppressed scale Ammeter. Push Button Station for VFD shall have Speed Setting Potentiometer and speed indicator in addition to Push Buttons and Ammeter
27
d)
Power And Distribution Transformer The following criteria shall be applicable for the sizing of Transformer 1) Total Connected Load shall be calculated based on Motor List. 2) Operating Load shall be calculated excluding Standby Loads and equipment for maintenance such as Crane. 3) Load Factors shall be considered on Operating Loads according to Load Factor to consider shall be as below: Motor Loads with DOL / S/D Starter / Soft Starters : 0.85 Motor Loads with VFDs 0.75 Lighting Loads : 1.0 Utility Plug Sockets : 0.5 Cranes, winches etc. : 0.1 4) Average Power Factor 0.8 shall be considered to arrive at KVA. 5) Equipment Efficiency shall be considered 90% as average. 6) On such Calculated load + 20% Margin shall be considered. 7) If necessary percentage impedance shall be increased more than the impedance indicated in IS to limit 415 V side Fault Level to 50KA for 1 sec.
e)
Power Factor Improvement 01) 02) Plant PF shall be required to improve above 0.95 This is achieved by providing: Capacitors across HV Motors as per recommendation of manufacturer. Provide Automatic Power Correction Panel with required no. of APP type capacitor banks in 415V PCC in Cogen Plant.
28
03)
To determine number of capacitors following consideration be given Operating KW & Average operating P.F. Drive with VFD shall maintain P.F. above 0.95. These loads shall not to be considered for deciding capacitor rating.
f)
LV Power Control Centre (PCC) The following points shall be considered while designing and selection of components. I) TYPE OF FEEDERS: Incomers : D.O. 3-Pole ACB Emergency Power Supply : D.O. 4-Pole ACB Feeder Outgoing Feeders : SDF up to 630 A : MDO Type ACB Above 800A II) BUSBARS Color Coded Sleeved Aluminum Bus bar Size shall be selected as per following norms: Continuous current carrying capacity as per the Rated Current of Incomer Temperature Rise Limit Short Circuit Withstand Capacity
29
g)
Motor Control Centre (MCC) : The following points shall be considered while designing & selecting components. I) Incomer Feeder A Fixed Switch Fuse Disconnector up to 630 A II) Outgoing Starter Feeder Feeders shall be comprising of: Switch Fuse Disconnector Contactors Thermal Overload Relay Timer in case of Star Delta Starters Push Buttons Indicating Lamps Above 125A rating Plant shall be capable of operation from MCC, DCS located at Central Control Room or locally from Push Button Station near motor. 02) It will be possible to start the Motor locally through enable command from PLC. 03) P.F. and KW parameter of Incomer shall be communicated to PLC. 05) ON/ OFF Status of the Motor shall be communicated to PLC. In MCC total 10% spare feeders shall be provided, depending on feeder ratings in MCC following feeders shall be provided. - MDO ACB above 800 A up to 2000
III) IV)
Bus bar Control Logic
V)
Provision of Spare feeders
30
h)
LV Bus Ducting Bus duct up to 3200A shall be CRCA enclosure with color coded sleeved Aluminum bus bar. Short circuit rating shall be 50KA, 1 sec.
i)
Battery And Battery Charger 01) BATTERY: 1) VRLA Maintenance Free 2) Capacity shall be determined by total operating load and 20% margin. 3) AH shall be determined for 8 hour backup time. 1) Float and Float cum Boost with 20% capacity Built in with Battery charger panel with Incomer as MCCB & Outgoing as MCB.
02) BATTARY CHARGER 03) DCDB :
j)
Grounding / Earthing System) & Lightening Protection 01) Earthing shall be done according to IS 3043 1987. 02) Earthing shall be carried out by G.I. Strips & Wires. Earth Electrodes shall be G.I. Plate type & Pipe type as per requirement. However, Transformer Neutral will be connected to G.I. Earth Electrode through Copper Strip. 03) Total Resistance of Earthing system shall be Less than one ohm. 04) Plant shall be protected against lightning according to IS 23091989.
31
k)
Cables The following consideration shall be given for Cable Sizing and Selection on Nominal Current Capacity Ambient Temperature in Air/Ground Continuous Load Current Short Circuit Withstand Capacity Voltage Drop at the Starting of Motor limited to 15% & 5% at Steady state up to motor terminals. Deration Factor due to type of Laying & Grouping. Generally Power and Control cables shall be stranded. XLPE insulated cables upto & including 4 sq.mm shall be with stranded copper conductors. Cables of 6 sq.mm & above size shall be with Al. conductor Generally Cable trays shall be prefabricated Hot Dip Galvanized Iron. Cable Trays shall be run in Vertical formation as far as possible. HV & LV Power Cables shall have separating distance of 300mm. Separating distance between Power and Control cable shall be 300mm. Instrument cables & screened shall run on perforated cable tray having 300 mm separating distance of 300 mm. The Lux Level in various indoor areas shall be as per IS. In plant areas, the lighting shall be provided as per functional requirement. HPMV Well Glass with integral control gear box fittings (IP55) shall be provided in plant areas. Industrial FL. Lamp fittings will be provided in sub station and other indoor areas. Mirror Optic fixtures shall be provided in CCR. In outdoor areas HPSV Lamp fixtures (IP 55) shall be provided. The lighting shall be catered by Main Lighting DB. LDB & SLDB connected by Al. conductor cables. The Emergency power supply from 415V DG set will be made available to lighting transformer in case of failure of power
32
1.1.6.13 Instrumentation & Control System The entire plant will be controlled by a centralized DCS with high redundancy level with inputs and controls of all loops, analyzers, control valves, motorized valves, motors, etc. The integration of all the inputs / signals for continuous monitoring, operation, data logging, data analysis, alarms, safety interlocks, annunciations etc. will be achieved through the DCS. The DCS will include the DCS control station, related licensed software & hardware, instrument & control cabling from the marshalling cabinet receiving signals from junction boxes of all cogeneration equipment, all MCCs and software links with Turbovisory panel, Woodward Governor and turbine temperature scanner. The entire cogeneration plant will be smoothly started, normally operated, provided with necessary interlocks & emergency trips, monitored, controlled and smooth shut down from the DCS. The DCS to have required software or compatibility to internet. Basic Control Design should be as below: a. b. Generator, gearbox, turbine bearing temperature monitoring shall be through the temperature scanner. Critical AI/AO/DI/DO signals will be redundant while non-critical & DAS points will be non-redundant. All controllers for critical controls will be redundant. The field inputs for critical inputs will be1/2 logics. 25% of the I/Os to be considered as critical. Sequence of event recorder will be provided Required Annunciation windows shall be included 25% spare I/Os to be considered. TG governing will be by Woodward 505E. However the critical parameters will be monitored by providing serial Modus Interface
c. d. e. f.
33
g.
All I/Os will be potential free
Plant communication shall be provided with Telephone system, Public Address System and Walkie-talkies 1.1.6.14 In-Plant Communication System The cogeneration power plant will have an EPBAX system with intercoms at all operating locations, admin building and security points. The EPBAX will have expandability and junction box to be interconnected to the EPBAX systems of the sugar, ethanol and non-plant buildings. The system will have minimum 20 extensions. The Tenderer will provide a wireless handheld walkie talkie system of Motorola / Philips make for intercommunication of all plant personnel with minimum of 15 instruments. The required battery, battery charger, centralized transmission system, etc. to be included. The system will have a frequency which will not disturb any other public or radio system. The tenderer will be responsible for obtaining the in-principle and operating license and the frequency allocation. Statutory fees, if any, will be paid by the Owner.
1.1.6.15 Civil & Structural a) Construction Specification For Rough Grading This specification covers furnishing all labour, materials and equipment, and performing the necessary work to complete the clearing, grubbing and excavating, filling, rough grading, consolidation and compacting i Clearing And Grubbing :Within the battery limits, all shrubs, stumps, vegetation and jungle, including roots, shall be removed and burned except as directed by the Owner / Architect.
34
ii
Excavation :Excavation will include earth, weathered rock and hard rock. Whenever finishing grade is referred to, it shall mean to elevations indicated on the drawings plus or minus thirty millimeters. For descriptive purposes, excavation shall be classified as follows :Earth excavation shall be defined as unconsolidated, or consolidated material which can be broken with a pick. Weathered rock shall be defined as consolidated or cemented material which can be broken with a pointed pry bar or pick. Hard rock shall be defined as competent consolidated material with few fractures that cannot be broken with a pointed pry bar and must be blasted. Ditch or channel excavation shall be defined as that excavation between the invert of the channel and the point at which the channel side slope intersects natural or finish grade, whichever is lower
iii
Filling :Filling shall consist of performing all operations necessary to place the fill to the line and grade. Filling shall be placed in layers that are not over 150 mm thick before compaction, then watered and compacted as hereinafter specified.
35
In platforms for structures, roadbeds, the top 150mm shall not contain lumps or rock of 60mm size or larger. When filling is to be placed against hillsides or existing fill, the material consists of large rock material or hard lumps which cannot be readily broken, such material shall be well distributed throughout the fill, and sufficient earth or other fine material as it is deposited, so as to fill the interstices and produce a dense compact fill. iv Watering :Watering for compacting backfill material and water required for laying dust caused by grading operations shall be applied as directed by the Owner. The water shall be applied so as to obtain the optimum moisture content for compaction. The application of water will be by a distributor equipped with a spray system that will ensure a uniform application of water. At the direction of the Owner, water may be applied to the excavation area from which the fill is obtained. v Compaction :All fill shall be compacted by road rollers, tamping rollers, or by tamping, as specified herein. All areas within the bench area of buildings marked, compaction of all roads, shall be compacted by tamping rollers and / or road rollers. The layer excluding the top layer shall be compacted by not less than four passes with the tamping roller. Before the last layer is placed the road roller shall make one pass over the area. The last layer shall then be placed and compacted with the road roller by making not less than four passes. The balance of the fill may be compacted by using air operated or hand rammers, as directed by the Owner.
36
Tamping rollers shall be a metal drum surrounded with metal studs with tamping feet projecting not less than 160mm from the surface of the drum. The tamper feet shall be arranged in rows spaced not less than 150mm, nor more than 300mm on centre. The load on each foot shall not be less than 250 pounds per square inch (17.58 kg/sq.cm.). The load per foot will be determined by dividing the roller weight by the cross-sectional area of one row of feet across the roller. Road roller shall be three wheeled and weight not less than 12 tonnes and shall produce a compression on the rear wheel of not less than 325 pounds per liner inch (60 kg per liner cm) of wheel width. Rammers shall have a base area of at least 28 square inches (182 sq. cm.). vi Weed Killer :All roadway base shall be treated with a commercial weed killer applied according to the manufacturers recommendations. vii Civil Works Requirements Scope of Work The scope of permanent works includes the construction of all earthworks associated with site levelling and embankments, mass and reinforced concrete foundations to machinery and buildings incorporating all holding down bolts and all site roads, hard-standing and drainage for the structures
37
Materials Materials used in the works shall be new and as per approved list or relevant IS standards. The Owners Representative shall have the right to reject any material that is damaged or has deteriorated and such materials shall be removed from site immediately. Branded materials shall be handled, stored and used, and processes shall be carried out strictly in accordance with the manufacturer's instructions and recommendations. The Owners Representative may require the Tenderer to obtain at his own expense a certificate in respect of any material stating that it is in accordance with the relevant Indian Standard Specification. Elevations and Benchmarks Except where otherwise specified, all elevations will be in meters above mean sea level with an accuracy of two decimals. The data for all levels will be based on Benchmarks. The Tenderer, on his own responsibility, shall ensure that the Works are constructed in relation to this data. Benchmarks and other points of reference in the vicinity of the Site may be indicated on the Drawings.
38
viii
Demolition And Site Clearance Removal of Termite Hills All termite hills shall be demolished and the surplus material removed to tip. The cavity formed by the removal of the termite hill shall be treated with the solution specified below in "TERMITE PROOFING" and then filled with approved material in the specified manner for in-filling trenches. Termite Proofing Termite Proofing shall be undertaken over the whole area of the buildings and aprons and shall consist of the application of a solution of 5 parts pentachlorophenol and 95 parts of furnace oil (by weight) well mixed together and applied by means of watering cans with fish tail spouts at a rate of 5 liters per m2. Before treatment the surface must be cleared of all rubbish and in particular scrap timber. The treatment shall be on the ground after removal of the top soil and/or soft layer before making up levels. Site Clearance The site of the works shall be cleared of all trees, bushes and vegetation. Trees and bushes shall be uprooted and raked into windrows and burnt. Holes left by stumps and roots shall be filled with suitable material and compacted as specified.
39
Mature trees required to be preserved for landscaping purposes will be indicated and marked by the Owners Representative before site clearance commences. The Tenderer shall take all necessary precautions to protect such trees from damage during all phases of the works. ix Earthworks The excavation and fillings shall be carried out in such manner and order as the Owners Representative may direct. The following definitions of the earthworks materials shall apply to this tender in which reference is made to the defined materials: 'Top Soil' shall mean the top layer of soil containing more than 5% by weight of organic matter. 'Unsuitable material' shall mean other than suitable material and shall include: (i) (ii) material from swamps, marshes or bogs; peat, logs, material; stumps and perishable
(iii)
material susceptible to spontaneous combustion; clay of liquid limit exceeding 80 and/or plasticity index exceeding 55;
(iv)
40
'Rock' shall mean material which in the opinion of the Owners Representative requires the use of wedges, pneumatic tools or blasting to enable the excavation to be completed, but specifically excludes isolated volumes of rock or other hard material of up to one cubic meter in content. Rippable soft rock' shall mean material which, in the opinion of the Owners Representative, requires the use of tractor drawn tines to break up the material. These rocks will, in general, be weathered sandstones and other sedimentary rocks. 'Ordinary ground' shall mean material which in the opinion of the Owners Representative can be excavated by normal excavation machinery.
b)
Construction Specification For Structural Excavation And Fine Grade The work covered by this specification includes furnishing all labour, materials, equipment and performing the operations necessary to complete the excavation and filling required, for all buildings; structures and foundations and the fine grading. i Excavation:The Tenderer shall perform all excavation required for the various structures and foundations. All excavation shall be to line and grade required for the proper installation and removal of the forms and to facilitate the construction. Excavation for all foundations shall be carried one meter below the floor slab for interior footing or one meter below the finished grade for wall footings and exterior footings.
41
ii
Back- Filling :After all below grade work has been completed and all debris has been removed, the excavated area shall be backfilled. The backfilled material shall be the excavated material and it shall be placed in 150 mm layers.
iii
Compaction :All backfill areas shall be well watered and well compacted by ramming as directed by the Owner.
iv
Shoring And Bracing :The Tenderer shall furnish and install all shoring, bracing and sheeting as required to adequately support the excavation and to provide safety for the personnel. This shoring shall be removed as the backfilling takes place.
Fine Grade :The Tenderer shall furnish and install the sand or gravel sub grade below the floor slabs. This sub grade shall be levelled and compacted. Exterior fine grade will include cutting, filling and compacting.
vi
Earthworks Where the excavation reveals a combination of suitable and unsuitable materials the Tenderer shall, unless otherwise agreed by the Owners Representative, carry out the excavation in such a manner that suitable materials are excavated separately for use in the Works without contamination by the unsuitable materials.
42
The Tenderer shall dispose of excavated materials in such a manner and, at such time, as instructions provided by the Owner vii Limits Of Excavation The excavation shall be carried out to the required lines, levels, widths and depths. Before commencing any excavation the Tenderer must satisfy himself as to the accuracy of the levels shown and bring to the notice of the Owners Representative any discrepancies. Excavations shall be suitably trimmed and leveled before oversite concrete is placed. In locations where the material is subject to softening, a bottom layer of soil approximately 75 mm thick shall be left in and removed immediately before the placing of concrete. In the event of over-excavation, the area shall be filled with selected excavated material or Grade 10 concrete. viii Protection Of Excavations The faces of excavations shall be retained with sheeting, timbering, strutting and shoring as necessary to protect the workmen and to prevent damage to adjacent services and structures. If, in the opinion of the Owners Representative, sufficient support of the excavation is not being provided and the work is dangerous to workmen or property or to permanent work, the Owners Representative may suspend operations until sufficient timbering or sheeting is provided.
43
The Tenderer must take every precaution against slips or falls and should any occur he shall remove the surplus as required by the Owners Representative. All necessary temporary drains and culverts shall be constructed to keep the site free of water. Trenches and excavations shall be kept free of surface water by pumping or other means. ix Approval Of Bottoms Of Excavation The Tenderer shall report to the Owners Representative, at least 24 hours before concreting is required, when suitable bottoms to the excavations have been reached. Any further work executed before the excavations have been inspected and approved shall, if required by the Owners Representative, be removed and new work substituted after the excavations have been approved, at the Tenderer's expense. x Infilling Of Channels, Trenches And Pipes When no longer required, all temporary channels, trenches or pipes which it may have been necessary to construct in or under the permanent work shall be filled with suitable material, approved by the Owners Representative. Infilling shall be performed in layers not exceeding 300 mm thick and each layer thoroughly compacted to the satisfaction of the Owners Representative. xi Blasting The Tenderer shall store explosives, if required, in a store or magazine provided with separate compartments for detonators. Explosives shall be handled by experienced and competent shot firers.
44
The Tenderer shall ensure that there is no unauthorized issue or improper use of explosives brought on the Site. Explosives shall be used in the quantities and manner recommended by manufacturers. The written permission of the Owners Representative shall be obtained for each location or series of locations where the Tenderer wishes to use explosives. xii Filling By Embankments Suitable material arising from excavations shall be used where possible for filling on the Site, unless otherwise specified or required by the Owners Representative. Where insufficient suitable material is available from excavations approved suitable material from borrow areas may be used. Borrow areas within the Site will be those areas specifically designated as such by the Owners Representative. Sand for filling, in making up levels, etc. shall be naturally occurring sand, or sand prepared by crushing natural stone. The compaction achieved in filling will be measured by the following tests, carried out in accordance with Indian Standards 'Methods of Testing Soil for Civil Engineering Purposes'. Density-Moisture Tests Density Tests
45
The moisture content of the fill materials shall be adjusted as necessary to achieve the required compaction. The minimum relative compaction to be achieved in the compacted areas shall be 100% of maximum dry density as measured above. Any material which, after repeated compaction, does not achieve this figure will be removed. Filling in areas on which no roads, structures or services are to be constructed shall be spread in layers not thicker than 100 mm and subjected to as much traffic as possible during construction. At the end of each day, the surface shall not be left with areas that can retain water and, if necessary, ditches shall be cut to ensure that this object is attained. When the state of the weather is such that, in the opinion of the Owners Representative, it would adversely affect the placing of compacted fill, all such work shall be stopped. All filling material, whether placed and/or compacted or awaiting placing and/or compaction which, in the opinion of the Owners Representative, does not comply with the specification or has been damaged by weather or in any other way. xiii Frequency Of Compaction Test Each layer shall be compacted satisfactorily before proceeding with the next layer, with a maximum thickness of 200 mm per layer.
46
xiv
Surplus Excavated Material The disposal of excavated material shall be carried out as required by the Owners Representative. All surplus excavated material, where so required, shall be removed and transported to a tip. The location of such tip will be specifically designated by the Owners Representative, within the overall Site or without.
xv
Hard Core Hard core shall be sound approved uniformly graded stone of maximum size 150 mm.
xvi
Clay For Lining Clay used for impervious lining shall be excavated from borrow pits on site as required by the Owners Representative. The location of borrow pits will be determined by the Owners Representative on site during the progress of work. The maximum haul distance from borrow pits to areas requiring lining shall not exceed 4,000 meters.
xvii
Compaction Of Clay For Lining Materials for impervious linings shall be deposited in uniform layers, not exceeding 150 mm. The material shall be compacted so that it is homogeneous and free from lenses, pockets, streaks or other imperfections. Each layer shall be compacted using a 'sheepsfoot' roller of sufficient weight for proper compaction, by hand or power tampers or by other means and equipment approved by the Owners Representative.
47
The dry density of the soil fraction in the compacted material shall not be less than 95 per cent of the laboratory standard maximum soil density (dry) as determined by Test as specified. If the water content is less than that required for optimum compaction, water shall be added either at the site of excavation or at site of compaction as necessary. If the water content is more than that required for optimum compaction the material shall be rejected for use or compaction shall be delayed until such time as the material has dried out to the optimum water content. xviii Stone Pitching Stone pitching shall be of sound, durable, crushed rock or natural stone as approved by the Owners Representative and shall be uniformly sized between 100 mm minimum dimension to 150 mm maximum dimension. The stone shall be hand placed in a single layer and bedded on a uniform surface of approved excavated material to give a uniform finished surface with maximum opening between contiguous stones of 25 mm. Stone pitching shall be pointed with a mortar of 3 parts sand to 1 part cement. xix Rip-Rap Rip-rap shall be of sound, durable, crushed rock or natural stone as approved by the Owners Representative and shall be uniformly sized at 200 mm nominal maximum dimension.
48
The stone shall be placed and spread to produce the minimum finished thickness with a uniform finished surface. xx Seeding The ground shall first be rotovated to a depth of 300 mm, leveled and raked free of stones. Prior to sowing, the ground shall be well watered and seed then spread at the rate of 1 kilogram per 20 square meters. Seed will be covered by raking and the ground consolidated with a light roller.
The area will be watered daily by the Tenderer until the site has been accepted by the Owners Representative.
c)
Construction Specification For Concrete The work covered by this specification includes furnishing all labour, materials, equipment and performing the operations necessary to complete the concrete work. The Tenderer has to prepare the working drawing alongwith the bar bending schedule in detail alongwith the form drawings from the R.C.C. drawing and shall get approved the same, prior taking up the actual work activities at site. i Applicable Publications :All work shall be in accordance with the latest revision of the Indian Standard except where specifically noted otherwise : Plain and Reinforced Concrete Cement Aggregates Structural Safety Testing of Concrete I.S. 456 I.S. 269 I.S. 383 I.S. 875 I.S. 516
49
Sampling Compaction Rapid Hardening Cement Admixtures ii Materials :Cement
I.S. 1199 I.S. 2505 I.S. 8041 I.S. 9103
I.S. 2506 I.S. 2645
Cement shall be ordinary portland cement conforming to I.S.269. All cement used in exposed concrete faces of the structure shall be of the same manufacturer. All cement shall be suitably protected from exposure to moisture until used. Special cement, if any, shall be used only after the approval of the Owner/Architect. Coarse Aggregate Coarse Aggregate shall consist of approved sound crushed rock or gravel. It shall be free of organic matter or other deleterious material. Adequate supplies of coarse aggregate shall be stockpiled sufficiently in advance of construction to permit sampling and testing before use. Fine Aggregate Fine Aggregate shall consist of approved natural sand, or crushed stone screenings combination of both;and shall be hard and durable. It shall be free of organic matter or other deleterious material. Adequate supplies of aggregate shall be stockpiled sufficiently in advance of construction to permit sampling and testing before use.
50
Water Water shall be clean, fresh and free from organic or deleterious matter in solution or in suspension, and shall be added in such amount that may not impair the strength of concrete as specified. Water, for mixing concrete, shall be supplied by the Owner, if available at site, otherwise Tenderer has to make his own arrangement for the construction water requirement. For all purpose, the Tenderer shall arrange his own supply, storage and necessary pumping and conveyance system. Forms Forms shall be of wood or metal, approved by the Owner/Architect. Admixtures The use of admixtures is encouraged where a sound technical reason justifies it, but with the approval of the Architect/Owner. Water stops Water stops may be either rubber or copper. Copper water stops shall be 24 guage material.
51
Expansion joint filler Expansion joint filler material shall consist of formed strips of a durable resilient compound. Where stiffness is lacking in proformed expansion joint filler, the strips shall be encased in saturated felt, asphalt impregnated cotton webbing or other satisfactory material. Any material used for encasement shall be firmly sealed to the body of the joint filler and shall not become detached there-from after immersion in water for a period of 48 hours. Expansion joint filler material shall be manufactured in a workman-like manner and when 10 percent or more of any lot or shipment is of non-uniform or improper construction, the entire lot or shipment may be rejected. iii Concrete Design Mix And Strength :Unless otherwise noted on the drawings, all concrete shall be proportioned so as to obtain a twenty eight (28) days cube compressive design strength of 200 kg/cm2 at preliminary test. The grade of concrete shall be M:15 (1:2:4 approximately) / M:20 (1:11/2:3) or as specified. The design mix shall be prepared by an established testing laboratory and submitted by the Tenderer to the Architect / Owner for approval before use. iv Grading Of Aggregates :Aggregate shall be furnished in primary sizes specified herein and shall be stored in separate batching. Bins and batched as required to confirm to the combined grading requirements. The proportioning of the fine and coarse aggregate may be varied as directed by the Engineer to produce a workable mixture.
52
The maximum size of aggregate shall be controlled by the purpose for which the concrete is intended and in accordance with the following table. Location Maximum Size Coarse Aggregate Massive Foundations 2 inch (63mm) Typical Foundations 1 inch (38mm) Columns, Beams and Girders 1 inch (25mm) Walls 8 inch (200mm) and thicker 1 inch (38mm) Walls 6 inch (150mm) and thinner inch (18mm) Slab at grade thicker than 4 inch 1 inch (25mm) (100mm) Slab at grade 4 inch (100mm) thick inch (18mm Structural slabs inch (18mm)
The grading of aggregates shall be as follows : SIEVES Primary 2 Inch 3 100 2 90-100 2 35-100 1 0-15 1 0-10 0-5 3/8 No.4 No.8 No.16 No.30 No.50 No.100 No.200 Aggregate Size 1 Inch Inch PERCENTAGE PASSING SIEVES Combined Aggregate Sizes Fine 2 max 1 max max 100 95-100 80-85 100 65-85 95-100 50-75 50-80 100 45-65 45-75 90-100 100 35-55 35-60 60-80 95-100 30-45 30-45 40-60 80-85 20-35 20-35 30-45 50-85 15-30 15-30 20-35 25-60 10-15 10-15 10-25 10-30 5-10 5-10 5-15 2-10 0-3 0-3 0-5 0-2 0-2 0-2 0-2
100 95-100 55-85 35-70 10-30 0-5
100 90-100 20-55 0-10 0-5
53
Storage Of Aggregates :Aggregates shall be stored or stockpiled in such a manner that separation of coarse and fine particles of each size will be avoided and also that various sizes will not become intermixed before proportioning. Aggregate in storage shall be adequately protected from dust or other foreign matter and all aggregates, which have become coated with dust or foreign material to such an extent as the Engineer may determine, has impaired the quality of the aggregates, shall be washed or rejected as the Engineer may decide In placing materials in storage or moving them from storage to the mixer, any method which may cause segregation, degradation, or combining of materials of different grading, shall be discontinued and the materials so handled shall be reprocessed.
vi
Mixing Of Concrete :Machine Mixing : All concrete shall be mixed in batch mixers of approved type except where hand mixing is specifically approved by the Engineer. The capacity of the mixer shall be considered to be rated capacity as given in the manufacturer's catalogue, provided that a quantity equal to the rated capacity can be thoroughly mixed in the prescribed time period and further, provided there is no loss of ingredients during the mixing. Each batch shall be mixed not less than two minutes after all the ingredients are in the mixer and until the mass is uniform and homogeneous. The mixer shall be completely discharged before being recharged. The peripheral speed of the concrete mixer drum shall be approximately 60 m/minute.
54
Hand Mixing : Where specifically approved by the Engineer, hand mixed concrete may be made in batches of not more than one cement bag and shall be mixed in a watertight mixing boat placed in a level position. The coarse aggregate shall be placed in the boat and the fine aggregate shall be sprayed on this layer, the two layers together not being more than 300 mm in depth. On this mixture shall be placed the cement and the whole mass turned not less than two times dry; then the whole mass shall be sprinkled with sufficient water evenly distributed, and again turned not less than three times or until uniform consistency is obtained. vii Amount Of Water And Slump Tests :The amount of water added at the mixer shall be in accordance with the design mix and shall be regulated in accordance with the free water in the aggregates and the requirements for workability within the limits of slump test forth. The amount of water, including the free-water in the aggregates, shall not exceed 25 litres per sack of Cement. The equipment for measuring and supplying the water to the mixer shall be so constructed and arranged that the amount of water to be added to the mixture can be measured positively, and the predetermined quantity of water required can be discharged rapidly in one operation. The equipment shall be so designed that water from the source of supply cannot enter the measuring tank while the water is being discharged from the measuring tank into the mixer.
55
Location Of Concrete Slump Heavy sections & foundations 2-3 inches (50mm to 75mm) Thin sections 8" and under. 3 inches (75mm) Slabs at grade 3-4 inches (75mm to 100mm) Structural slabs. 3 inches (75mm) All slumps are to be plus or minus 12mm. Slump test shall use the procedure of I.S.- 456. Slump test will be made by the Tenderer in presence of the Engineer/Architect. viii Form :The forms shall be smooth, true to line and grade and of sufficient strength to resist any appreciable springing out of shape during the placing of concrete. All dirt, chips, saw dust, tie wire, or other foreign matter shall be removed from the forms before any concrete is placed therein. Before concrete is deposited in the forms, all inside surfaces of the forms shall be coated with an approved form oil. The form oil shall be of high penetrating quality leaving no film on the surface of the forms that can be absorbed by the concrete. All sharp corners above grade shall be chamfered with 1"x1" (25mm x 25mm) triangular fillets. The fillets or chamfer strips shall be surfaced on all sides. Forms shall be of sufficient strength to carry the lean weight of the concrete as a liquid without any deflection. Forms for beams, girders and slabs shall be cambered such amount as may be directed.
56
Form ties shall be approved form clamps or bolts to fasten the forms. The use of twisted wire-loops to hold the forms in placing during concreting will not be allowed. Bolts or clamps shall be positive in action and shall be of sufficient strength to prevent spreading out of the forms. They shall be of such type that can be entirely removed or cut back 25mm below the concrete surface. All forms for side of members shall be constructed with stiff wales at right angle to the studs and all form clamps shall extend through and fasten such wales. Plans of false work and centering shall be submitted to the Owner/Architect two weeks in advance of the time, the Tenderer begins construction of the false work. All false work and centering shall be designed and constructed to provide the necessary rigidity and to support the loads. All false work shall be adequately braced. The forms and false work shall not be removed or released before the concrete has obtained sufficient strength to support itself, but in no case less than the following time, shall the forms remain in place:--------------------------------------------------------------------LOCATIONS. TIME --------------------------------------------------------------------Sides of footing 24 hours Mass footings 3 days Columns 3 days Walls 5 days Sides of beams or girders 5 days Soffits of beams or girders 21 days Structural slabs 14 days --------------------------------------------------------------------At time of low temperature or other adverse conditions, the Owner may increase the setting time to 28 days.
57
Removal of forms shall be in such a manner as to not damage the concrete. Centering shall be removed uniformly and gradually starting at the middle of a span and working towards the support. ix Concrete Coverage Of Reinforcing :The concrete coverage of reinforcing steel shall be as follows, except, as specifically noted otherwise on the drawing. ---------------------------------------------------------------------------LOCATION COVERAGE ---------------------------------------------------------------------------Footing poured against earth 3 inches (75mm) Footing poured against forms 2 inches (50mm) Formed concrete against earth 2 inches (50mm) Columns 2 inches (50mm) Beams and Girders :Bottom of beams Sides of beams Tops of beams
2 inches (50mm) 2 inches (50mm) 1 inches (38mm)
Structural Slabs :Bottom 1 inch (25mm) Tops 1 inch (25mm) ------------------------------------------------------------------------------
58
Waterstops :Waterstops shall be accurately located and secured against displacement during the placing of concrete. For rubber water stops, all field splices shall be fullvulcanised, shall be bevelled at 45 degree or flatter. All finished splices shall have a tensile strength of not less than 50 percent of the un-spliced material. For copper water stops, all splices be lapped 25 mm and soldered each side of the joint to form a smooth watertight joint.
xi
Expansion Joint Filler :Expansion joint filler shall be placed true to line and grade and shall be placed full depth of slab or width of wall. It shall be securely held in place by cementing to the oldest concrete, at the joint, with a bitumastic cement. The ends will be butted tight. Expansion Joints In Buildings Where shown, expansion joints shall be formed between the concrete faces, or between concrete and brick work or blockwork, by means of incorporating in the formwork an approved impregnated fibre-board filler. The exposed edges of expansion joints shall be sealed. Filler boards shall be adequately wired into adjoining concrete to prevent their falling out when the joint opens. In-situ ground floor slabs on hardcore shall be cast in bays but not exceeding 140 mm in area. The layout of construction joints in the slab shall be approved in advance. The mesh reinforcement shall be so arranged that no laps shall occur along the joints.
59
xii
Placing Concrete :Before placing concrete, all form work, reinforcing embedded items, end etc. will be checked for completeness and location. Concrete shall be placed only upon the issue of an approved pour slip from Engineer-In-Charge/Architect. Concrete shall be transported to the forms and shall be placed at location without segregation of its ingredients and before it has taken its initial set. Concrete shall be placed as nearly as possible in its final position. In walls, concrete shall be placed in horizontal layers, between pour joints of such depth that it may be adequately vibrated. Before concrete is placed in beams, girders, or caps of beams, columns, the concrete in the column shall have been in place at-least two hours. With the exception of sidewalk, curbs, gutters and concrete placed on a slope at grade, all concrete shall be compacted with high speed internal vibrators of a type and size approved by the Owner. The number of vibrators employed shall be adequate to consolidate incoming concrete within 15 minutes after it is deposited in place. In all pours there shall be at least one vibrator as standby in addition to those required for consolidation of the concrete. The location, application and duration of vibrating shall be sufficient to secure a minimum consolidation of the concrete. free of voids and a proper texture to exposed surfaces. No concrete will be allowed to fall from a height of more than two meters without the use of adjustable length pipes or "Elephant-Trunks".
60
The use of chutes in conveying or placing concrete will be allowed only at the discretion of the Owner and when used shall be laid on such. No concrete shall be placed when the ambient temperature is 95 degree F (35 Degree Centigrade) and rising, nor when the ambient temperatures is below 50 degree F (10 Degree Centigrade) and Falling. Transportation Of Concrete The concrete shall be discharged from the mixer and transported to the Works by means that shall be approved by the Owners Representative and which shall prevent adulteration, segregation or loss of ingredients, and ensure that the concrete is of the required workability at the point and time of placing. Mixed concrete shall not be modified by the addition of extra water or cement or otherwise, in order to facilitate handling or for any other purpose. Additives to improve workability may be added only with prior approval. When the concrete will be carried in purpose made agitators, operating continuously, or truck mixers, the concrete shall be compacted and in its final position within 2 hours of the introduction of cement to the aggregates, unless a longer time is agreed by the Owners Representative. The time of such introduction shall be recorded on the delivery note together with the weight of the constituents of each mix.
61
When truck mixed concrete is used, water shall be added under supervision either at the site or at the central batching plant as agreed by the Owners Representative, but in no circumstances shall water be added in transit. Unless otherwise agreed by the Owners Representative, truck mixer units and their mixing and discharge performance shall comply with the requirements of Indian Standards. Mixing shall continue for the number and rate of revolutions recommended in accordance with Indian Standards or, in the absence of the manufacturer's instructions, mixing shall continue for not less than 100 revolutions at a rate of not less than 7 revolutions per minute. xiii Bonding :Construction joints shall only be located where shown on the drawings or on the Tenderer's approved pouring schedule. Joints at stoppage of work shall be horizontal in walls and columns and in general be at the tops and bottoms of sections or stories. After the pour is completed to the construction joints, and before the concrete has taken its permanent set. the entire surface of the joint shall be thoroughly cleaned of laitance. Clean aggregate shall be exposed by wire brushing and washing with water. The joint shall be level across the section. Sloping joints will not be permitted. Before placing new concrete against a construction joint in a wall, beam, girder or structural slabs, the joint shall be wetted and splashed with sandpaste.
62
xiv
Finishing :Concrete in slabs shall be thoroughly tamped and struck to grade by a strike-board operating between the headers or screeds. It shall then be floated to a smooth surface and trowelled to raise the fines to the surface. When the concrete is firm enough to support the weight of a man, without marking the slab, it shall again be steel trowelled to a hard dense surface. Topping layers or dashing cement on the surface will not be allowed. Non-slip finish for slabs such as at ramps, shall be made by brushing the surface with a stiff bristle broom after the first steel trowelling and in lieu of the second step trowel operated.
xv
Curing :All concrete shall be kept wet by the continuous application of water, for a period of seven days. Walls, beams, girders and columns may be cured by wetting the forms. In the event the forms are removed, burlap shall be used to cover the surface, and this shall be kept continuously wet. Slabs shall be cured by applying water from a nozzle that automizes the flow so that a mist and not a spray is formed, until the slab is covered by the curing medium. The moisture shall not be applied under pressure directly upon the concrete and shall not be allowed to accumulate on the surface in a quantity sufficient to cause a flow or to wash the surface. After the surface is sufficiently hard not to mark it, shall be covered with at least a 50 mm depth of sand or earth blanket. This blanket shall be continuously watered and kept saturated for a period of seven days.
63
xvi
Repairs And Patching :As soon as the forms are removed from vertical surfaces all fines and projections shall be removed. All rock pockets from bolt holes and other voids shall be filled and patched. The voids shall be thoroughly cleaned, dashed with water and then filled with a mixture composed of one part cement and two parts sand by volume, and sufficient, water to make a homogenous mixture. Care shall be exercised to completely fill the void, and to obtain a perfect bond with the concrete. Where in the opinion of the Owner the work cannot be adequately repaired, that section shall be removed and replaced at the Tenderer's expense.
xvii
Test Cubes :From each pour of 25 cubic meters or as per the direction of the Owner, cubes shall be taken. The first cube shall be broken at the age of seven days and should indicate approximately 70% of the design strength. The second cube shall be broken at the age of 28 days and should indicate the design strength, specified. If the second cube indicates the design strength, third cube shall be disposed off. If the second cube does not indicate the design strength the third cube shall be tested. If the average strength of the second and third cubes indicate a strength of 90% of the design strength, the concrete shall be assumed to meet this specification. If the average strength of the second and third cube does not reach 90% of the design strength, the concrete shall be declared defective and shall be removed and replaced at the Tenderer's expense.
64
Before removal of the concrete under the conditions of the preceding paragraph, the Tenderer may elect, at his own expense, to core the section. If the section in question is eight inches (200mm) or more in thickness, two cores shall be taken, and sawed in half to give four sample cores. If the section is less than eight inches (200mm) four cores shall be taken. If the average compressive strength of the cores, adjusted for high ratio, indicate the compressive strength of the section equals 90% of the design strength, the questioned section shall then be judged to comply with these specifications and if it does not indicate an average strength of 90% of the design strength, the Tenderer shall then remove the defective concrete and replace it at his own expense. Cube shall be taken in accordance with I.S. 456 except that in all cases, rodding must be done and vibration will not be permitted. The cost of taking and breaking the cubes shall be borne by the Tenderer. xviii Drypack :Dry pack shall be composed of one part cement, one and one-half parts sand and sufficient water to make a stiff paste. Dry pack shall be placed by ramming into position with a metal ram. Curing of dry pack shall be by covering with burlap and keeping the burlap continuously wet for 7 days.
65
xix
Grout :Plastic grout shall be composed of one part cement and one-and-one half part of sand to which shall be added 4.75 imperial gallons (22 litres) of water per sack of cement. Flowable grout shall be composed of one part cement, one-and-one-half parts sand to which shall be added 4.75 imperial gallons (22 litres) of water per sack of cement. Curing of grout shall be by covering with burlap and keeping the burlap continuously wet for three days.
xx
Non-Shrink Grout :Plastic non-shrink grout shall be composed of one part portland cement, one part sand and one part Embeco or Cico no.3 or equivalent approved to which shall be added 3.9 imperial gallons (18 litres) of water per sack of cement. Flowable non-shrink grout shall be composed of one part portland cement, one part sand and one part Embeco or Cico or equivalent approved to which shall be added 4.25 imperial gallons (20 litres) of water per sack of cement. No more non-shrink grout shall be mixed than can be placed in 20 minutes. Retempering of non-shrink grout shall not be permitted. Curing of non-shrink grout shall be by covering with burlap and keeping burlap continuously wet for three days.
66
Commercial non-shrink grout as marketed by various manufacturers can be allowed, after the approval to the same from the Architect / Owner, and shall be used as per the manufacturers instructions and specifications. Concrete shall not be placed in standing or running water unless so specified or approved. xxi Concrete Lining For Canals The sub grade of the canal profile shall be thoroughly wetted before placement of concrete. xxii Construction Joints Concreting shall be carried out continuously up to construction joints. When work has to be resumed on a surface which has set, the whole surface shall be thoroughly roughened. It shall be cleaned of all loose and foreign matter and laitance, washed with water and all free water removed immediately before placing the fresh concrete, which shall be well compacted against the joint. xxiii Special Measures For Hot Weather Working Mixing - In hot weather suitable means shall be provided to shield the aggregate stockpiles from the direct rays of the sun or to cool the aggregates by spraying with water and to insulate the mixing-water tank and pipelines to ensure that the temperature of the concrete when deposited shall not exceed 32oC (90oF).
67
Placing - In hot dry weather suitable means shall be provided to avoid premature stiffening of concrete placed in contact with hot dry surfaces. Where necessary the surfaces, including reinforcement, against which concrete is to be placed shall be shielded from the direct rays of the sun and shall be sprayed with water to prevent excessive absorption by the surfaces of water from the fresh concrete. xxiv Building In Pipes, Bolts, Etc. Pipes and pipe specials through concrete walls and floors shall as far as possible be positioned and built in during construction. They shall be true to line and level. The Tenderer shall take particular care to ensure that fully compacted concrete is in contact with the pipe at all points. Where it is impracticable to cast pipes and specials in the concrete, box holes shall be formed in the shuttering. The box shall have six or eight sides, depending on the pipe diameter, and shall be no larger in size than will give adequate clearance for the subsequent positioning and grouting in of the pipe. The sides of the hole shall be provided with a tapered central annual recess to provide a positive key. The box hole shall be stripped with the main shuttering and the concrete surface thoroughly cleaned and roughened. When the pipe is later fixed, the hole shall be re-shuttered and filled with approved expanding grouting material. Holding down bolts shall be fitted with expanded metal cones, positioned and built in during construction. The bolts shall be fixed in the precise position using an approved expanding grouting material.
68
xxv
Precast Concrete Precast concrete - general Precast concrete shall be cast in properly made strong moulds to form shapes required. For work described as "fairface" the mould shall be lined with sheet metal or other approved material. Surfaces against which insitu concrete mortar or grout is to be placed, shall be prepared as soon as possible after casting by spraying with a fine water spray or brushing with a stiff brush, just sufficient to remove the other mortar skins and expose the large aggregate without disturbing it. Lifting links, pockets or sockets that may be considered necessary for erection shall be subjected to prior approval and shall be so constructed and positioned as to be invisible after construction is complete. Precast concrete shall be concrete Class 25 as described and shall be thoroughly compacted by vibration in the moulds and shall not be removed from them until seven days after placing the concrete. The sides may be removed after three days provided that the moulds are such that the sides are easily removable without damaging the concrete. The precast work shall be cast under sheds and shall remain there for seven days in the moulds and a further seven days after removal from the moulds. During the whole of this period the concrete shall be shielded by sacking or other approved material kept wet. It shall then be removed from the sheds and stacked in the open for at least seven days to season.
69
Precast work shall be cast in lengths convenient for handling unless otherwise required. The precast units shall have adequate strength to resist overstressing and damage during handling and erection. Care shall be taken to ensure that the units are not chipped or damaged. Testing of precast concrete units Load testing to destruction shall be carried out in 1% of all precast units. Units for routine testing shall be taken at random and those units destroyed shall be immediately replaced. Erection of precast units Precast units shall be hoisted and placed in proper position in such a way as to avoid overstressing or damaging the units or causing damage to previously erected structure. Where shown, the units shall be laid on a thin bed of cement in order to even out irregularities of supporting members. Steps necessary, such as taping of joints shall be taken to prevent escape of grout which lead to staining of brick and block works and exposed concrete surfaces when the insitu topping is laid. Precast members shall be held rigidly in position during placing of insitu concrete. Holes in precast units Examine architectural, structural and services drawings to determine dimension and location of holes.
70
Permission to form holes in precast units after casting shall not normally be given, but in exceptional cases where the structural soundness of the perforated unit and its visual acceptability is satisfactory such permission may be given in writing. Marking Precast units shall be clearly marked after casting or demolding, showing the identification of the unit and, if necessary, erection instructions. The marking is to be such as to be invisible after erection. Samples Samples of precast units, before fabrication in bulk specimen samples of the precast units shall be submitted for approval, with which further deliveries or casting shall be compared for uniformity of color and finish. d) Construction Specification For Reinforcing Steel The work covered by this specification includes furnishing all labour, material and equipment and performing the operation necessary to complete the reinforcing work for concrete and masonry. If demanded by the Owner, the Tenderer shall produce manufacturer's test certificate for steel procured and proposed to be put in the work. i Applicable Publication :All work shall be in accordance with the latest revision of the standards except where specifically noted otherwise. Tor steel I.S. 1786 Reinforcing steel I.S. 432 Welded steel wire Fabric A. S. T. M. A. 185, I.S. 1566
71
Fixing of Reinforcement ii Materials :-
I.S.
2502
Reinforcing shall be made from new billet steel conforming to I.S. 432, of tested quality, No re-rolled material shall be allowed. Welded steel wire fabric shall conform to A.S.T.M.A. 185 or I.S. 1566. Reinforcing tie wire shall be annealed wire of 14 or 16 gauge. Cold work deformed bars conforming to I.S. 1786 and hot rolled variety conforming to I.S. 1139. iii Steel Lists And Placing Diagrams :Two copies of all reinforcing lists and placing diagrams shall be furnished to the Owner before any fabrication of reinforcing is done. The list and diagram will be reviewed for design only and one corrected or approved copy will be returned to the Tenderer. iv Cleaning :Reinforcing steel, before being placed in the forms, shall be thoroughly cleaned of scale and rust, mortar, oil, dirt or coatings of any character that would destroy or reduce bond, and it shall be maintained in this condition untill the concrete is placed.
72
Bending :Reinforcing steel shall not be bent or straightened in a manner that will injure the material. Bars with bends or kinks not shown on the drawings shall not be used. Bends for stirrups and ties shall be made around a pin having a diameter of not less than two times the thickness of the bar. Bends for other bars, shall be made around a pin having a diameter larger than 25 mm where the pin shall not be less than eight times the bar diameter. All bars shall be bent cold.
vi
Placing :Reinforcing steel shall be accurately placed and secured and shall be supported by chair, spacers, or hangers. Reinforcing steel shall be securely held in position by wiring at inter-sections with annealed wire of 14 or 16 gauge. Placing bars on fresh concrete as the work progresses and adjusting bars during the placing of concrete will not be permitted. The minimum clear distance between parallel bars, except in columns, shall be either the diameter of the bar, 25 mm or one and one third times the maximum coarse aggregate whichever is greater. Cover of concrete over reinforcing steel shall be as specified in this tender document All dowels shall be accurately placed with a lap length of 40 bar diameter extending across the joints. Vertical reinforcing for masonry shall be held in place with a frame like device until the masonry is in place. Horizontal reinforcing may be placed as the masonry progresses.
73
Welded steel - fabric shall be rolled flat before placing concrete. Wire fabric shall be positioned and held against vertical or horizontal movement by devices. If during placing it is found that the mesh is being displaced, the Tenderer shall provide means of pulling mesh into the proper position while the concrete is being placed. Polythene covers or suitable covers available in the market shall be used. Splices in reinforcement in slabs, beams, girders, shall not be made, at points of maximum stress. Splices where permitted shall be lapped a sufficient length so as to develop the bar in bond but not less than 40 bar diameter. In such splices the bars shall be wired together. Splices in reinforcement in columns where change in column cross section occurs shall be spliced in a region where lateral support is afforded. Where offset, the slope of the inclined portion of the bars shall not be more than one in six, and in tied columns the ties shall be spaced at 75mm on centre for a distance of 30 cms. below the actual point of offset. Splices in welded steel wire fabric shall be by lapping one mesh length. The test reports of the various lots supplied at site, as directed by the Engineer at site, shall be obtained from time to time, after getting the sample tested from the approved laboratory as directed by the Owner, at the cost of the Tenderer. e) Construction Specification For Structural Steel The work covered by this specification includes furnishing all labour, materials, equipment and performing the operations necessary to complete the structural steel work
74
The Tenderer has to prepare the shop drawing from the structural drawing and the shop drawing shall be got approved prior taking up the Fabrication work from the Architect / Owner. i Applicable Publications :All work shall be in accordance with the latest revision of the Indian Standards except where specifically noted otherwise. Structural Steel Structural Safety Structural Safety ii Materials :All materials shall be new and tested quality, Necessary test certificate from manufactures, from whom materials are procured shall conform to the following :Structural steel shall conform to I.S. 226 and shall be of tested quality. Rivets shall conform to I.S. 1148. I.S. 800, I.S. 226 I.S. 806 & 1161 I.S. 875
Welding electrodes shall conform to I.S. 814 Electrodes for general welding shall be I.S. Code M 317443. Low Hydrogen Electrodes shall be I.S. Code M 615499. All low Hydrogen electrodes shall be delivered in hermetically sealed containers until used and after the containers are opened, shall be maintained at a minimum moisture-content in an oven.
75
All bolts and nuts shall conform to I.S. 1608. Washers shall conform to I.S. 226. Structural Tubes shall be yst 22 grade finished welded and tested quality with minimum wall thickness of 3.25 mm unless otherwise mentioned and shall conform to I.S. 806 and I.S. 1161 Paint Shop coat shall be one coat Red lead and oil or Zinc chromate Noble Chrome Prime or equal, GHD shall confirm to I.S. 2074 Field coat except as noted shall be two coats of Noble Iron coat or equal. Acid Resistant paints shall be Noble chlorcote or equal. iii Fabrication And Shop Assembly :Before being fabricated or worked in any manner, all material shall be straightened, by method which do not damage the steel, and all rust and scale shall be removed. After working, all twists or bends shall be removed before parts are assembled. All members and section shall be closely fitted and finished true to line. Joints between columns and base or cap plates shall have the contact faces milled to a true surface and shall be rigidly held in position while fastening together. All necessary accessories such as fixtures, fittings, connections, shall confirm to the relevant specifications of I.S. 730
76
iv
Welding :All welding shall be done by the Electric Arc welding process, and shall confirm to I.S. 816.
Riveting :All riveted members shall be accurately held in place during the riveting operation. All rivets shall be properly heated and when driven shall completely fill the hole. Drifting of unfare holes will not be permitted.
vi
Bolting :All bolted members shall be accurately held in place during the bolting operation. Drifting of unfair holes will not be permitted. On sloped connections bevel washer shall be used to ensure satisfactory bearing under bolt heads and nuts.
vii
Erection :All members shall be erected plumb, square and true to the line and grade and in the precise position as indicated. Temporary guys, shores and bracings shall be installed where necessary and shall be capable of sustaining all loads which occur during erection. Temporary guys, shores and bracings shall remain in place as long as necessary to safeguard the structure. As erection progresses, the work shall be bolted up as required to maintain the structure in proper position during erection and to sustain all loads during erection. After the structure is properly aligned, plumbed and levelled, all field connections shall be made.
77
Each column base plate shall be accurately set with proper alignment and shall be plumbed at the proper height. The base plate shall be held accurately in position with either levelling nuts or steel shims. Except as specifically called for, levelling plates will not be permitted. The erection of all members shall be carried out in proper sequence with the work of other trades, and shall be anchored to other materials in conformance with the details. viii Painting :After fabrication all steel shall be thoroughly cleaned of scale, grease, oil, dirt or other foreign matter and all surfaces, except those to be embedded in concrete or masonry, shall be given a shop coat of the specified primer to a dried thickness of 0.06 mm. The paint shall not be applied until all surfaces to be covered are clean and thoroughly dry. It shall be worked into all joints and angles and shall cover all surfaces. This coat shall be completely dry before being loaded for delivery. After erection, all field connections, and abrasions shall be cleaned and given a touch-up coat of primer and the either work shall be left in a neat and acceptable condition to receive the field coat of paint. After the touch-up coat is thoroughly dry and all surfaces are clean, the field coats shall be applied to all surface not encased in concrete or masonry. Each field coat shall have a dried coat thickness of 0.05mm. Colours of field coat will be selected from standard Manufacturer's colours, and shall be approved by the Architect.
78
ix
Fencing Materials Materials for fencing and gates shall conform to the following requirements: (a) Chain link intermediate and straining T posts shall conform to the requirements of I.S. Gate posts and frames shall conform to the Indian Standards. Bracing bars shall requirements of I.S. conform to the
(b)
(c)
(d) Concrete for fencing and gate posts shall be Grade 10 concrete as described in this tender document. Fencing shall be galvanized steel with a thickness of 2.5 mm. The mesh shall be diamond shaped with 50 x 50 mm opening to the center of wires. Fence posts and strainers shall be 35 x 35 x 3 mm mild steel Tee profiles . Fence bracing shall be 12 mm mild steel reinforcing bars. Gates shall be RHS expanded metal Tying wires for chain-link fencing shall be 2 mm thick mild galvanized steel wires.
79
Fabrication Fence posts, strainers, gate posts and gates shall be fabricated in accordance with the applicable codes. Welding for gates and posts and bracings to fence posts shall be in accordance with the requirements in Structural Steel. Welded joints on gates and gate posts shall be neatly made, filed smooth and left clean. Gate and gate posts shall be primed at shop and painted after installation as specified in Anti-Corrosion Measures. Installation Intermediate, strainer and gate posts shall be fully embedded in concrete. Chain link fences shall be securely tied to fence posts bracings using tie wires. The holes in the posts for tying shall be spaced at a maximum distance of 100 mm. Bracing bars shall be securely welded to posts and strainers. Fence posts, strainers and bracings shall receive one coat of primer preceding the installation of chain link fence.
80
Execution Inspection: The Owners Representative shall examine the areas and conditions under which miscellaneous metal items are to be installed and notify the Tenderer in writing of conditions detrimental to the proper and timely completion of the work. Do not proceed with the work until unsatisfactory conditions have been corrected in a manner acceptance to the Owners Representative. Preparation: Furnish setting drawings, diagrams, templates, instructions and directions for the installation of anchorages, such as concrete inserts, anchor bolts and miscellaneous items having integral anchors, which are to be embedded in concrete or masonry construction. Coordinate the delivery of such items to the project site. Installation: (i) Fastening To In-Place Construction: provide anchorage devices and fasteners for securing miscellaneous metal items to in-place construction; including, threaded fasteners for concrete and masonry inserts, toggle bolts, through-bolts, lag bolts, wood screws and other connector as required.
81
(ii)
Cutting, Fitting And Placement: perform cutting, drilling and fitting required for the installation of the miscellaneous metal items. Set the work accurately in location, alignment and elevation, plumb, level, true and free of rack, measured from established lines and levels. Provide temporary bracing or anchors in formwork for items which are to be built into concrete, masonry or similar construction.
(iii) Fit Exposed Connections accurately together to form tight hairline joints. Weld connections which are not to be left as exposed joints, but cannot be shop welded because of shipping size limitations. Grind joints smooth and touch-up shop paint coat. Do not weld, cut or abrade the surfaces of exterior units which have been hot-dip galvanized after fabrication, and are intended for bolted or screwed field connections. (iv) Field Welding: Comply with BS.4870, 4871, 4872, 5135 for the procedures of manual shielded metal-arc welding, the appearance and quality of welds made, and the methods used in correcting welding work. (v) Touch-Up Painting: Immediately after erection, clean fields welds, bolted connections, and abraded areas of the shop paint, and paint all exposed areas with the same material as used for shop painting. Apply by brush or spray to provide a minimum dry film thickness of 0.05 mm.
82
Metallic Coatings Parts to be galvanized shall be properly prepared and galvanized in accordance with I.S. Safeguards against possible embrittlement of steel products shall be in accordance with I.S. Galvanized surfaces shall be supplied free from damage. Repair of Paint Film The Tenderer shall provide paint of compatible material and colour to repair any shop paint film which has been damaged during transit. If the base metal has deteriorated due to the damaged protective coat, the affected area and the immediate surrounding area for a distance of 50 mm shall be cleaned and repainted in accordance with the original specification. Sufficient paint for the repair of shop coating shall be delivered in containers sealed by the manufacturer and the capacity of the containers for single pack paints shall not exceed 5 liters. xi Testing and Inspection Testing The Owner may appoint a testing consulting laboratory to carry out testing and inspection as required by the Owners Representative to ensure conformance with the design and specifications. The Tenderer shall assist the testing laboratory by making access to fabrication facilities and erected sections.
83
Shop welding shall be tested by the Owners Representative's inspector at the factory at the Owners Representative's option. If testing is required by the Owners Representative no item shall leave the shop until approved by the testing laboratory. Inspection or Test Failure In the event of failure of the product or any part to fully meet any inspection or test requirements specified herein, the Tenderer shall notify the Owners Representative should he wish to repair and/or use such product or part. At the discretion of the Owners Representative, suitable repairs and re-inspection and retesting may be carried out. If the repairs, including redesign, are likely to affect the results of the tests or work previously completed, appropriate re-inspection and retesting shall be conducted. Test Reports Within thirty days of completion of each and every test required, as proof of compliance with the Specification and/or each and every specified test, including commissioning tests, the Tenderer shall submit to the Owners Representative 6 signed copies of a report covering such tests. The test records for materials shall identify the component parts in which the materials are to be used and the certificate shall be prepared in such a way that it can be easily determined if the applicable Specification or standard has been complied with.
84
Field Testing The Owner reserves the right to make any laboratory and/or field tests to determine whether or not any item supplied meets the requirements of this Specification. xii Structural Steel Requirements Materials (i) Structural steel for buildings, including rolled shapes bars and plates shall comply with the requirements of I.S. (ii) Nuts and bolts I.S. regular series hexagon head and nuts. (iii) Shear connectors shall be of sizes and welding in accordance with I.S. codes. (iv) Shop painting shall be of red lead iron oxide linseed oil primer. and Miscellaneous Structural
Cutting, Sawing and Drilling Plates and sections shall be true to form. Stiffeners, plates and the like shall be ground to fit the profile of the member. Sections to be cut to 'exact' lengths shall be accurately cold sawn or machined. Preparation of edges by flame cutting shall, wherever practicable, be done by machine. Cold sawn, machine-cut and flame-cut edges shall be cleaned free of burrs and slag and left as smooth and regular as those produced by edge planning.
85
Check Plate Check plate flooring shall be 'Durbar' non-slip raised pattern or other equal approved. Individual plates shall be cut and fitted so that the pattern on adjacent panels matches in all directions. Unless otherwise stated, the plate shall be 8 mm thick on plain and shall be fastened to the steelwork by 10 mm counter-sunk set screws at a pitch not exceeding 500 mm centers. Kicking strips not less than 100 mm high shall be provided at the edges of all platforms and doors. Steel Grating Steel grating 40 mm thick, of a non-slip all welded type shall be supplied and supported. Crane Rails Joints shall be staggered on opposite sides. Manufacture in accordance with I.S. for Crane Rails. Galvanized Steel Railings 40 mm inside diameter standard steel pipe handrail. Brackets not to exceed 1.5 m on centre. All joints and corners to be smooth. Bends in hand railing shall be carefully formed to give satisfactory continuity of curvature and alignment and rails shall be jointed with a flush scarf joint held together by means of a tapered pin or other approved joint.
86
Steel Stairs The treads and landings of stairways shall be check plate or similar. The treads shall have double nosing bar to emphasize the leading edge of the tread, or other equal approved. All treads in a flight shall match one with another and also with the line pattern of the landings and, where possible, with the floors served by the stairs. Unless otherwise specified the widths of landings shall be 1,000 mm and the width between staircase stringers 760 mm minimum. The inclination of stair stringers to the horizontal shall not exceed 42 degrees. Kicking strips not less than 100 mm high shall be provided at the edges of all landings. Insulated Roof Cladding Steel roof cladding shall conform with the structural steel layout. Insulated roof cladding shall be 0.5 mm minimum thick with a "U" value of 0.10 (minimum). All roof cladding material shall be hot dip galvanized. Steel Cladding Steel sheet cladding shall conform with the structural steel layout, 0.5 mm thick. All sheeting material shall be hot dip galvanized unless otherwise specified. Chain Link Netting The chain link netting surrounding the fermentation section of the ethanol plant shall be hot dip, galvanized and supplied in sections to facilitate removal.
87
Holding Down Bolts Bolts shall be I.S. regular series hexagon head and nuts. Ventilators The ventilators shall be 26 gauge galvanizing steel mounted ridge and of the gravity type. Ventilators shall not permit entry of insects or birds into the building. Metal Ladders Ladders shall be as detailed with single rungs, shouldered at each end, and inserted into prepared holes in the stringers and welded. The pitch of additional rungs to bridge the gap between the top rung of ladders and edges of platforms shall not exceed 57 mm. The stringers shall open out at the top of the ladder to allow adequate room for the user to turn to face the ladder when descending and the stringers shall extend a minimum of 1,060 mm above the level of the platform. Where necessary the stringers shall be bent over to form a continuous connection with the platform hand railing and at the same height as the top rail. Ladders shall be provided with safety hoops. Stringers shall be attached to the adjacent structure by suitable cleats which shall be firmly attached to the stringers and the supporting structure and be sufficiently close together to make the ladder rigid throughout its length.
88
The cleats shall be of sufficient length to give the required clearance at the back of the ladder. The top rung of a ladder shall be at the same level as the floor or edge of the platform unless the flooring of the platform has been extended to form the top rung and there shall be no obstructions above this level. Metal Flashing The metal flashing shall be of 26 gauge galvanized steel and formed to the required profile. Light Panels (Translucent Sheets) :Translucent sheeting shall comply with I.S. and shall be continuous and of thermosetting polyester synthetic resin. The sheeting shall be coated to prevent attack by ultra violet light. Light transmission shall be at least 75%. It shall be graded AA when tested to I.S. and shall have a Class 1 surface spread of flame. Louvers Louvers shall be of galvanized steel designed as an integral part of the cladding system. They shall be fixed type louvers. Gutters The gutters shall be fabricated of 26-gauge galvanized steel designed with a contour fitting the general configuration of the buildings.
89
Downspouts The downspouts shall be of 26-gauge galvanized or as specified. Bearing Splices Fastening of bearing splices of compression members shall be done after the abutting surfaces have been brought completely into contact. Bearing surfaces and surfaces that will be in permanent contact shall be clean prior to final assembly of members. Bolted Joints All bolted connections shall be in accordance with I.S. Structural steel bolts, nuts, studs and washers shall comply with I.S. High strength friction grip bolts shall comply with I.S. and shall be used in accordance with I.S. Lining and Plumbing Tolerances The tolerances within which the final position of the steelwork will be accepted shall be as follows: Permissible Deviation Linear Dimension (in plan): Up to and including 8 m +/- 10 mm Over 8 m up to and including 15 m - 15 mm Over 15 m up to and including 25 m 20 mm Over 25 m 20 mm
90
Plumb: In 30 m height +/- 15 mm Levels: Plumb distance between designed and actual level of the base of the first column to be erected +/- 5 mm Plumb distance between designed and actual level of any beam at its junction with a column (in any 30 m length) +/- 15 mm Plumb distance between designed and actual levels of the upper and lower surfaces of two or more beams meeting at a column +/5 mm Qualification and Testing of Welders The Tenderer shall satisfy the Owners Representative that welding operators are suitable for the work upon which they will be employed. Welders shall provide evidence to the satisfaction of the Owners Representative that they are capable of passing the tests as specified in I.S. Crane Runways Crane runways shall be erected complete with all columns, girders, beams, bracing, crane rails, crane stops, and other required components as indicated. The gauge, alignment and elevation of crane rails shall be accurate to a tolerance of plus or minus 3 mm. Crane rails joints shall be staggered with respect to each other on opposite sides of the runway and shall not coincide with the crane girder joints. The top of the crane rails shall be flush at all joints.
91
Non-Destructive Testing of Welds Weld quality and correct standards shall be in accordance with I.S, as modified herein. The Tenderer shall furnish facilities for performing the tests, including power and utilities, at no additional cost to the Owner at the expense of the Tenderer. (i) Radiographic testing shall be in accordance with I.S. The welder or welding operator's identification mark shall be stamped on the steel as specified so that full and complete identity and history of the welding operation will be known. Correction of Defective Welds. Weld areas containing defects exceeding the standards of acceptance in the above I.S., revealed by radiography shall be repaired under the direction of the Owners Representative, and additional radiographs of the repaired areas shall be made at the Tenderer's expense, 100 percent radiographic inspection of that welder's work will be required at the Tenderer's expense. Ultrasonic Inspection. Technique and standards of acceptance shall be in accordance with I.S. Magnetic Particle Inspection methods shall be in accordance with I.S. Liquid Penetrant Inspection methods shall be in accordance with I.S.
(ii)
(iii)
(iv)
(v)
92
f)
Construction Specification For Masonry Construction The work covered by this specification includes furnishing all labour, materials, equipment and performing the operations necessary to complete the masonry work i Applicable Publications :All work shall be in accordance with the latest revision of the Indian Standards except where specifically noted otherwise. Cement Sand Lime Stone Brick Concrete Block ii Material :Cement :Cement Shall be ordinary portland Cement conforming to I.S. 269. All cement used shall be suitably protected from exposure to moisture until used. Sand Sand shall consist of approved natural sand, manufactured sand or a combination of both and shall be hard and durable. It shall be free from organic matter or other deleterious material. Adequate supplies of sand shall be stockpiled sufficiently in advance of construction to permit sampling and testing before use. Sand shall conform to the following sieve analysis. I.S. I.S. I.S. I.S. I.S. I.S. 269 383 712 1127 1077 2185
I.S.
1725
93
Sieve Percentage Passing 10mm 100 No. 4 (4760 Micron 95-100 No. 8 (2380 Micron) 80-100 No. 16 (1190 Micron ) 50- 85 No. 30 ( 590 Micron) 25-60 No. 50 (297 Micron) 10-30 No. 100 (149 Micron) 2-10 With not more than 45% retained between any two consecutive sieves. The fineness modulus shall be between 2.25 and 2.75 Stone :Stone shall be natural stone and shall be sound, clean, hard, durable and free from seams or other imperfections, and free from skins form. No weathered stones will be accepted. Brick :Brick shall be hard burned clay bricks and at the time of laying shall have a rate of absorption of not more than 4.60 gms. of water per square cm. of surface submerged to 3 mm. of water for one minute. iii Mortar And Grout :Mortar :Mortar shall be composed of one part cement, one part lime putty, four and one-half parts sand, and sufficient water to make a plastic mix or as specified on drawing and schedule of quantity.
94
Grout :Grout shall be composed of one part cement, two part sand, and sufficient water to allow the grout to flow into all joints and interstices of the masonry. Grout compressive strength shall be not less than 70.3 kg per square cm. at seven days nor less than 104.61 kg. per square cm. at twenty-eight days. Mixing :Mixing shall be done either in a mechanical mixer or in a mixing pot. The sand, cement and water shall be placed in the mixer, in that order, for each batch of mortar or grout and shall be mixed for a period of at least two minutes, and the mixing continued as long as need to secure a uniform mass, but in no case less than two minutes. Equipment for mixing and handling shall be approved. Retempering of mortar shall be done only by adding water into basic made with mortar, and the mortar carefully worked into it. Retempering by dashing water over the mortar will not be permitted. Any mortar or grout unused within one hour after the initial mixing shall be removed from the work. Mortor shall be mixed and maintained while being used to a slump of 5.08 cm. & 1.27 cm. to 10 cm. using a truncated cone 100mm or 50mm, 150mm high, and grout should have a slump of 12.7cm. to & 1.27 cm. Mortar compressive strength shall be not less than 52 kg. per square cm. at seven days nor less than 105 kg. per squrae cm. at twenty-eight days.
95
iv
Stone Construction:Wetting of stones : All stones shall be thoroughly wetted before placing in position. Laying of stones : The walls shall be carried up truly plumb. Every stone shall be carefully fitted to the adjacent stones, so as to form neat and close joints, stone may be laid at random without being brought up to any level courses except at plinth, window sills, bond beams and roof level. The bond shall be obtained by filling in closely the adjacent stones and by using two bond stones for every 1 Sq. meter of wall surface and staggered. Through bond stone shall run right through thickness of wall. The stone shall be laid on its natural quarry bed. Face stone shall extend and bond well into the backing. These shall be arranged to break joints as much as possible, and to avoid long vertical joints. Their heights shall not be greater than the breadth at the face or the depth inwards. The hearting or interior filling of the wall face shall consist of rubble stone not less than 13 cm in any direction. The hearting will be laid nearly level with facing and backing except that at about one meter intervals, vertical "Plumbs" projecting about 15 to 20 cm. shall be firmly embedded to form a bond between successive courses. The use of chips shall be restricted to the filling of interstices between the adjacent stones in hearting
96
and these shall not exceed 15% of the quantity of stone masonry. Selected stones roughly squared to line shall be placed at all wall angles, corners and ends. Flat or stratified stones shall be laid in a horizontal and not on edge. Joints in face of the wall shall be not less than 12mm. nor more than 25mm. in thickness. Interior spaces between stones shall be filled with mortar. No voids will be permitted in any part of the wall. Pointing : Within 24 hours after construction, the joints on all exposed wall faces shall be racked clear of loose mortar, to a depth of not less than 20mm and pointed with the mortar specified, so that all joints are recessed a minimum of 6mm. Curing : All masonry shall be kept continuously damp for a period of seven days after laying by either fog spraying or by covering all surfaces with burlap and wetting this burlap. v Brick Construction :All bricks shall be wetted thoroughly so that at the time of laying, the bricks will have a residual rate of absorption of between 5 and 15 per cent. Laying of Brick : All Bricks shall be laid true to line and grade, level and plumb in a full bed joint, with a full shoved head joint set in English bond. Furrowing of mortar will not be allowed.
97
Horizontal concrete surfaces which are to receive brick work shall be damp, clean and free of laitance. In reinforced grouted masonry, the vertical reinforcing shall be in place before the masonry work begins. The first course on each side of the wall shall be laid and then 40mm. of grout shall be placed between the bricks. The bricks shall then be laid so that not more than three bricks in height are laid on one side of the wall before one course is laid on the opposite and the grout space is then filled. This procedure shall be followed throughout so that at no time is one way more than three bricks high than the other, and at no time is the top of the grout more than 40mm. below the top of the brick in the lower whythe. Mortar shall not project into grout space on head or bed joints. Grout shall be placed as the work progresses and shall be poured from the inside face of wall. Grout shall be well puddled with a stick, slicing with a trowel will not be permitted. Tooling of joints : Except for walls to be plastered, all joints shall be tooled with a round tool of 2mm. diameter in such a way as to squeeze the mortar into the joints and fill all pinholes in the mortar. Joints in wall to be plastered shall be struck flush. Curing : Curing shall be as specified in this tender document
98
vi
Cleaning :On the completion of the masonry work, all surfaces which are to be exposed in the final condition are to be cleaned, removing all mortar, grout and stains from the exposed faces.
vii
Masonry To Be Plastered : All surfaces to be plastered shall be thoroughly wet down 48 hours and then again 24 hours before plastering operation begins. The surface must be clean and free from dirt, oil, paint, or other material which may reduce bond.
viii
Masonry To Be Painted :All surfaces to be painted shall be thoroughly dry and in no case paint be applied until two months have elapsed after the completion of masonry or two months after the monsoon season.
ix
Cleaning-Up :At the completion of the masonry work, the Tenderer shall remove all scaffolding, equipment, debris and surplus material from the site and dispose of all debris as directed.
Brickwork And Masonry Concrete Block Walls Concrete block walls shall be built with new hollow concrete blocks laid and bonded with mortar
99
All units shall be laid with full mortar coverage of the face shells in both horizontal and vertical joints. Units shall be lapped in successive vertical courses. Wall surfaces shall be plumb and straight. Wall thickness shall be as shown on the Drawings. Concrete blocks shall comply with I.S. Class A. They shall be obtained from an approved supplier or may be manufactured on Site. Samples shall be submitted to the Owners Representative and his approval must be obtained before any blocks are delivered or used in the construction of the Works. For blocks manufactured on Site, the Tenderer shall prepare a design mix using the materials available to him to give a minimum average compressive strength of 2.8 N/mm2 on gross area after 28 days from casting. A minimum of six blocks shall be prepared from this mix for testing. Samples of blocks from each subsequent batch (minimum number six) shall be submitted to the Owners Representative for testing to ensure that the prescribed standards are maintained and when blocks are manufactured on Site, the Tenderer shall mark each day's output with the date of manufacture for identification. Materials for the blocks shall not contain any impurities which will affect the strength for durability of the blocks or the durability and appearance of any applied finishes.
100
Blocks shall be uniform in texture, shape and size, with sharp arises and free from any cracks or defects. Curing shall be carried out for at least seven days under moist coverings. All manufacture and curing shall take place on a suitable smooth concrete floor and only machines of approved design may be used for manufacture. The surface characteristics of the blocks shall be such that a good key for rendering or plastering, is provided where required. Portland cement shall conform with the latest specifications of the Indian Standard I.S. Sand shall comply with I.S. Lime shall be hydrated lime and shall comply with I.S. Water shall be as that specified in this tender document Block walls shall have concrete tie columns at corners, ends of free standing walls, at sides of wall openings exceeding two meters and at two meters on centres. Tie columns shall be 200 mm wide by 300 mm long, reinforced with four vertical bars 14 mm diameter and ties 8 mm diameter spaced 300 mm on centres. Block walls shall be capped at top of wall with a tie beam and reinforced with intermediate tie beams vertically spaced two meters on centres. Concrete tie beams shall be 200 mm wide by 300 mm high reinforced with four bars 16 mm diameter (two top and two bottom).
101
Blocks shall be properly stacked on level hard standing and be adequately protected from inclement weather. Cements and limes shall be stored in dry, watertight sheds or stores and in such a manner to enable them to be used in rotation, in order of delivery. Sands shall be stored separately, according to type, on clean, dry, hard standing and protected from contamination. xi Damp Proof Courses Damp-proofing for horizontal application shall be hessian based bituminous felt conforming to I.S. Damp-proofing for vertical application shall be high melting point bitumen of approved manufacture. xii Mastic Pointing Joints and surfaces to receive mastic shall be properly cleaned and primed as required and the mastics mixed and applied strictly in accordance with the manufacturer's instructions. xiii Movement Joints Movement or expansion joints are to be provided only if shown or specified on the drawings and shall be plumb, continuous open vertical joints 10 mm wide, the centre of each joint plugged with either expanded polystyrene or soft board and the faces of the joint subsequently sealed with a bitumastic sealant approved by the Owners Representative.
102
xiv
Protection Of Finished Walls The Tenderer shall ensure that all finished walling will not be damaged by subsequent operations. The Tenderer shall protect newly or partially erected walling from drying out too rapidly by the sun's heat. In particular, the Tenderer shall, as necessary, dependent upon the climatic conditions, keep all newly erected walling well-watered for at least three days.
xv
Stone Dressing Stone shall be roughly hewn to manageable sizes, more or less prismatic in shape. The least dimension shall be not less than 100 mm. In addition, stone for exposed masonry shall be fair chisel dressed on the exposed face and shall measure 450 mm +/- 70 mm in the longest direction. Paving stones shall be random shapes and sizes. Maximum sizes shall not exceed 600 mm and minimum sizes shall not be less than 200 mm measured on the face. Fill-in stones shall be sized as required. Paving stones shall be 100 +/- 20 mm thick.
xvi
Stone Paving Stone paving blocks shall be laid on 100 mm thick tamped sand bedded or on concrete, to levels, falls and patterns. Joints shall be cleaned to a depth approximately equal to the thickness of the paving stones and subsequently filled with cement mortar, the joints shall be finished flush with the stone surface.
103
PERMISSIBLE TOLERANCES FOR VARIOUS TYPES OF FINISH Tolerances (mm) in Finish Type F2 F3 U1 U2 +/-15 -
Type of Structure Buried concrete in foundations, Culverts, retaining wall
Type of Irregularity Departure from alignment and grade as shown on the approved drawings Variations in crosssectional dimensions Abrupt Gradual
F1 +/-15
U3 -
+15 -8 +/-15 +/-15 -
+/-15
+/-15
+/-15 +/-15 -
Exposed concrete in columns, piers, retaining walls, abutments
Departure from alignment and grade as shown on the approved drawings Variations in crosssectional dimensions Abrupt Gradual g)
+/-8 +/-8
+15 -8 +/-8 +/-15
+15 -8 +/-4 +/-8
+/-8 +/-4 +/-8 +/-4
Construction Specification For Plastering And Pointing The work covered by the specification includes furnishing all labour, materials, equipments and performing the operations necessary to complete the plastering and pointing works. i Applicable Publications :All work shall be in accordance with the latest revision of the Indian Standards except where specifically noted otherwise. Cement I.S. 269 Sand for plaster I.S. 1542 Building Lime I.S. 712 Structural Safety I.S. 875
104
ii
Material :Cement shall be ordinary Portland Cement confirming to I.S. 269. All cement shall be suitably protected from exposure to moisture until used. Sand shall consist of approved natural sand, manufactured sand, or a combination of both and shall be hard, clean and durable. It shall be free of organic or other deterious material and conform to I.S. 1542 class A. Building Lime shall conform to I.S. 712 class A. Water shall be supplied by the Tenderer.
iii
Mixing:Material which has partially set shall not be retempered or used. The mixer or mixing box shall be thoroughly cleaned of all set or hardened material, before materials for a new batch are loaded. Machine Mixing :The sand and Cement shall be placed in the mixer dry and thoroughly mixed; then the water shall be added to obtain the proper consistency and the entire mass shall be mixed for five minutes after all ingredients are in the mixer. The entire mixer shall then be emptied before being recharged.
105
Hand Mixing :Hand mixing shall be done in a water tight mixing boat placed on the level. The dry sand and cement shall be placed in the boat and turned twice. The water shall then be added and the entire mass hoed into the water and well mixed for 10 minutes or until the entire mass is homogeneous. The mixing boat shall be completely emptied before a new batch is mixed. iv Plaster Mixed :Plaster over exterior concrete shall be single coat or 12mm. thickness and shall be composed of one part cement, four parts plaster sand, or as noted in the schedule of quantity. Plaster over exterior masonry shall be two coats with the first coat of 15mm. thickness and shall be composed of one part cement, three parts plaster sand. The second or finished coat shall be 10mm thick and shall be composed of one part cement, three parts plaster sand, and finished as noted in the schedule of quantity. Plaster over interior masonary shall be two coats with the first coat of 5mm. thickness and shall be composed of one part cement and three parts plaster sand. The second or finishing coat shall be 10mm. thick composed of one part cement, three parts plaster sand, and finished as noted in the schedule of quantity. Plaster backing for glazed ceramic tile shall be of 15mm.thickness and shall be composed of one parts of cement and two parts plaster sand, or as specified.
106
Cement punning shall be applied over a first coat of the same proportions as the first coat of paragraph 5.4 and shall be not over 3mm. thick and shall be composed of one part cement, one part ground sand, or as specified. Suspended ceilings shall be of three coats over metal lath. The first coat shall be 10mm. in thickness and shall be composed of one part cement, three parts plaster sand. The second coat shall be as same as the first coat. and finish coat shall be not over 3mm. in thickness and shall be composed of one part Lime putty and one part ground sand, or as specified. Raised pointing shall be 18mm. high and 12mm. wide and be composed of one part cement and three parts sand. Deep sunk pointing shall be 30mm. deep and full stone joint wide and be composed of one part cement and three parts sand or as specified. v Surface Preparation :All surfaces to receive plaster shall be cleaned of all loose material and dirt with a clean bristle brush. Concrete surfaces shall be sufficiently roughened to provide a proper bond. If in the opinion of the Owner, the surface is not sufficiently rough, it shall be roughed by hacking or hammering. Stone and brick masonry surfaces shall have the mortar joints raked about 15mm. provide proper key for raised pointing and 30mm. for deep sunk pointing.
107
vi
Application :First coat of two and three coat work shall be applied with sufficient material and pressure to form good full keys or good bond. This coat shall be applied to cover well and to fill out to the grounds. It shall be placed to a true plane with rod and darby and left rough. Second coat of three coat work shall be applied upto screeds, well rodded, screeded and floated with angles true, straight and plump and just slack of grounds. Finish coat shall be applied after under coat is dry. It shall be applied so that all surfaces are straight true, plumb, even and flush with all grounds, corners, angles and wall intersections shall be straight, sharp and true. All coats of plaster shall be damp cured for two days and then be allowed to dry before an additional coat is applied. The previously applied plaster shall be uniformly redampened before additional coats are applied. When ballies have been inserted in the walls, when they are removed, the hole shall be filled and uniformly patched with plaster conforming with balance of the wall. As far as possible the scaffold for walls shall be free from wall but shall be selfsupporting, sound and safe for erection Loading.
108
vii
Clean-Up :Upon completion of the work in a space, the Tenderer shall remove all rubbish, debris, scaffolds, and surplus material, and leave the area or space, broom clean.
h)
Construction Specification For Painting The work covered under this agreement includes furnishing all labour, material, equipment and performing the operation necessary to complete the painting work. i Preparation Of Surfaces :All spaces shall be broom clean before painting is started and all surface shall be clean, dry, free from foreign materials, and in the opinion of the Owner, ready to receive the painting. All wood surface shall be lightly sanded and dusted before priming and between each coat. All surface shall be primed in accordance with the instructions of the manufacturer of the covering material. Surfaces to receive white wash, colour wash and distemper, shall be properly wet before the work begins. All concrete and plaster surface shall be spackled to fill all cracks and holes, it shall then be primed with an alkali Resistant primer. Metal surfaces shall have all grease removed with benzine, remove rust spots and defective paint down to bare metal and touch-up with metal primer.
109
ii
Protection :The Tenderer shall remove all electric plates, surface hardware and other accessories before painting and replace when painting is completing.
iii
Workmanship :All work shall be done by first class skilled mechanics in a workmanlike manner. All material shall be evenly applied so as to be free from runs, sags, or other defects. All coats shall be thoroughly brushed out so as to show a minimum of brush marks except enamel which shall be flowed on. All coats shall be thoroughly dry before succeeding coat is applied with minimum of twenty four hours between coats except for white wash, colour wash, and distemper . All finishes shall be uniform as to colour and texture.
iv
Clean-Up :The Tenderer shall remove all paint spills, splashes, or spattered, on all fixtures, fittings or other materials including cleaning of paint off all glass.
i)
Construction Specification For Roofing, Damp-Proofing And Water Proofing The work covered by this specification includes furnishing all labour, material, equipment and performing the operations necessary to complete the roofing and dampproofing
110
Applicable Publications :All work shall be in accordance with the latest revision of the Indian Standards except where specifically noted otherwise:Specification for Bitumen Felts Code of Practice for Laying damp proof coursing Code of Practice for water proofing roofs with Bitumen Felts Specification for the Blown type Bitumen I.S. 1322 I.S. 1609 I.S. 1346 I.S. 702
ii
Materials :Roofing felts shall be Hessian base Self-Finished Felt type three grade one. Damp proofing Felts shall be Hessian base selffinished felt type three grade two. Flashing felts shall be fiber base self-finished felt two grade two. Laying of damp proof course in floor including the primer, bitumen binder and bitumen felts.
iii
Surface Preparation :Roof Surfaces shall be clean, dry and have had all cracks repaired by being cut in a 'V' Section, cleaned and filled with cement grout as specified in this tender document. All brackets, cants, angle fillers, chases for flashing felts shall be in place before roofing operation begins.
111
Walls to be damp proofed, shall be clean, dry and have all cracks filled as specified in this tender document. All sharp corners shall be eased with cement mortar fillets. iv Application For Roofing :After the surface has been prepared as specified in this tender document, the entire roof surface shall be primed. The Bitumen bonding material shall be heated to the proper temperature and maintained to that temperature until applied. The felts shall be laid so as to be free of wrinkles, buckles and so that pronounced ridges are not formed at laps. The mopping of the Bitumen bonding material between piles of the felts shall be uniformly applied to cover the entire surface so that at no place will felt touch felt. Gravel shall be dry and in no case be less than 75 degree F (24 Degree Centigrade) when applied. On the roof, the layers shall be lapped over each ridge from alternate sides in alternate layers. v Application Of Damp Proofing :After the surface has been prepared as specified in this tender document, the entire surface which is to receive damp proofing shall be primed. The excavation shall be maintained in a dry condition until the work is complete.
112
The Bitumen bonding material shall be heated to the proper temperature and maintained to that temperature until applied. The felts shall be cut to the proper length, cleaned and then brushed into the bonding material so as to be free of wrinkles, buckles and so that pronounced ridges are not formed at laps. The mopping of the Bitumen bonding material between piles of the felts shall be uniformly applied to cover the entire surface, so that at no place will felt touch felt. The second layer shall break joint midway between the joints of the layer below. vi Application Of Bitumen Layer :Primer shall be bituminous solution of suitable viscosity to be applied to the wall or floor surface to assist adhesion of the binding material. Bitumen binder shall conform to I.S. 702. The penetration of Bitumen shall be limited to 40 when tested in accordance with I.S. 1203. The exposed surface shall be thoroughly cleaned. Bitumen shall then be applied at the rate of 2 Kg per Sqm. at a temperature of not less than 121 degrees C. (250 Degrees F.) evenly throughout, and allowed to set before laying the top flooring.
113
vii
Cement Water Proofing Compound :Cement water proofing compound shall be as per I.S. 2645. The Cement water proofing compound shall be CICO products as manufactured by the Structural Water Proofing Co. Pvt. Ltd. Calcutta or approved equal. The application shall be 2 % or 3 % of CICO cement water proofing compound or equivalent by weight of cement as specified by the Manufacturer's instructions and specifications.
viii
Clean-Up :All surplus material, scraps, scaffolding shall be removed from the site at the completion of the work. All Bitumen smeared on surfaces other than those to be covered, shall be removed and the surface restored to its previous condition.
j)
Construction Specification For Miscellaneous Architectural Items The work covered by this specification includes furnishing all labour, materials, equipment and performing the operations necessary to complete the Architectural finishes. i Applicable Publications :All work shall be in accordance with the latest revision of the Indian Standards except where specifically noted otherwise. Plain cement tiles I.S. 1443, 1237 Marble Mosaic Tiles I.S. 1237 Glazed Tiles I.S. 777 Plywood for general purpose I.S. 303 Veneered Decorative plywood I.S. 1328 Sheet glass for Glazing I.S. 1761
114
ii
Materials :Terrazzo Aggregate shall be well graded from onehalf inch and down, of a colour to be selected. Terrazzo tiles shall be 12" x 12" x 3/4" thick, colour to be selected. Glazed tile shall be of size and colour to be determined complying with I.S. 777 Marble mosaic tiles shall be as per I.S. 1237 Veneered decorative plywood shall be 1/4" (6mm) thick and four feet by eight feet sheets, complying to I.S. 132, with a Indian Teak face ply. Glass shall be of the best quality, free from bubbles, scratches or imperfections of any kind. Glass for windows shall be clear Twenty-one ounces per square foot, except for toilet rooms which shall have an opaque glass. Glazed door shall be 1/4" (6mm) plate. Plain Cement Tiles shall be as per I.S. 1443 and 1237
iii
Application Of Terrazzo :The Concrete slab shall be cleaned of all dirt and foreign matter and the underbed 1 & 1/2" (40mm) thick composed of one part cement and four parts sand, shall be placed to a level 5/8" (15mm) below finished floor elevation. The Division strips of 1/8" x 1" (3mm x 25mm) brass shall be installed while the underbed is still semiplastic but in no case over four feet (1200mm) centers each way, with the top of the strip at the elevation of the finish floor.
115
The topping mix composed of one part "colorcrete" to two parts marble granules shall be mixed just with sufficient water to make a workable mix. Place topping mix into spaces between strips and tamp to a compact mass and until super-fluous cement and water are extracted, then hand trowel to an even surface flush with top of strips. The finished surface shall show a minimum of 70% marble granules. The surface is to be kept moist during these operation and shall be cured at least six days. Terrazzo base shall be applied to a backing coat of cement, sand, mortar and the base shall be set 1/4" ( 6mm) beyond the face of the finished wall above. After the surface has set hard, the surfacing of the floor shall be polished with machine or hand rubbing with coarse carborundum grit stones. Next, a light grouting of colorcrete shall be rubbed over the surface to fill all voids. The surface shall have the final grouting removed with a final carborundum grit 72 hours after final grouting, the surface shall be washed with clean water. iv Application Of Terrazzo Tiles :The concrete slab shall be cleaned of all dirt and foreign matter and the underbed 1 & 1/4" (30mm) thick composed of one part cement and four parts sand and shall be placed to a level 3/4" (20mm) below finished door elevation. The tile shall be embedded in the underbed with a 1/4" (6mm) joint space on all sides. After the tile has been set the joints shall be filled with colorcrete.
116
After the joints have been filled, all surplus colorcrete shall be wiped off, and the surface cured for six days. After the surface has cured, it shall be washed with clean water. v Application Of Concrete Hardner :The concrete surface shall be swept and washed with clean water to remove all dirt and foreign matter. All cracks shall be filled with admixture of cement and water. Surface shall be well mixed with equal quantity of water immediately before using. The diluted mixture shall be evenly sprinkled on the surface with a fine spray in a generous quantity but without leaving actual pools on the surface. Twenty-four hours later the surface shall be cleaned if necessary and a second coat, similar to the first shall be applied. CICO surface hardener or CICO hard seal liquid concrete hardener or equivalent approved, shall be used as specified as per the instructions of manufacturer. vi Application Of Shahabad Flooring :The slab stones specified in the item shall be got approved by the Owner. At its thinnest part, no stone shall be thinner than minimum specified. The stone shall be hard, sound, durable, resistance to wear. Uniformity of size shall be maintained and shall have plain surface. They shall have, even, natural surfaces free from broken flakes on the top and shall be chiselled on edges to half its depth, true and square to ensure uniform width of joint. The surfaces and the edges of the slab shall be straight.
117
Cement mortar or lime mortar for the bedding and cement mortar for pointing shall be of the proportion as specified in the item. The base as specified shall be laid and compacted to a true plain surface below the level of the finished floor to the extent of the thickness of the slabs and mortar bedding. The surface to receive shahabad slabs shall be cleaned off all dirt and foreign matter. Underbed of 20mm thick composed of one part cement and four parts sand or as specified in item shall be placed to a level. The required slope shall be given to the bed. Before laying, the slabs shall be thoroughly wetted with clean water. Cement grout of honey like consistency shall be spread on the mortar bed over the area which could be covered with the slabs within half an hour. The specified type of stone slabs shall be laid on the neat cement float and shall be evenly and firmly bedded with the help of wooden mallet tapped gently till there is no hollow sound from the slabs. The joint shall be 6mm to 10mm thick and filled solidly with mortar for full depth and shall be struck smooth but there shall be no smearing of mortar over the slabs. All surplus grout shall be wiped off. The joints shall be of uniform thickness and straight lines to give continuous parallel long joints with cross joints at right angles. Diamond pattern paving slabs shall be square and laid with triangular shaped slabs to make up the edges. In plain pattern, stones on each course shall break joint with those in the next. The joints shall be pointed with cement mortar of the proportion mentioned in the item.
118
The flooring shall be kept well wetted with damp sand or water for 14 days. It shall be kept undisturbed for at least seven days. After the surface has cured, it shall be washed with clean water. vii Application Of Indian Patent Stone :The coarse aggregate shall be carefully selected, sufficiently tough and hard stone pieces broken in a manner that will provide particles of approximately cubical shape affording good interlocking. The maximum size of the coarse aggregate shall be 12mm. The fine aggregate shall consist of properly graded sand. The proportion of mix shall be M 150 (1:2:4). The least amount of water that will produce a workable mix and will allow finishing without excessive trowelling shall be used. The sub grade for the concrete floor shall be of sufficient thickness and properly executed as per specifications. The sub grade shall be at proper levels and slope, well compacted and cured. The top surface shall be kept slightly rough. The surface of the sub grade shall be cleaned of all loose materials and moistened immediately before laying the concrete floor. The concrete flooring shall be laid in alternate bays not exceeding 6 Sq.m. The edge of each panel into which the floor is divided shall be supported by flat bars of steel or wood duly oiled to prevent stickings. The bars shall be removed before filling in the adjoining panels.
119
The concrete shall be laid immediately after mixing. The formation of voids or honey comb pockets shall be prevented. Compacting and levelling shall be carried out with a heavy straight edge. The floating shall be followed by steel trowelling after the concrete has hardened sufficiently to prevent excess of fine material from working to the surface. The finish shall be brought to a smooth and even surface free from defects and blemishes and tested with straight edges. After the concrete has sufficiently dried, the rendering with a thin coat of 1:1 cement mortar with fine sand and uniform float shall be carried out. Approved colour pigment confirming to I.S.459 shall be added to cement mortar to give the required colour and shade to the flooring. When the cement mortar rendering is sufficiently stiff, lines shall be marked on it with strings or by any device to give the appearance as specified. After the concrete in the bays has set, the joints of the panels shall be filled with cement cream or with suitable bitumestic compounds. Vertical edges shall be neatly marked on the surface of the concrete with appointed trowel after filling the joints. When rendering is somewhat stiff, neat cement of approved colour cement mixed with the required shade of approved pigment may be sprinkled on the surface and rubbed lightly to give smooth cement coloured surface. Surface shall be protected from direct sun when it is green. Curing shall start on the next day after finishing and shall be continued for 14 days.
120
Even the small strips of I.P.S. in between shahabad stone flooring panels, shall be carried out in the same manner as specified above. viii Application Of Glazed Tile : The surface to receive glazed ceramic tile shall be clean and free from foreign materials. Before the setting bed is spread, the surface shall be thoroughly moistened with clean fresh water. All excess water shall be removed. For floors the setting bed shall be composed of one part cement and four parts sand. For walls, if the scratch or backing coat is not sufficiently even and true, a plumb coat composed of one part cement, 1/2 part lime putty and four parts sand shall be applied to true the surface. For floors, the cement mortar shall be applied over the setting bed until the surface is absolutely true and smooth and even in plane as to drainage. The entire surface shall be sprinkled with cement and the tiles placed, with 1/8" (3mm) joints, and beaten into the mortar until true to line and even. As soon as the cement mortar beds have set sufficiently, the tiled surface shall be washed, and the joints between the tiles pointed with a cream consistency mixture of one part white portland cement and one part white sand. For vertical surfaces, the tile shall be buttered with the setting mortar and tamped into place, with 1/8" (3mm) joints and brought to a plumb and true surface flush with other tile. The back of each tile shall be covered with mortar to make a even and level bed. All joints shall be plumb and true and the joining strings or wedges shall be removed before pointing.
121
Clean-up : After the tile joints have been pointed, all the tile surfaces shall be wiped clean. After the joints have set, all tile surfaces shall be washed with clean water. ix Application Of Thermofriz :The sheets of Thermofriz shall be unbroken and be set with full sheets in the field with any irregularities taken up in the border. The sheets shall be face nailed with nails 1 1/2" (40mm) long set 1/2" (12 mm) from the edge of the sheet. All joints shall be tight butt joints. After all sheets are in place, the joints shall be covered with wood battens 1/4"x2" (6mmx50mm) which shall be attached through the joint of the Thermofriz with counter sunk screws 2" (50mm) long. The joints of the battens shall be tight, smooth and square. Clean-up : At the completion of installation, all excess materials and debris shall be removed from the site. x Installation Of Teak Decorative Panelling :The surface to receive the teak panelling shall be true to line and grade and all backing walls shall be dry. The panelling shall be applied to the ceiling first starting in the middle of the space with full sheets and working to the walls where irregularities shall be taken up.
122
The wall panelling shall begin in the middle of wall surface with a full width sheet and irregularities shall be taken up at the corners. All sheets shall be blind nailed with finishing nails 1 & 1/4" (32mm) long. Where blind nailing cannot be done, the nails shall be set 1/8" (3mm) and the hole filled with a putty coloured to match the panel. All panel surfaces shall be fine sanded and then finished with three applications of a dull finish wax. Clean-up : At the completion of the panelling work, all debris shall be removed from the site. All rebates not primed shall be painted black before the installation of glass. All glass panes shall have 1/6" (4mm) clearance all around the pane. All glass shall be back puttied so as to fill the void between the glass and the rebate. Putting shall be carefully done so that putty runs in neat straight lines parallel with the inside of the mounting or rebate, corners shall be carefully made and excess putty removed. Glass Breakage :The Tenderer shall be responsible for all glass broken because of faulty setting and shall replace same at his own expense.
123
Cleaning : At the completion of the construction, the Tenderer shall remove all dirt, stains, paint, excess putty and any other foreign materials and clean and polish all glass. xi Application Of Plain Cement And Marble Mosaic Tiles :The cement slab or bed shall be cleaned of all dirt and foreign matters. The tiles shall be as per I.S. 1237 of specified cement colour, patterns, marble chips, designs, thickness and size as directed for marble mosaic and as per I.S. 1443 for plain cement tiles. Fixing, polishing & cleaning shall be done entirely as per I.S. 1443. Polishing shall be done by machine to a smooth & plane surface. The item includes cleaning the base and laying mortar and levelling, providing and laying the tiles in neat cement floor on the bedding mortar, filling the joints of tiles with neat cement or colour cement slurry, curing, all labour, materials, use of tools & Equipments for carrying out the items as specified.
124
The amount of water while preparing the mortar for bedding shall be minimum as to give sufficient plasticity for laying, and free from hard lumps, evenly and smoothy spread over the base to proper level or slope. The thickness of bedding shall be not less than 12mm or more than 25mm in any place. The tiles shall be laid on the mortar bedding when it is still plastic but turned sufficient stiff to offer the firm cushioning. The tiles shall be soaked in water for at least 2 hrs. before laying. Neat cement grout of honey like consistancy shall be spread over the bedding mortar to cover the area which can be tiled within half an hour. Each tile shall be pressed & gently tapped with wooden mallet till it is properly bedded in & in level with the adjoining tiles. The edges of tiles shall be in straight lines and as clean as possible. The joints shall be grounded with white cement slurry. The joint between tiles shall not exceed 1.5 mm (about 1/16") wide. The flooring shall be cured and allowed to mature undisturbed for 14 days. The surplus cement grout shall be cleaned off and remove before set or after every days fixing, works, machine polishing shall be carried out as per the instruction of the Architect and the flooring shall be got cleared up and washed with water and kept ready for occupation.
125
xii
Application Of Frc Composites (Tapecrete) Floor Toppings :Prior to installation, all surfaces must be properly cleaned, free of foreign matter and thoroughly wetted. Depression, if any, shall be filled and levelled using Tapecrete Fillers. Tapecrete Membranes shall be applied in the required number of Fabric layers of 3 mm, 6 mm thickness as specified. Each layer of Fabric in the membrane shall provide a uniform thickness of about 1.5mm (1/16"). Topping shall be applied by the skill labour by way of trowelling, spraying and by other approved mechanized means. Tapecrete system is cured by air drying. The system shall be applied with air temperatures above 7 degree C (45degree F). During the First 12-Hours of curing it must be protected from abrasion, rain, and other adverse conditions. No traffic shall be allowed on a standard Tapecrete surface within 48 hours after installation. The flooring shall be open for surface traffic after 7 to 10 days. For 8mm thickness Tapecrete Topping, material required for one cu.m is cement 650kg/Cum, Polymer P151-338kg./m3 and fine silica sand 1300 kg/m3 while for 6mm thickness cement 512 kg/m3, P151-266 kg/m3, coarse silica sand 768 kg/m3 and fine silica sand - 768 kg/m3.
126
xiii
Carpentry And Joinery Introduction This tender describes the materials and workmanship required for the construction of wood roof framing, wood cabinets, doors, door frames, wood trim and miscellaneous other items to be constructed of wood. References Reference to relevant Indian Standards shall be made. Samples Samples, measuring 300 x 300 mm, of each type of panelling, of each type of solid wood, chipboard or plywood and of laminated plastic shall be submitted in duplicate for approval. Samples, measuring 300 mm in length, of each type of trim and moulding shall be submitted in duplicate for approval. Quality Control Certificates of treatment from vacuum/pressure impregnation plant shall be submitted for preservative treated timber. Preservative treated timber shall be branded so that it is distinguishable from non-treated timber.
127
Product Data Product data shall be submitted for approval for the following (i) Wood preservative treatment process (ii) Preservative for use on cut surfaces of vacuum pressure impregnated timber. (iii) Preservative for use on timber to be encased in masonry. Product Delivery And Storage Timber shall be protected from rain and dampness and shall be packaged as far as practicable, to prevent moisture absorption, contamination by dirt, oil, grease or other harmful materials, and to prevent damage or loss during transport and storage. Transport and storage requirements as recommended by the preservative treatment plant shall be strictly adhered to. Timber and assembled woodwork shall be stored off the ground in weatherproof enclosures, timber shall be open stacked. Packaged materials shall be clearly labeled with manufacturer's name. Contents, quality and quantity shall be clearly marked on packages. Protection Installed cabinet work, trim and other joinery shall be protected in a manner and until such time as directed.
128
Shop Drawings Shop drawings of built in cabinets, counters, closets, shelves and benches shall be submitted for approval. Shop drawings shall show general arrangement, details of construction, jointing, fastening, finishing, other related details, wood species and descriptions of other materials used. Materials Timber shall be hard and soft woods in accordance with their definition as given by Indian Standards. Unless otherwise specified or shown on Drawings, timber shall be used as follows: (i) Carpentry work Trusses, purlins, ceiling battens Fascia and barge boards and skirting Wedges, studs, backings and blocks (ii) Joinery work - cabinets, counters, closets, shelves and benches - to be determined
Glue for treated timber shall be of resin type. Plywood shall conform to the requirements I.S. and shall be first grade plywood. Chipboard shall conform to the requirements of I.S. The board shall be weatherproof and bonded with synthetic resin.
129
Laminated plastic sheeting shall be 1.6 mm thick. The colour and pattern shall be subject to approval. Nails, screws, bolts, spikes, fasteners, brackets, supports, guides, stops and holders shall be of size, material and finish consistent with the function. Nails shall comply with the requirements of I.S. Closet, cabinet and counter hardware shall be chromium plated brass. Door hinges shall be forged iron, regular type with removable threaded pivot. The handle shall be chromium plated brass level handle and the locks shall be Yale type. Fabrication And Manufacture - General Timber shall be well seasoned, sawn square and in straight lengths and shall be free of dirt. Timber shall be inspected as it arrives and any timber not approved shall be removed forthwith. Timber shall be dried to a moisture content of not more than 20% prior to preservative treatment. Timber shall be cut, machined, planed, notched and bored prior to preservative treatment as far as practicable. Where cross-cutting, notching or boring or treated timber cannot be avoided, the exposed surface shall be "brush-treated" with approved type and grain preservative. Timber shall be pressure impregnated with the approved preservative at a pressure of not less than 1 MPa and in accordance with the chemical manufacturer's instructions.
130
After pressure treatment timber shall be reduced to a moisture content of not more than 12% for joinery work and 20% for carpentry work. Pressure treated surfaces to receive glue shall be wire brushed or lightly sanded to remove dirt and excess galts. Actual dimensions of scantlings for both carpentry and joinery shall not vary from the specified dimensions and shall be uniform throughout. Boards shall hold up to the specified thickness and timber shall be as long as possible and practicable in order to eliminate joints. Joinery shall be accurately set out on board to full size for the information and guidance of the artisans before commencing the respective work, with all joints, iron work and other works connected therewith fully delineated. Such setting out must be approved before joinery is commenced. Joinery shall be cut and framed together soon after the commencement of the building or as is practicable, but is not to be wedged up or glued until the building is ready for fixing same. Joinery shall be properly mortised, tenoned, housed, shouldered, dovetailed, notched, wedged, pinned, etc. as directed and all properly glued up with approved resin type glue. Joints in joinery shall be detailed, designed and secured to resist or compensate for any stresses to which they may be subjected. Nails shall be punched.
131
Joints shall be made loose where shrinkage is liable to occur, and glued where sealed joints are required. Exposed surface of joinery work shall be wrought and all arises "eased off" by planning and sand papering to an approved finish. xiv Glazing References Reference is standards: Materials Glass shall conform to I.S. cutting and edgework on glass shall conform to I.S. Glass shall be of such quality that surface deterioration will not develop after glazing (if under normal conditions of use). Glass shall be free from flaws, bubbles, specks and other imperfections. Clear sheet glass for glazing shall be ordinary transparent glass manufactured by the flat drawn process. Figured/frosted glass shall be clear cast glass manufactured by the rolling process. Figured/frosted glass shall be of the deep pattern type to produce greater obscuration and diffusion. Lead glass panels shall be panels of glass held together with lead clamps. made to the relevant Indian
132
Mirrors shall be 6 mm thick special selected (SSG) silvered plate glass with polished edges. Glass louvers shall be clear or frosted sheet glass with ground edges. Putty for glazing in metal frames shall be quick hard-setting tropical putty specially manufactured for use with metal windows. Fixing And Cleaning Rebates and grooves shall be clean, dry and unobstructed and primed at the time of sealing and glazing. Edge clearance shall be equal all round each pane, and no more than 2 mm play all around and where puttied shall be clipped to metal frames. External glazing shall be wind and watertight on completion. Smears and excess compound and sealant shall be removed. Both faces shall be cleaned with approved cleaner and the surface left free from scratches. Fixing of mirrors to wall shall be with chromium plated screws.
k)
Construction Hardware
Specification
For
Rough
And
Finish
The work covered by this specification includes furnishing all labour, material, equipment, and performing the operations necessary to complete the rough and finish, Hardware work.
133
Applicable Publications :All work shall be in accordance with the latest revision of the Indian Standards except where specifically noted otherwise. Cold Rolled Mild steel Bolt Hinges Tower Bolts Butt hinges Tee and strap Hinges Gate and shutter Hooks and Eyes Door Handles Sliding Door Bolts for use with Pads locks Parliament Hinges Hasps and Staples I.S. I.S. I.S. I.S. I.S. I.S. I.S. I.S. I.S. 1341 204 205 206 207 208 281 362 363
ii
Material :All material shall be new and delivered to the site in unopened manufacturer's containers. All Hardware shall be delivered complete with all component parts including screws of proper size. They shall be sound, strong and of the best quality. They shall be of brass or oxidised brass of Aluminium. Door Hinges 4" x 1" (100mm x 25mm) Toilet Door Hinges 3" x 1" ( 75mm x 25mm) Swinging Door Hinge Skeleton Bolts sectional Flush Bolts level type 6" x 1" (150mm x 25mm) All drops 12" & 5/8" (300mm & 15mm) Safety Hasps and Staples 6" x 1 1/2" (150mm x 38mm) Finger plates 3" x 8"1/8" (75mm x 200mm x 3mm) Coat Hook Door stopper and holder Toilet compartment Latch
134
Toilet Compartment latch for Administration Buildings Stair Nosing for Administration Building 2 & 1/2" (65mm) Door Pulls 10" x 1-1 1/2" x 1/8" (250mmx38mmx3mm) Rim Lock 4" (100mm) Tumbler Holder Locks and Handles Barrel Bolts 9" x 1 1/2" (230mm x 38mm) with 1/2" (12mm) sheet. iii Installation :All the fixtures shall be fixed to the joinery in a secure and efficient manner or as specified by the Manufacturer's directions and shall be installed plumb, true and secured with the proper fastenings so as to make all work, rigid and firm. Any of the fixtures damaged during fixing shall be removed and new ones fixed in their place and the surface of joinery made good where affected, at the Tenderers expenses. All drops, safety hasps and staple locks and handles and tubular latches shall be installed 36" (915mm) from the floor. Night latches shall be installed 48" (1200mm) from the floor. All locks and tubular latches shall be installed with brass strike plates. iv Protection :Hardware that might be damaged by the construction work shall be protected during the progress of the work and uncovered at its completion.
135
Cleaning :Upon the completion of the construction, all hardware shall be cleaned and polished and left in perfect operating condition.
l)
Construction Specification For Plumbing The work covered by this specification includes furnishing all labour, materials, equipment, and performing the operations necessary to complete the plumbing work shown on the approved drawings and specified herein. i Applicable Publications :All work shall be in accordance with the latest revision of the Indian Standards except where specifically noted otherwise. Specification for white glazed Earthenware Sanitary appliances Specification for Enamelled cast I.S. iron Sanitary appliances. Specification for flushing cisterns I.S. Brackets and supports for lavatory basins and sinks. Specification for metal gate, globe and check valves Specification for sand cast brass screw down bib taps and stop taps Specification for caulking Lead Specification for centrifugally cast I.S. 771
772
774 I.S. 775
I.S.
778.
I.S.
781
I.S. I.S.
782 1536
136
iron pressure pipes Specification for vertically cast iron pressure pipes Specification for cast iron manhole covers and frames ii Work Included :The Tenderer shall furnish and install all the fixtures, fittings, all piping, underground and above ground complete with all valves, taps, fittings, insulation, and all items including cutting all chases and restoring them to their original condition. iii Materials :European type water closets Shall be new, unmarred, white glazed, wash down type, of one piece construction with integral flushing rim and water inlet with integral "S" trap or "P" trap complete with low level cistern I.S. 1538
I.S.
1726
Indian type water closets shall be new, unmarred, white glazed, wash down type with integral flushing rim, and water inlet, 58 cm (23") long or as specified in item confirming to I.S.771 type two complete with "S" or "P"trap. Wash basins shall be new, unmarred, white glazed, flatback single tap 56cm. x 40cm. (22" x 16") or as specified in item, complete with non-ferrous waste chain, fittings and stopper, chrome plated "P" trap, support brackets with studs, and nuts and backing plate, confirming with I.S. 771.
137
Urinals shall be new, unmarred, white glazed, flat back, one piece construction with an integral flushing rim and water inlet, complete with fixing bolts and backing plate, confirming with I.S 771. European type water closet seats and lids shall be of Bestolite Sinks shall be new, enamelled, cast iron, two compartment, one piece construction 106 cmx79 cm x 25 cm with centre over-flow with one waste outlet in each compartment complete with waste plug, nonferrous waste chain, fittings and stopper, fixing brackets with stud bolts, nuts, "S" trap and confirm to I.S.772 except if specified otherwise. Flushing water closets shall be (13.60 Lit) capacity siphonic high level cistern, complete with concealed type brackets Faucet shall be 1/2" (12mm) chrome plated with American standard tapered threads. For wash basins, faucets shall be piller tap. For sinks, faucets shall be combined mixing faucet with swivel nozzel similar to shanks A-9287. For showers, faucets shall be combined mixing faucet or as specified. For washing troughs, faucets shall be similar to shanks D-5730 Galvanised pipe and fittings shall be new, free from cracks, threaded with tapered threads and confirm to I.S. 1239-1958. Pipe sizes from 12 mm through 40 mm shall be medium class. Pipe sizes above 40 mm shall be medium class. Black iron pipe and fittings shall be new, free from cracks, threaded with tapered threads and conform to I.S 1239- 1958. Pipe sizes from 12 mm through 40 mm shall be medium class. Pipe sizes above 40 mm shall be medium class.
138
Cast iron pipe shall be new, free from cracks and blow holes, with spigots and/or sockets suitable for lead joints, without head, confirming to I.S. 1536 or 1537 class B. Cast iron fittings shall be new, free from cracks and blow holes, with spigots and/or sockets suitable for lead joints, confirming to I.S. 1538 heavy type. Gate valves shall be split taper wedge rising spindle gunmetal, confirming to I.S. 778, except female ends threaded to National Pipe Tapered threads. Globe valves shall be renewable disk rising spindle, all gunmetal, confirming to I.S. 778, except female ends threaded to National pipe Tapered threads. Stop taps shall confirm to I.S. 781 except female ends shall have threads confirming to National pipe Tapered Threads and shall be chrome plated. Bib-taps except as hereinbefore specified, shall confirm with I.S. 781, except threads shall confirm to National Pipe Tapered Threads and shall have a G.I. socket screwed on the male end. Floor drains shall be cast iron with an integral "P" trap. It shall have a separate grating which is attachable with counter sunk screws. Cowls for all events shall be cast iron and or PVC with 12mm wide slots all around and a domes top. The female end shall have National Pipe Tapered Threads to receive a 75 mm pipe. Water Coolers :- Shall be instantaneous pressure type with a 14 G.P.H. nominal cooling capacity, with a hooded angle stream jet, foot pedal operated. Toilet paper holder at European type water closet shall be white, shanks no. 7643
139
Soap Dishes in shower Rooms shall be shanks no.119 iv Installation :Drainage Pipes :All lines shall be pitched at 3mm per 30 cm. Hung lines shall be supported by at least 18 G x 11/2" galvanized iron strap hangers with two straps per pipe length. Vertical line shall be strongly secured to the structure. Provide clean out at every change in direction of waste lines. All clean outs under floors shall be provided with flush to the floor plates of cast iron. Outlet size for fixtures : Outlet and vent lines shall be as follows :---------------------------------------------------------------------Fixtures Drainage Vent ---------------------------------------------------------------------Water closets 10 cm (4") 5 cm (2") Urinals 5 cm (2") 4 cm (1-1/2") Urinal Troughs 5 cm 4 cm Sinks 5 cm 4 cm Wash Basins 4 cm 4 cm Drink fountains 4 cm 4 cm ---------------------------------------------------------------------Joints : Cast iron shall be caulked with Oakum and Soft caulking lead. Threaded joints reamed and with red lead on male end only.
140
Vents Vents shall be located and shall be increased to a size to fit the cowl before going through the roof. ON sloping roofs, vents shall be cut off 10 cm above the high side of the roof at the vent, on Flat roofs vents shall be cut off 30 cm above the roof. v Cleaning And Protection :All exposed metal surfaces shall be cleaned from dirt, grease and other foreign material. Chrome plated surface shall be polished upon completion of the construction. Fixtures shall be protected from damage during construction and shall be cleaned in accordance with manufacturer's instructions upon the completion of construction. At the completion of the construction, all surplus material, cartoons, boxes and other debris, shall be removed from the site. vi Tests :Waste pipes shall be tested by being water-filled to the roof. Water lines shall be tested by 100 pounds per square inch (7.03 kg. per sq cm) pressure. Air lines shall be tested by 200 pounds per sq. inch. ( 14.06 kg. per sq. cm. ) pressure. Steam line, before the insulation in installed, shall be tested by 200 pounds per square inch (14.06 kg. per square cm) pressure.
141
vii
Pipework - Pipes Reference General directions and descriptions of materials and work which are included in this tender but which also apply to the provision of pipework are not necessarily repeated. Pipelines below ground - inspections The Tenderer shall give notice to the Owners Representative for purpose of inspection whenever sections of: Excavations are completed Concrete beds are laid Pipework installations are completed and no further work shall be executed until each stage of the work has been inspected. Asbestos cement pipes Asbestos cement pipes shall comply with relevant I.S. 'Asbestos cement pressure pipes'. Pipe joints shall be made using one of the following types of flexible coupling: (i) (ii) Rubber ring joint incorporating an asbestos cement sleeve Rubber ring joint incorporating a cast iron or steel spacer and cast iron or steel flanges.
Asbestos cement pipes shall be coated internally and externally with bitumen in accordance with relevant I.S.
142
Clay pipes Vitrified clay pipes to be used for sewerage or surface water shall be manufactured in accordance with the requirements of relevant I.S. complete with flexible spigot and socket connections. Ductile iron pipes Ductile iron pipes shall conform to relevant I.S. joints shall be flexible spigot and socket connections. Pipes shall be coated internally and externally with a coal tar pitch or bitumen material as specified in relevant I.S. Steel pipes Steel pipes shall comply with relevant I.S. Diameters and thicknesses of pipe shall be selected from those given unless otherwise approved by the Owners Representative. Pipe ends shall be prepared for butt welded, sleeve welded, or slip-on coupling joints and in accordance with I.S. Internal protection shall be spun bitumen with suitable primer, all to I.S. External protection shall be fiber glass reinforced bitumen sheathing for below ground installation with suitable primer, all to I.S. For above ground installation the pipe shall have one coat zinc chromate primer and two coats of approved bituminous aluminium paint.
143
Galvanized steel pipes Distribution pipe work for potable water supply shall generally be galvanized steel pipe conforming to I.S. having plain ends suitable for screwing to I.S. pipe threads. Corrugated steel culverts Corrugated steel culverts shall be Armco Type E.100 bolted nestable culvert or approved equivalent and shall consist of corrugated, galvanized and bitumen coated steel sheets bolted into rings to form a pipe of the required diameter. The corrugations shall have a pitch of 100 mm and a depth of 20 mm. The steel used in the fabrication of the sheets shall conform to the requirements, of I.S., condition HR. The sheets shall be hot-dip galvanized after fabrication to ensure a coating weight of not less than 755 g/m2. Where the zinc coating has been damaged by field cutting or other means, the damage shall be made good using an approved zinc-rich paint. Pre-cast concrete pipes Pre-cast concrete pipes for foul and surface water drains shall comply with I.S. Pre-stressed concrete pipes for pressure pipelines shall comply with I.S.
144
Unplasticized P.V.C. Pipe Unplasticized P.V.C. (U.P.V.C.) pipes for cold water services shall comply with I.S. 'Unplasticized P.V.C. pipe for cold water services'. Joints shall comply with I.S. Unplasticized P.V.C. pipes for foul and surface water drains shall comply with I.S. Steel components and bolts All steel components shall be hot dip galvanized in accordance with I.S. 'Hot dip galvanized coatings on iron and steel articles'. Bolts, nuts and washers shall comply with the following standards: I.S. 'ISO metric black hexagon bolts, screws & nuts'. I.S. 'Metal washers for general engineering purposes'. All bolts, nuts and washers are to be zinc coated in accordance with I.S. 'Sherardized coatings on iron and steel articles'. All steel flanges shall comply with I.S.. Rubber rings and gaskets Rubber rings and gaskets shall conform with I.S. 'Materials for elastomeric joint rings for pipe work and pipelines'. Dimensions of gaskets shall conform with I.S. 'Dimensions of gaskets for pipe flanges to I.S.
145
Temporary storage The Tenderer shall take into temporary protective storage all pipes not required for immediate installation in the Works, or for stringing out along the pipeline. Pipes in storage shall be laid on wedged timber bearers so as to be at least 75 mm clear of the ground; pipes other than thin shell pipes may be stacked if suitable protective packing is placed between the layers. The period between taking delivery of a pipe and the completion of its installation shall be kept to a minimum. Any period during which the pipes are laid out along the pipeline or placed alongside the Works awaiting installation shall also be kept to a minimum and if this period exceeds one month pipes shall be raised at least 75 mm from the ground on timber bearers. Handling and installation generally Throughout the construction of the pipeline including the operations of off-loading on delivery, handling, storing, and transporting pipes and valves on or about the Site, the Tenderer shall use such methods plant and equipment as will prevent damage to the pipes and to any sheathing lining or paintwork, and such methods shall include the use in appropriate cases of pipehooks, lifting beams, reinforced canvas slings, protective padding, struts, cradles and pipe trailers. No pipe shall be moved by rolling save over suitable timber planking so arranged as not to damage the pipe or its sheathing.
146
Setting Out The Tenderer shall set out all drains and services in accordance with the approved drawings and shall set up and maintain temporary bench marks and shall provide all necessary labour and materials, instruments and boning rods and shall erect and maintain all sight rails. Sight rails shall be set up for all lines of drains, such that there will always be at least three rails in position at one time on each line of pipes, to any one gradient. The drains shall be laid in straight lines and to even gradients to the levels shown, with pipes and specials of the kinds and diameters shown. Level pegs shall be accurately boned in from the sight rails and driven into the bottoms of the trenches to the levels of the inverts of the lines of pipes. Excavation The bottoms of all excavations shall be trimmed and consolidated to the correct levels. Unauthorized excavations below the required level shall be filled with material of the same composition as for pipe work beds. Where the bottom is insufficiently firm, the Tenderer shall excavate until, in the Owners Representative's opinion, a firm bottom is obtained and the level shall be made up with material of the same composition as for pipe work beds. Particulars of such additional work shall be agreed with the Owners Representative before the work is covered up.
147
The minimum trench width for all buried pipelines shall be 600 mm or as described in the following table: Pipe dia mm 200 225 250 300 400 450 500 550 600 650 750 900 1200 1250 1400 1600 Laying Pipes All pipes shall be inspected for defects prior to laying. Any damaged pipes shall be rejected. Pipes shall be carefully lowered into the trenches, and all damaged pipes shall be rejected. Pipes shall be laid truly straight on line and gradient with sockets upstream. The pipes shall be laid singly on the bed and the level of each pipe shall be tested by a straight edge laid in the invert of the pipe from the invert of the pipe previously laid and on to the nearest level peg. If the bottom of the trench or bed is too low, it shall be made up with the appropriate bedding material. Minimum Trench Width mm 600 650 850 900 1000 1000 1100 1100 1200 1200 1300 1500 1800 1800 2000 2000
148
Care shall be taken to ensure that there is no irregularity to the invert of the joints and the bore of the pipe shall be cleared of any obstruction before the next pipe is laid. No pipes shall be laid on their collars or on bricks, tiles or other temporary supports. Where it is required to shorten any pipe, it shall be cut off square and cleanly with approved pipe-cutting equipment. Pipe runs shall be kept free from mud, debris, superfluous cement or other obstructions during laying and until the completion of the Contract. In the event of any pipe being fractured from any cause whatsoever, after having been to all appearances properly laid, the Tenderer in every instance will be held responsible and any such defective pipes shall be replaced to the satisfaction of the Owners Representative. Where possible pipes shall be laid with not less than 1m cover. If the cover is less than lm or under roads with less than 1.2m cover or where ordered by the Owners Representative they shall be haunched or surrounded with Grade 20 concrete, minimum thickness 150mm. Jointing Of Pipes Jointing of pipes shall be carried out strictly in accordance with the manufacturer's instructions. Welding Joints For Steel Pipes Welding of joints in steel pipes shall be carried out manually by the metal-arc process complying generally with the requirements of BS 4515.
149
In all other respects the requirements for welding set out in Class M shall apply. Internal And External Protection After completing a joint any protective paint or bitumen lining shall be made good and any steel joint which is not already coated shall be cleaned and coated to the standard specified for the pipes. The method proposed for making good of lining at the joints shall be submitted for the Owners Representative's prior approval. Sleeves All pipes, conduits, cables or the like passing through walls or foundations shall be protected by sleeves of U.P.V.C. pipe. Backfilling Where pipes are not surrounded by granular bedding or concrete, the filling around and 300 mm above the pipe shall be of suitable material free from stones which would be retained on 20 mm sieve. Backfilling of trenches shall be done with suitable material in layers not exceeding 150 mm. The highest possible degree of compaction shall be obtained with the provision that no mechanical rammer will be used within one meter of the top of any pipe.
150
Testing The Tenderer shall give notice of testing to the Owners Representative. All works shall be tested as described and to the satisfaction of the Owners Representative before backfilling of the excavations is commenced. The Tenderer shall locate and remedy all defects before further pipe laying proceeds and shall repeat the test until a satisfactory test is obtained. Where a length of pipe under test terminates at a manhole, the restriction on further pipe laying will not apply. The Tenderer shall provide and fix testing branches and bends, as required and shall seal off or remove them as directed by the Owners Representative. The Tenderer shall ensure that all sections of the pipelines are completely clear of any obstructions, debris and superfluous matter, before any tests are applied to such sections and upon completion of the Contract. Testing of pipelines shall comply with the following as applicable. i. Foul gravity drains shall be filled with water under a head of not less than 1,500 mm after the joints have been made and before any backfilling is commenced. After a reasonable period has elapsed, the water level shall be made good by adding water, as required. The water level shall then be maintained for half-an-hour without adding further water.
151
ii.
Pressure mains shall be subjected to pressure and leakage tests which shall be carried out on all pipelines at the direction of the Owners Representative. The maximum section of pipeline under test shall be 1,000 meters and joints shall be left uncovered throughout the duration of the hydrostatic test. Pipelines shall be slowly filled with water such that all air is expelled; after filling, the pipeline should be left under operating pressure for a period agreed by the Owners Representative, such that conditions as stable as possible can be achieved. Unless agreed in writing by the Owners Representative, the test pressure shall be 1.5 times the operating pressure at the lowest point of the pipeline section under test. This test pressure shall be applied by means of a pump connected to the pipe, in a manner satisfactory to the Owners Representative, and shall be held for a minimum of 30 minutes. If a drop in pressure occurs, the quantity of water required to re-establish the test pressure should be carefully measured. This shall not exceed 0.1 liters per millimeter of pipe diameter per kilometer of pipeline per day for each 30 m of pressure applied. The Tenderer shall provide a duplicate certificate test book for pipelines as follows: Each test certificate shall be consecutively numbered, the top copy of which is retained by the Tenderer. The book will remain the property of the Owners Representative.
152
Each test certificate will indicate the date of test, location of section under test; pipe diameter; test pressure; test duration; pressure drop (if any) and any other pertinent remarks. This procedure shall be carried out for each test made whether the outcome of the test is successful or not. viii Pipework - Fittings And Valves Fittings Generally Unless otherwise specified all bends, junctions and reducers shall be of the same material and comply with the same I.S. as for the main pipeline. Butterfly Valves Butterfly valves shall comply with I.S. 'Cast iron and carbon steel butterfly valves' for general purposes. Sluice Valves Sluice valves shall comply with I.S. 'Double flanged cast iron wedge gate valves for waterworks purposes'. Each valve shall be the same nominal size as the pipe unless otherwise specified, fitted with a spindle cap and arranged for clockwise closure. Check Valves Check valves shall comply with I.S. 'Cast iron check valves for general purposes'. For nominal bore of 500 mm and above they shall be of the tilting disc or double disc type with bolted split casing.
153
Fire Hydrants Hydrants shall comply with I.S. 'Underground fire hydrants and surface box frames and covers'. Air Valves Each air valve shall be of the type and size specified. It shall be suitable in all respects for the operating conditions and in the case of a large orifice air valve or air valves incorporating a large orifice, it shall be designed to prevent valve closure when discharging large quantities of air. Each valve is to be complete with an isolating valve to allow removal of the air valve under operating conditions. Protective Coatings All valves shall be coated internally and externally with bitumen solution to I.S. Flanges And Gaskets All flanges shall be to I.S. 'Flanges and bolting for pipes, valves and fittings' unless otherwise specified. Gaskets shall conform to I.S. Slip On Type Couplings Slip on type couplings, stepped couplings and flange adapters shall be 'Viking Johnson' (V.J.) or similar approved. They should be the proper model for the pipe with which they are to be used and be supplied with central register (standard couplings only), galvanized bolts, and tapped plugged holes (for application of internal extensive coating).
154
In jointing plain ended pipes with couplings the Tenderer shall take account of the manufacturer's recommendations as to the methods and equipment to be used in assembling the joint. In particular the Tenderer shall render the end of each pipe perfectly smooth so as to allow the joint sleeve to slide freely and where necessary shall re-coat the pipe ends with two coats of quick drying bituminous solution. If the internal diameter of the pipe is 500 mm or more the coupling shall be sealed internally after completion. A temporary flexible internal backing strip coated with mould whiting shall be fitted inside the pipe to seal the cavity between the pipe ends and the joint sleeve and funnels shall be screwed into the plug holes in the V.J. coupling. Hot bitumen compound shall be poured in through the lower plughole (the upper funnel acting as an air vent) until the cavity is full. After the bitumen has cooled the backing strip and funnels shall be removed and the screw plugs replaced. Where the couplings are used for below ground installation they shall be cased in bitumen using a proper mould supplied by the coupling manufacturer, into which hot bitumen compound shall be poured as for the internal lining. Installation Of Valves Installation of valves shall include installation and fixing of any operating gear and associated fittings.
155
Before installing valves the Tenderer shall tighten all loose nuts and bolts on the valves and associated equipment and shall ensure that they are watertight and in proper working order. Flanged joints shall be made with steel bolts and nuts which shall include two washers per bolt. All nuts shall first be tightened by hand and nuts on opposite sides of the joint circumference shall then be alternately and progressively tightened with a spanner so as to ensure even pressure all round the joint. After installation valves shall be cleaned inside and out, any protective coating made good, and shall be left in the closed position. Ferrules Ferrules for connecting service pipes to water mains shall be of non-ferrous metal fitted by clockwise screwing down. The nominal diameter of a ferrule shall not exceed one quarter of the nominal diameter of the main into which it is inserted. The ferrule shall be screwed into the main at an angle of 90 degrees to the vertical and the outlet shall be directed along the main so that the service pipe leads off with a right angle turn away from the main.
156
Drilling And Tapping Mains Tappings in pipes shall be made by first fitting a purpose-made saddle on the main with wedges, bolts and rubber washers or other equally effective device. Using a sharp drill a hole shall then be drilled slowly through the boss of the saddle piece and through the barrel of the pipe and the hole shall be tapped to give a continuous thread through the saddle and the pipe. ix Pipework - Manholes And Pipework Ancillaries Manholes Manholes shall be precast concrete to I.S. or of blockwork or brickwork construction. The design shall generally comply with recommendations in I.S. Blockwork or brickwork walls shall be constructed such that joints shall be well flushed up with mortar leaving no internal voids, flush-pointed on the inside of the manhole and weather-pointed on the outside. Cement rendering of the inside surface of the walls shall consist of two coats of equal thickness, and the total thickness shall be 12 mm. The surface to be rendered shall be thoroughly cleaned and scored to form a key and moistened with water twenty-four hours before commencement of work. The surface of the first coat shall be similarly roughened to form a key for the second coat, which shall not be applied until the first coat has thoroughly set. The second coat shall be applied within three days of the first coat and shall be floated to a smooth, even surface.
157
The base of the manhole shall be mass concrete Grade 20 of minimum thickness 150 mm below the pipes. The channel may be formed using half-pipes or constructed in concrete. It shall be a smooth transition between the inlet and outlet pipes. Pipe soffits shall be kept level when there is a change in pipe diameter. Benching shall have a minimum slope of 2 in 5 towards the channel and shall be rendered to a smooth, hard finish. Particular care shall be taken to provide a water-tight joint where pipes enter and leave the manhole and a flexible joint shall be made 500 mm from the manhole wall. The centre lines of pipes shall intersect at the centre of the manhole. Step irons shall be securely grouted 150 mm into the wall. After the grout has hardened each step iron shall be struck a hard blow with a 2 kg hammer and any rung which is broken shall be cut out and replaced. Manhole Covers, Surface Boxes And Gratings Cast iron and cast steel manhole covers and frames shall conform to I.S., surface boxes, valve covers and the like shall comply with I.S.. Two sets of each type of key for locking covers and gratings shall be provided and handed over to the Owners Representative on Contract completion. Rodding Way Covers The access to all rodding ways shall be covered by a cast iron cover fixed to a frame with at least two screws and sealed with a composition gasket.
158
Septic Tanks Septic tanks shall be constructed in accordance with I.S. The septic tank effluent shall be piped to a soak away the size of which shall be agreed with the Owners Representative from approved seepage trials to be completed by the Tenderer. x Copper Water Tubes And Fittings Copper "domestic" water pipes shall conform with I.S. solid drawn, supplied in straight lengths, suitable for connection by means of compression fittings and capillary fittings, which shall conform to I.S. xi U.P.V.C. Tubes And Fittings U.P.V.C. waste and overflow pipes to cisterns and geysers shall conform to I.S. all erected strictly in accordance with the manufacturer's instructions, using solvent welded joints. m) Construction Specification For Roads And Pavings i Reference General directions and descriptions of materials and work which are included in the tender but which also apply to the provision of roads and pavings are not necessarily repeated. Reference should, therefore, be made to the Specification as a whole when dealing with this part of the Works.
159
ii
Stripping The areas shall be stripped of all top soil, which shall be deposited evenly in the adjacent fields. All roots, tree stumps, rocks and waste material shall be loaded and carted to tip.
iii
Sub grade And Improved Subgrade Unless otherwise specified or required by the Owners Representative, materials forming the direct support of the pavement shall comply with the following requirements: CBR (100% I.S. - 4 days soak) : minimum 5 Swell (100% I.S. - 4 days soak) : maximum 2% Organic matter (% by weight) : maximum 3%
Where, in the opinion of the Owners Representative, material unsuitable for the direct support of the pavement occurs in cuttings, the Tenderer shall excavate it to the depths and widths required and replace it with selected fill material to form an improved sub grade. iv Laying And Compacting Subgrade The maximum compacted thickness which shall be laid, processed and compacted at one time shall be 300 mm. The layer shall be scarified, water shall be uniformly mixed in or the material allowed to dry out to the correct moisture content.
160
The upper 300 mm of the earthworks (that is to say the sub grade) shall be compacted to a dry density of at least 100% MDD (Standard Compaction) in cuttings where there is no improved sub grade and everywhere in fills and embankments. In cuttings, where an improved sub grade is to be placed, the upper 150 mm of the sub grade prior to the placing of the improved sub grade layer(s), shall be compacted to at least 100% MDD (Standard Compaction) and the lower 150 mm shall be compacted to at least 95% MDD (Standard Compaction), unless otherwise specified. All improved sub grade shall be compacted to a dry density of at least 100% MDD (Standard Compaction) for its full depth. The moisture content shall be adjusted in order that the above minimum compactions are obtained. Unless otherwise accepted by the Owners Representative, the moisture content at the time of compaction shall not exceed 105% of the Optimum Moisture Content (I.S.). v Forming Of Subgrade During the above process, the final surface of each sub grade layer shall be graded to level, parallel to the cross fall and camber and profile shown upon the approved drawings
161
The sub grade shall be cleaned of all foreign matter and any potholes, loose material, ruts, corrugations, depressions or other defects which have appeared in the sub grade layer, due to improper drainage, traffic or any other cause, shall be corrected. If required by the Owners Representative, the Tenderer shall scarify, grade and recompense the sub grade to line, level and specification. No work above the sub grade shall be executed until the sub grade has been approved by the Owners Representative. Fill for sub grade or improved sub grade shall, wherever suitable, be excavated material obtained from drainage ditches and road cuttings. vi Drainage Of Works All cuttings, embankments and borrow areas shall be kept free of standing water and drained during the whole of the construction. Should water accumulate on any part of the earthwork either during construction or after construction until the end of the Maintenance period, the Tenderer shall remove and replace any material which, in the opinion of the Owners Representative, has been adversely affected. The Tenderer shall so order his construction programs that the construction of culverts and drains does not lag behind the earthworks. Well in advance of commencing earth-moving operations over swampy or waterlogged areas, the Tenderer shall cut drains and ditches and carry out any other works as necessary to assist in draining the ground.
162
All drains and ditches shall be maintained in proper working order throughout the duration of Contract. The Tenderer shall allow in his rates for draining the earthworks satisfactorily at all stages during the construction and arrange his methods and order of working accordingly. vii Drainage Ditches Drainage ditches, shall be shaped by excavating to the lines, slopes and widths shown upon the approved drawings and finished off so that the sub grade levels and camber of super elevation of the sub grade, level and cross fall of the shoulders and slope and invert levels of the side ditches are required. viii Pavements Generally The term "gravel" used throughout this tender shall be deemed to include lateritic gravel, quartzitic gravel, calcareous gravel, some forms of weathered rock, soft stone, coral rag and conglomerate. "Graded crushed stone" shall mean crushed stone, with a smooth grading curve, which is within a specified envelope. A "gravel" base shall be made up of one of these natural gravels, or of a combination of them, or of a combination of gravel and sand, without the adding of any stabilizing agent. A "gravel wearing course" shall mean a top surfacing course made from one, or from a combination of materials and may be applied to some or all of a new road formation where no pavement and final bituminous surface is included.
163
A "crushed stone wearing course" shall mean a top surfacing made from graded crushed stone and may be applied to road base course where no final bituminous surface is included. A "surface dressing" shall mean a top surfacing of bituminous binder and stone chipping applied to the road base course. ix Material For Gravel Base And Wearing Courses Unless otherwise required by the Owners Representative, the Material shall comply with the following requirements: Gravel For Plasticity Index Los Angeles Value Maximum Aggregate Crushing Value Maximum CBR (95% MDD Heavy Compaction 4 days soak) Minimum Base 5-15 70 50 Wearing Course 5-25 50 35
30
80
164
The grading curve of the material, after processing and compaction shall be of a smooth curve within the following envelope: Sieve Size (mm) 50 37.5 20 10 5 2 1 0.425 0.075 x Percentage by Weight Passing Base Wearing Course 100 95-100 100 60-100 95-100 35-90 65-100 20-75 45-85 12-50 30-68 10-40 25-56 7-33 18-44 4-20 12-32
Material For Crushed Stone Wearing Course The material shall consist of crushed stone, free from clay, organic or other deleterious matter and have the following properties: (i) Los Angeles Abrasion ValueAggregate Crushing Value Max. 40 Max. 30
(ii)
Cleanliness and plasticity: The fines passing 0.425 mm shall be non plastic. Crushing, screening and mixing: Unless otherwise required by the Owners Representative, crushing shall be done in at least two stages.
(iii)
165
(iv)
Grading: The grading curve of the material, after processing and compaction, shall be a smooth curve within the following envelope: Sieve Size (mm) 37.5 20 10 5 2 1 0.425 0.075 Percentage by Weight Passing 100 65-95 40-70 30-55 20-40 15-32 10-24 -
The screening and proportioning of materials, and their subsequent mixing shall be carried out using such methods and machines as may be approved by the Owners Representative. Where the graded crushed stone is deficient in fine aggregate and, in the opinion of the Owners Representative, the Tenderer has made every reasonable effort to produce the required grading, the Owners Representative will allow admixing of approved non-plastic fine aggregate such as sand or crusher-dust. No extra payment will be made for providing and mixing of such fines. Where the addition of fine aggregate is necessary, it shall be thoroughly mixed in with the crushed stone. The percentage of fine aggregate to be added to the crushed stone will be agreed with the Owners Representative and shall in any case not exceed 15 per cent by weight of mixture.
166
xi
Order Of Work Unless otherwise required by the Owners Representative, the base or wearing courses shall be laid starting as close as possible to the Materials Site and working away from it so that the maximum amount of compaction is given to the wearing course by the Tenderer's vehicles, and the Tenderer shall route his vehicles to give even wear and compaction over the whole width of the wearing course.
xii
Laying And Compacting Base And Wearing Courses The base or wearing course materials shall be deposited and spread in a uniform layer across the full width required so that the final compacted thickness is nowhere less than required. The compacted thickness of any layer laid, processed and compacted at one time shall not exceed 200 mm and where a greater compacted thickness is required, the material shall be laid and processed in two or more layers. The materials shall be broken down so that the maximum size of any particle is not greater than specified. This may require a grid, cleat or sheepfoot roller or a pulverize and the Tenderer shall allow for such processing in his rates. Any oversize material which cannot be broken down to the required size shall be removed and disposed of as required by the Owners Representative. The layer shall then be scarified and water shall be uniformly mixed in, as approved by the Owners Representative. It shall be graded, compacted to a dry density of at least 95% MDD (Heavy Compaction), and graded to final level.
167
The moisture content shall be adjusted so that the minimum compaction is obtained. Unless otherwise approved by the Owners Representative, the moisture content at the time of compaction shall be between 80 and 105% of the Optimum Moisture Content (Heavy Compaction). xiii Geometric Tolerances Of Pavement And Subgrade The pavement layers and the sub grade shall be constructed within the tolerances shown in the table below. Levels: The levels of pavement layers and sub grade shall be determined from the specified surface of the wearing course, calculated from the carriageway vertical profile and cross fall. For checking compliance with the table, measurements of surface level shall be taken at 20 m intervals along the centre-line and along a line parallel to the centre-line but 500 mm from the edge of the layer. Pavement widths: The half width shall be measured from the centreline of the road to the edge of the layer. The final average width of all kinds of wearing courses, binder courses, bases and sub-bases measured at six points taken at 20 m intervals over a length of 100 m shall be at least equal to the width specified or ordered.
168
Cross fall: The cross fall of the pavement shall nowhere vary by more than 1.0% from the specified value. Pavement Thicknesses: In addition to the above tolerances, the thickness of any pavement layer shall nowhere be less than 90% of the specified thickness. The final average thickness of all kinds of wearing courses, binder courses, bases, sub-bases and shoulders over a length of 100 m shall be at least equal to the thickness specified or ordered. Variations Permitted (mm) Irregularity Half Width Half (under 3m Maximum straight Width Variation in edge) 20 m N.A. N.A. N.A. +/-25 -50,+100 N.A. N.A. +/-15 +/-25 +/-25 +/-25 N.A. -25,+50 -25,+50 30 N.A. 50 50
Layer Subgrade Base Surface Dressing Shoulder Gravel Wearing Course Crushed Stone Wearing Course
Level -40,+25 -30,+25 N.A. +/-15 +/-25 +/-25
169
xiv
Surface Dressing Primer: The prime coat shall be a low viscosity medium curing cut-back bitumen (MC-30 or similar approved) sprayed uniformly over the road base at a rate of between 0.5 L/m2 and 1.0 L/m2 as approved by the Owners Representative. Binder: After a period of not less than 24 hours the primed surface shall be sprayed uniformly with a medium curing cut-back bitumen (MC-3000 or similar approved) at a rate between 0.9 L/m2 and 1.5 L/m2 as approved by the Owners Representative. Chippings: Chippings shall be spread uniformly onto the binder and rolled with an approved pneumatic-tyred or steel wheeled roller. The chippings shall be single sized crushed stone as cubical as possible and free from visible stone dust and deleterious substances such as clay, salt, or organic matter. The nominal size of chippings shall be in the range 6 mm to 15 mm as approved by the Owners Representative.
xv
Use Of Surfaces By Constructional Traffic Constructional traffic used on pavements under construction shall be suitable in relation to the courses it traverses so that damage is not caused to the sub-grade or the material constructed.
170
The wheels or tracks of plant moving over the various pavement courses shall be kept free from deleterious materials. Bituminous base course material shall be kept clean and uncontaminated for so long as it remains uncovered by a wearing course or surface treatment. The only traffic permitted access to base course material shall be that engaged in laying and compacting the wearing course or, where the base course is to be blinded and/or surface dressed that engaged on such surface treatment. Should the base course become contaminated the Tenderer shall make good by cleaning it to the satisfaction of the Owners Representative and if this proves impracticable, by removing the layer and replacing. xvi Concrete Roads Concrete roads shall be laid on a sub-grade of compacted fill as detailed in this tender document. Levels of the finished layer shall permit the full minimum thickness of concrete slab to be constructed at all places. The sub-grade shall be thoroughly wetted before placement of the concrete. Concrete road slabs shall be constructed using Grade 20 concrete having a minimum thickness of 200 mm. Reinforcing layers are required at the top and bottom of the road using 10 mm dia. mild steel reinforcing bar at 200 mm centers both ways. These layers shall be fixed and supported in place before the concrete is poured and there should be a minimum concrete cover over all steel of 50 mm.
171
All construction and expansion joints shall be as indicated on the approved drawings with the following maximum spacings, 60 meters (expansion joints), and 20 meters (construction joints). 1.2 SCOPE OF WORK The Tenderer is responsible for the entire scope of the cogeneration project between the given terminal points. This document elaborates on the specific requirements of this project and need not be considered comprehensive. All plant & equipment, civil works and services required to commission the cogeneration project are deemed in the scope of the Tenderer. All services, plant & equipment will be as per relevant IS / ASME / IBR or other applicable standards. Partial list of applicable standards are given in this document. In case of conflict between given standards and alternate applicable standard, the more stringent will prevail. In case of absence of detailed standard for particular service / equipment, the Tenderer will follow good engineering practices as approved by the Owner / Consultant. The scope of work inter-alia will include : a. Detailed engineering and design including submission of the same for all civil, mechanical, electrical and I&C requirements of this cogeneration project. All required civil works for soil investigation, dismantling of any balance RCC structures or columns, levelling, back filling, foundations, buildings, chimney, cooling tower, internal roads, reservoir, drains, trenches, sewerages, compound wall, rainwater harvesting and greenery development, alongwith required site facilities including batching unit, vehicles, excavators, dumpers, concrete pumps, vibrators and all tools & equipments deemed necessary by the Owner / Consultant for appropriate & timely execution. Steam generator & auxiliaries Steam turbine generator & auxiliaries including air cooled condenser Fuel & ash handling Cooling tower & cooling water circulation Electrical evacuation upto BSEB substation in factory site, cogeneration auxiliaries and power supply to sugar complex including sugar mill and ethanol.
b.
c. d. e. f. g.
172
h. i. j. k. l. m. n. o. p.
Water treatment plant & auxiliaries Electrostatic precipitator DCS Fire fighting system Overhead EOT for powerhouse and required monorails for all large motors / fans / pumps / transformers. All required cabling, piping and earthing within the terminal points All required utilities to operate the cogeneration plant including DM water, UPS power, DC power, compressed air, lighting, etc. Required plant air conditioning and ventilation systems. Obtaining all required statutory approvals for construction of cogeneration plant including local body approval for construction of cogeneration plant electrical inspectorate approval for power evacuation scheme, IBR approvals, labours commissioner, excise, factory inspector as applicable, electrical inspector for electrical works, required approvals for synchronizing with grid, providing stability certificate as per local norms, registration & payment of all taxes & duties for tenderers staff & labour, as per all applicable laws, etc. Statutory fees, if any, will be paid by the Owner and applications required, if any will be paid by the Owner.
1.3
TERMINAL POINTS Utility Raw water Bio-gas Export power Effluent Ash Bagasse Outside Biomass Power supply to cogen plant Terminal Point From delivery header of raw water pumps at ground water reservoir to cogen plant and further distribution, thereof and from the proposed borewells including the borewells At one point at the boundary of cogen plant Upto BSEB substation for LILO arrangement in sugar factory site Neutralized effluent collected in the effluent pit adjoining the DM plant and pumped upto the intake well of the common ETP At bottom RAV of ash silo at 3.5 m elevation from FFL At inlet of BC-1 At 0 m level in bagasse yard All power supplies from generator or back feeding, entirely in cogen package
173
Terminal Point At 2 Nos. 11KV Feeders identified in 11KV Swichboard in Cogen Plant TG building At 1 No. 415V, 1000A, TPN, MDO ACB identified in Power supply to ethanol Cogen Auxiliary LT Panel for distillery load (Approx. plant 600KW) Earthing Entirely in Tenderers scope within terminal points Power Distribution including Panels, Cabling, Entirely in Tenderers scope within terminal points cable trays & Accessories Lighting and Plant Entirely in Tenderers scope within terminal points Utility supplies Upto and including MP & LP headers located towards sugar side of the power house at 1.5 m level from FFL Steam supply with tappings and valves. Required tapping on MP header for ethanol is for 25 TPH and required tapping on LP header for sugar is for 40 TPH At outlet header of condensate transfer pumps in Condensate evaporation and juice heater area of sugar mill (35 m/hr, 40 m head) Compressed air Consumables including acid, alkali, sulphur, lime, etc. Civil Works 1.4 BUILDING DIMENSIONS 1 2 3 4 5 Boiler Powerhouse Cooling tower DM plant Switchyard 80 x 30 30 x 30 40 x 15 40 x 20 100 x 50 Entirely in Tenderers scope within terminal points At tanker transfer pump header of bulk acid & alkali storage tank As demarcated in the proposed master plan given in Appendix IV
Utility Power supply to sugar plant
174
CHAPTER - 2
TECHNICAL SPECIFICATIONS FOR MECHANICAL & ELECTRICAL EQUIPMENTS, INSTRUMENTATION & CONTROL AND ERECTION & COMMISSIONING
2.1 2.1.1 STEAM GENERATOR & AUXILIARIES The principal fuel will be bagasse or biomass. Biomass in general would include sugarcane trash, rice husk and maize cobs. Steam generator will be designed, manufactured and approved as per latest amendment of Indian Boiler Regulation Act. The steam generator will be complete including items as per the list given below: Bagasse feeding system with bagasse silo All pressure parts (drums, water walls, headers, etc.) Refractory Integral piping with insulation Travelling grate system Ash hoppers ID, FD & SA fans with vibration isolators and VFD for ID, FD and SA Ducting Structural from RCC footings, ladders, platforms, supports and foundation bolts, insert plates j) All internal piping for steam, pegging steam, cooling water, feed water, service & instrument air, economiser and air pre-heater, etc. k) Instrumentation and control suitable for total operation through DCS l) Dampers, soot blowers and associated controls / piping m) De-aerator & DA storage tank n) HP heater stations o) PRDSH station p) Grit separator chamber & cinder re-injection system before HRU to collect & re-inject the cinder. q) HRU including APH & economiser r) Attemperator system comprising of direct spray type s) LP and HP dosing system, SWAS analyzer a) b) c) d) e) f) g) h) i)
2.1.2
2.1.3
175
ESP for 100 mg/Nm3 CBD with flash recovery & IBD with steel tanks Steam, water & exhaust piping of HP heater Valves and fittings Vents up to safe elevation External canopy for the boiler to cover bagasse feeding system, up to steam drum operating floor. z) Electrical and instrumentation control panels aa) All other auxiliaries and steam generator components required for safe, reliable and continuous year around steam generation. bb) Pegging steam line from steam generator to de-aerator for start up.
t) u) v) w) x) y)
2.1.4
Steam Generator Technical Parameters 1. No. of water tube generators (Nos.) type steam One
2. 3.
Maximum Continuous Rating (kg/hr) Peak Generation
110,000 110% of M.C.R for half an hour / shift 110 kg/ cm2 540oC 105 kg/cm2 535oC 2200C 110 0C to 130C
4. 5. 6. 7. 8. 9. 10.
Steam pressure at boiler MSSV Steam temp. at boiler MSSV Steam pressure at turbine inlet valve Steam temp. at turbine inlet valve Feed water temperature to economiser De-aerator outlet temperature Excess air required % of Theoretical
air Not exceeding 35% at MCR
11.
Temperature of flue gas at the outlet 150C at MCR of air pre-heater
176
12.
Steam generator efficiency
a)
70 % (minimum) on bagasse having 50 % moisture with GCV of 2270 Kcal / kg.
13.
Fuel Normal
Bagasse & Cane trash. Source of bagasse would be from mill of 50 % to 52% moisture or stored, with moisture of 20 - 50 %. Cane trash should not exceed 10% of fuel fired on weight basis. Procured biomass 1:4 bagasse &
Off Season
14. Note:
Turn down ratio
Steam generator to be designed for continuous operation through the year with normal steam generation of 110,000 kg/hr It is envisaged to supplement bagasse with sugarcane trash and other biomass during season & off-season. Steam generator to be top supported with minimum civil works. Steam generator should be 100 % bagasse fired, travelling grate. Boiler to be capable of 100% capacity with combination of bagasse and biomass. The heating surface of the steam generator shall be determined with reference to Main Bank of the steam generator tubes, Front wall, Side Walls, Rear wall and Roof tubes. The Air pre-heater and economiser shall be designed so as to give final flue gas temperature within 140C. The final superheated steam temperature shall not exceed beyond the design temperature. The steam generator will be designed to keep the refractory works to the barest minimum possible.
177
2.1.5
Steam Generator Drum The steam generator shall be provided with one steam drum and the drum shall be of fusion welded type. The drum shall be provided with Tori-spherical / Semi-Ellipsoidal dished ends fitted with oblong man ways at either end. The man way doors shall be hinged and arranged to open inwards. The drum shell, dished ends and the man way doors shall conform to IBR. The steam drum shall be liberally sized to assure low steam space loading, with adequate space to accommodate the internals. The steam drum shall be provided with internals of proven design, shall be bolted type, and of size that will enable removal through the man ways. The system of internals consisting of the primary and secondary separators shall ensure steam of highest purity with dissolved silica carry over limited to a maximum of 0.02 ppm. The steam drum of the Steam generator to be provided with suitable internal fittings comprising of cyclones, primary and secondary scrubbers to ensure steam of highest purity. The necessary nozzle connections for the following, but not limited, steam outlets, safety valves, feed water inlets, continuous blow down, level indicators, remote level indicator at operating floor, chemical feeding, vents and drains, sampling connections, down comers shall be provided on the drums as applicable. All nozzle connections on the drums shall be of welded type and the feed water inlet shall be provided with a suitably designed thermal sleeve. The necessary drum suspension / support arrangements shall be provided. All nozzle connections on the drums will be of welded type and FW inlet will be provided with suitably designed thermal sleeve. The steam drum of the steam generators to be provided with suitable internals to promote circulation and to ensure high purity of steam. The final drum internals shall be of stainless steel and bolted (dismantling) Construction to facilitate cleaning of the internal surface of steam generator bank tubes and furnace tubes etc. The water distribution system in the steam drum will be through a distribution header below low water level, to facilitate equal distribution through the drum. The steam generator will be top supported.
178
2.1.6
Steam Generator Tubes 2.1.6.1 Furnace Water Wall Tubes The Furnace envelope shall be constructed of fully water cooled membrane / Fin welded walls and adequately supported. The design shall be such as to prevent distortion of steel work due to thermal expansion. The construction shall be fully gas pressure light, and the furnace shall be strengthened by providing buck-stay and tie-bar system. The furnace shall be adequately sized for burning bagasse and biomass. Necessary provisions shall be made in the furnace for admitting the required quantity of over fire air at various levels, considering the various fuel mixes. The furnace EPRS should be so selected to give acceptable furnace outlet temperatures while firing bagasse or biomass or the combination of both the fuels. The furnace design shall incorporate necessary manholes, peep holes, openings for the fuel distributors, ignition / reflection arch and refractory covering in the lower furnace area if required. Adequate number of inlet and outlet headers, with the necessary stubs, commensurate with the arrangement of the furnace shall be provided. Each of the headers shall have at least two numbers of stubs for inspection and cleaning. The down-comers, supply pipes and raisers sizing shall be based on the circulation calculations. The entire water wall will be of fin welded construction with minimum refractory. The side wall tubes will be suitably bent for providing required peak & access holes / doors. The front and rear wall tubes will be stub welded to respective bottom headers and expanded into the drum. The roof tubes will be staggered to allow the super-heater coils to pass through. The fin welding to be carried out on appropriate jigs and fixtures to minimise distortion and retain required uniformity of tube array. Note: The water valve panel fin thickness and width shall be such that the fin tip to base temperature differential does not exceed 70C.
179
2.1.6.2 Steam generator Bank Tubes The boiler bank tubes will be of single pass design. The tubes will be bare without any fins. The tubes will be provided in inline arrangement. The tubes will be of HFS construction. Under all envisaged conditions, the design to provide natural circulation The tube spacing will enable easy removal of the tubes in case of any failure. There will be adequate approach space to the tubes of the bank for maintenance. The flue gas velocity will be restricted to about 10 m /sec. 2.1.7 Steam Generator Headers All headers in the steam generator shall have flat end covers, and a minimum of one stub at each end for the purpose of cleaning and inspection. No header shall be placed in the flue gas path. The boiler headers will be located at front wall bottom, rear wall bottom, right side wall bottom & top, left side wall bottom & top. The boiler headers shall be manufactured from pipes. The headers shall be provided with drain & air vent connections and hand-holes for inspection. 2.1.8 Bank Tubes The bank design shall be of inline arrangement and the tube spacing shall enable easy removal of the tubes in case of any failure. The bank tubes shall be expanded into both the top and the bottom drums, and the tubes after expansion shall be bell mouthed. There shall be adequate approach space to the tubes of the bank maintenance. Baffles if required shall be of simple design with material suitable for with standing the gas temperature.
180
Adequate number of soot blowers shall be provided to the cover the maximum surface area of the bank. The total number of bank tubes shall be divided into raisers and down comers, clearly identifying the number of down comers, their locations and the type, heated or unheated. The flue gas velocity in the bank area shall be restricted to a maximum of 10 meters/sec. No butt joints shall be permitted in the bank tubes. The Steam generator bank side walls shall be fin welded, or shall be of such construction totally eliminating air ingress or gas leakage and with suitable openings for the man ways, inspection peep-holes and soot blowers. Steam generator headers to be constructed in accordance with the IBR specifications. The headers shall be provided with end plates with extended stubs. The extended stubs will be cut for inspection & cleaning and will be rewelded. 2.1.9 Super Heaters & Superheated Steam Header The steam generator shall be provided with super heater of adequate heating surface capable of superheating the steam generated by the steam generator to the final steam temperature required at isolation valve of turbine and complete with headers, its mountings and fittings including safety valves, motorised isolation valves, NRV, start-up vent valves, flow nozzles, drain valves, air vent valves and pressure and temperature gauges etc., as per I.B.R. Temp. at super heater outlet will remain steady at design value from 60 to 100% MCR. The tube elements of the secondary super heater shall be constructed from Seamless alloy steel tubes as per IBR1 950 and its latest amendments. The SH inlet header, shall be connected to the steam drum by means of suitable number size of tubes which will be of carbon steel. The super heater manifold shall be fabricated from solid drawn seamless alloy steel pipes. The superheated steam manifold is to be equipped and complete with branches for main steam take off, safety valve, air release valve, drains, temperature and pressure gauges and other connection etc. Additional thermo wells in the outlet manifold shall be provided to measure the temperature of superheated steam.
181
The super heater design shall be such that the temperature of steam at super heater outlet shall not exceed the design value in any case. Design is a two stage super-heater with inter-stage attemperator. (a) Super-heater System The super-heater (SH) system shall be of two (2) stage design with interstage de-superheating to achieve the rated steam temperature over 60 to 100% load range. The super-heater shall be of convection or a combination of convection and radiation type arranged to give the minimum metal temperature. The super-heater pressure drop, the inlet and outlet header sizing, arrangement and sizing of their respective inlet and take off connections shall be so as to give minimum unbalance and the tube element material selection shall be based on the actual metal temperature calculations. The metal temperature calculations and the material diagram shall be approved by the Owner / Consultant. The tube spacing of the superheater shall be designed to minimize bridging and tube erosion and shall be suitable for proper on-line cleaning by means of soot blowers. Suitable spacers shall be provided both along and transverse to the gas flow directions. The SH system shall be complete with required seamless pipe headers, inter connecting piping, vents, drains, supports, tube spacers, valves, fittings, etc. The super-heater header material selection shall be based on the Average fluid temperature in the header plus 25C. The sealing at the super-heater tube penetrations with the steam generator roof or the wall shall be 100% leak tight and the arrangement shall be approved by the Owner / Consultant. The unheated terminal portion of the super-heater tubes shall be designed with adequate flexibility against thermal expansion differentials. The outlet header shall be suitably supported and anchored such that the piping forces and moments incident to the steam piping will not cause excessive stresses in the element tubes.
182
(b)
Attemperator System Inter-stage attemperator shall be located between the two super-heater stages to control the final steam temperature at 540 +/- 5C between 60% to 100% MCR load. The attemperator system will be of spray type. The spray water will be obtained from the boiler feed pump header. The de-superheating system shall be complete with all required, control valves, bypass regulating valves, piping and supports etc.
2.1.10 Furnace Basically the steam generator shall be radiant furnace. Bi-drum natural circulation, outdoor type with three stage super-heater. The steam generator shall be designed with water cooled membrane in welded walls and the refractory works shall be kept to the barest minimum possible. Suitable furnaces to burn bagasse with up to 52% moisture and biomass with preheated air shall be provided for the steam generator. The furnace design will be with bagasse fed pneumatically, complete with necessary Air piping, valves, fittings etc. The steam generator shall be provided with Pneumatic Spreader for bagasse. The firing floor will be of chequered plate of 8 mm thick min. Ash hoppers are to be provided below each furnaces and the steam generator height to be adjusted such that belt can be placed below ash hopper for quick removal of ash. The furnace ash hopper cleaning doors shall be rack and pinion type and the bottom most portion shall be at the elevation of + 2500 mm. or more. By pass arrangement to be provided with ash discharge hopper. The grate area loading will not exceed 2.2 million kcal/hr/sq.m. Furnace to be of water-wall membrane type
183
The bagasse feeding doors for steam generator bagasse feeders at the bottom of the bagasse carrier shall be of rack and pinion type to be operated by chain. The manhole / inspection doors shall be in line with the bagasse feeding chute. 2.1.11 Fuel Firing System The Steam generator is to be designed for firing 100% Bagasse, other biomass through the bagasse feeding system. 2.1.11.1 Fuel Feeding System The bagasse feeding system shall include a bagasse storage silo(s) with the Bagasse storage capacity of 7 minutes of MCR requirements. The excess bagasse in the slat conveyor shall be returned to the storage yard through the return bagasse conveyor to be provided by the Tenderer. The bagasse input to the steam generator shall be regulated by the feeding system. The bagasse feeding system in addition to the storage silo shall consist of inlet chutes, feeders, feed chutes and the distributor. The bagasse silo must have SS lining for smooth flow or should be of convergent type. The screw feeders used for bagasse feeding should also be of SS. The feeder shall be of proven design and shall be capable of handling occasional lumps. Drum pin feeder will be preferred. If the feeder is used for the regulation of fuel flow, variable speed drive shall be provided. The inlet and the feed chutes shall be designed to prevent choking of bagasse by providing necessary vibrators on the bagasse silos and necessary poking facilities shall also be given. For sizing the feeding system the density of bagasse shall be taken as 150 kg/m3 with moisture content of 52%. The distributor or feeders could be mechanical or pneumatic and with AC variable frequency drive. There shall be provision to vary the length and the angle of throw. The parts facing the furnace radiation shall be of heat resistant material.
184
The fuel feeders will be sized with one extra feeder to meet MCR fuel needs, such that even with one feeder outage the MCR can be achieved. 2.1.11.2 Firing system / Travel Grate System Front discharge twin travelling grate with individual hydraulic drives complete with front plate, seals, grate casting, carrier bars, skid shoes, skid rails, sprockets, shafts, bearings, forged chain links and structural framing suitable for mounting on foundation. The manufacturer should have a thorough understanding and experience in manufacturing travelling grate system The travelling grate system should be preferably shop tested in fully assembled condition before dispatch This system must maintain continuous tension in order to run smoothly and avoid jamming of the grate and grate bars. The catenary grate should be self tightening and should not require any expensive maintenance labour or external mechanical tightening devices, counter balances, or springs to maintain grate tension. Travelling Grate System components specifications / requirements Grates : High quality, heavy duty, heat resisting alloy CI or IS 3355 Gr.1 type C Grate Air Seals : Under grate, front & rear air seals of Cast Iron and Carbon Steel, self adjusting to maintain continuous close seating contact with the Grates. Should be bolted type. Forged Chain Links: To be fabricated from C45, Forged Steel with hardened roller and pin assemblies designed for high heat duty and tension loads. Grate support: Through underlying grate bar should not damage even if debris fall on the grates. Graphite Bearings : Heavy duty graphite carbon bearings which do not require any lubrication.
185
Hydraulic Drives: Low Horse Powered, self contained and mounted directly to the stoker drive shaft at the stoker front. Should be capable of regulating to control the grate output from 0 to 24 feet per hour and transmit the speed to DCS. Should also have necessary oil cooling arrangement. Alternatively, planetary gearbox with VFD is acceptable. Stoker Front & Housing: The stoker should have a reinforced steel main stoker front plate combined with dust tight front ash discharge extension housing. Pneumatic air swept distributors: Cast Iron Air Swept Fuel Distributor assemblies mounted on the Stoker front Plate and designed to assure uniform fuel distribution in the furnace. This should have a trajectory plate. Alternatively, 3-drum feeder type, which carries bagasse between two sheets of secondary air for even distribution can also be considered. This will prevent jamming of screw conveyors due to higher moisture by eliminating the same. Other requirements of the Travelling Grate System The Grate Area loading shall not exceed 2.2 Million kcal /Hr/ Sq. Mtr Cinder Re-firing System is to be included Hot air duct connection shall be to the wind box of under grate. Thermocouples to be provided in the under grate area to monitor the grate temperature and connected to DCS
The total combustion air formed by the FD fan, heated in the air preheater to a temperature of about 2300C. The under grate air shall be uniformly distributed under the grate. This distribution shall take into account the non uniform fuel distribution that could occur during the combination firing or during part loads.
186
The secondary air for distribution and for the over fire air (OFA) shall be supplied by the secondary air fan, and the SA fan shall take suction from the air outlet of the air-pre-heater. The secondary air handled by the SA fan shall not be less than 25% of the total. The number of OFA levels shall be decided based on the requirements for bagasse and biomass firing and there shall be provisions to cut of the levels, if necessary. The OFA pressure shall be selected to give a minimum penetration depth of two third the furnace dimension along the OFA jet. The travel grate structure and the travel grate are to be ensured not to sag due to increased width or other factors more than the limit. Indication to measure the chain sagging has to be provided. Firing system consisting of: Continuous bagasse feeding system: a. Bagasse storage silo of 7 minutes storage capacity with support structure. b. Bagasse extractors with Variable frequency drives c. Screw feeders with constant speed electric drives d. Air swept bagasse distributors with trajectory plate
2.1.12 Economiser The flue gas velocity over the economiser tubes shall be limited to a maximum of 10 meters / sec. Suitable number of soot blowers shall be located in the economiser for effective cleaning of the heat transfer areas. For the purpose of maintenance and for accommodating the soot blowers the economiser may be divided into suitable number of banks. Broadly the individual bank height could be maintained at about 2000 mm with the inter bank gap at about 600 mm. The economiser shall be complete with seamless inlet / outlet / intermediate headers with drains and vents, coil supports, supporting structures for the complete economiser, interconnecting piping for the inlet and the outlet, access galleries and stairs, etc. The economiser casing shall be of at least 6 mm thick, mild steel plate suitably stiffened / reinforced.
187
The economiser gas path shall be of the pressure tight construction with the proper design of the seals at the tube penetrations with the casing. The inlet and the outlet headers are adequately supported and anchored to take care of the loading from the connected piping. The economiser tubes shall conform to SA 210 Gr.A1 cold drawn Seamless (CDS). There shall be a minimum of two headers and the header material shall be conforming to SA 106 Gr.B or BS 3602 Gr.360 HFS. An economiser of suitable heating surface shall be provided for steam generator. The economiser shall give rise in feed water temperature below saturation temperature of steam at design value when supplied with water of 165C from HP feed water heater or 115 C from de-aerator The economiser shall be complete with tubes/economiser coils, supports, inlet and outlet water temperature, casing and dusting, soot blowers, lagging, vents, drains, safely valves, etc. Velocity of the feed water in economiser tubes/coils shall be about 0.5 to 0.7 Meters/Second. The economiser shall be designed in accordance with the requirements of I.B.R. The economiser assembly shall be designed to suit the transient condition of steam generators as prevalent in sugar plants. Load variations from 30 to 100% will be accounted in its design. To avoid erosion from incoming flue gas, the economiser will be provided suitable cascade baffles or / and sacrificial empty coils or / and SS cladding on first array of coils. Cinder re-injection system prior to economiser to be provided. It will consist of a grit collection hopper, with the collected grit being pneumatically re-injected into the furnace.
188
2.1.13 Air Pre-heater The Air Pre-heater (APH) shall be arranged as the last heat recovery section downstream of the economiser. The APH & economiser will be on different axis. The Air-heater shall be recuperative type with flue gas flowing inside the tubes and the combustion air flowing over the tubes. The air-heater shall be arranged with the tubes in the vertical direction. The inner diameter of the tubes shall be a minimum of 50 mm. The tubes except those required for staying purposes, if any, shall be welded into the tube sheets on both ends. APH tubes will be 13 g thickness. The air-heater arrangement shall provide for adequate access for replacing the tubes- considering the high moisture in the flue gases, suitable precautions should be taken to prevent the tube corrosion at the air inlet side of the airheater. If the air-heater is designed with more than a single pass on the air side suitable guide vanes shall be incorporated in the connecting ducting to prevent stratification. The cold end of the Air-pre-heater shall be designed to prevent corrosion and the cold end material of the air-heater tubes shall be corten steel. The last array or last block of APH tubes to be corten steel. At gas inlet side of tube sleeve pipe or ferrules to be provided to avoid erosion. Air pre-heater of suitable heating surface to heat the air by flue gases required for combustion for steam generator. Air-heater should be complete in all respects with ERW tubes, tube plates, supports, dampers, and ducting, etc. Rotary airlock valves and side manual gates and the bottom of Rotary airlock valves shall be provided. The air pre-heater and the economiser shall be designed so as to give flue gas temperature within 150C at the outlet of the air pre-heater. Suitable bypass should be provided for APH for start-up purposes. The cold end of the APH will be designed to prevent corrosion due to the condensation of flue gas. The final array of tubes on the cold end i.e. entire low temperature block will be of corten steel or anti-corrosive steel.
189
2.1.14 Electro Static Precipitator (ESP) A suitable ESP so that the fly ash contents of flue gases leaving the chimney confirm to the rules and regulations of the pollution act as applicable to the factory and as outlet concentration below 100 mg/Nm3. A certificate to this effect should be obtained from pollution control board under whose jurisdiction this mills falls. It shall be the responsibility of the steam generator manufacturer / Tenderer to provide all documents to pollution control authority. The ESP shall be installed on the suction side of the I.D. fan and shall to be complete with rotary airlock valve with drive provided with local and remote push button control, and a side manual gate. The minimum elevation of discharge flange of the rotary airlock valve shall be at + 2500 mm. Suitable platform, ladder, inspection and poking holes etc., shall be provided to facilitate regular inspection and cleaning of the ESP. Even with one field of ESP out of service the ESP must remain in operation. Manufacturer / Tenderer to specify the emission level with only one field in service at 100% boiler MCR with bagasse as fuel. All electrical including MCC, rectifiers, panels, electrical & control cables, earthing etc. in Tenderers scope. ESP control shall be from control room The manufacturer is to design & supply suitable flue gas cleaning system to ensure that the flue gases entering the chimney do not contain SPM in excess of 100 mg/Nm3.
2.1.15 Induced Draught Fan There shall be two (2) ID Fans (2 x 60%), designed for a minimum capacity of 15% higher than the theoretical requirement at 1700 C The I.D. fan shaft shall be both end supported, directly driven type, and complete with drive equipment etc. Fan shaft design as per IS : 1570 - 1979.
190
The I.D. Fan maximum speed shall not be more than 750 rpm. Renewable hard faced wear pads on blade shall be incorporated in the impeller. The blade of the fan rotor should be fabricated out of minimum 5 mm thick mild steel plate. ID fan blade will be of backward vane type. Variable inlet and outlet control dampers to be provided. ID fan inlet damper for air control and outlet damper for maintenance isolation. The rotor of the I.D. fan shall be dynamically balanced and tested for its parameters at their works and test certificate and inspection certificate to be provided. The rotor shall be dynamically re-balanced at site if vibration levels exceed limits. Induced Draft Fan Drive The I.D. fan shall be driven by an A.C. Motor drive with variable frequency variable speed control system. (VFD) The Drive unit shall be complete with control equipment, speed meter, voltage, amp., frequency indicators, etc. All electrical control accessories to be included.
2.1.16 Forced Draught Fan There shall be two (2) FD fans, capable of handling min. 60% each of the total gas flow. The Forced Draft fan shall be horizontal, radial and with backward curved blades. The fan shall be supplied complete with motor, common base plate for motor and fan, coupling, etc. The fan shaft shall be of simply supported design, conforming to 35 C8 for IS- 1570-1979 material. Renewable hard faced wear pads on blades shall be provided and the minimum thickness of the plates used in the construction of the fan shall be 5 mm. The fan design temperature shall be 500C. The forced draft fan is to be designed for minimum capacity of 15% higher than the theoretical requirement at peak load capacity. The F.D. fan shaft shall confirm to I.S.- 570, 1979.
191
The F.D. fan shaft shall be both end supported, directly driven type, and complete with drive equipment etc. The F.D. fan maximum speed shall not be more than 1500 rpm. The blade of the fan rotor should be fabricated out of minimum 5 mm thick mild steel plate. Variable inlet vane control dampers in the suction of the F.D. fan should be provided. A thick welded mesh screen shall be provided before the damper to avoid accidental entry of foreign material. The entry of FD fan will be on the Y axis with suction from atmosphere. The direction of rotation of the FD fans shall be same where more than one fan is provided. The rotor of the FD fans shall be dynamically balanced and tested for its parameters at their works and test certificate and inspection certificate to be provided. The rotor shall be dynamically re-balanced at site if the vibration levels, are found unacceptable. Forced Draft Fan Drive The F.D. fan shall be driven by a variable speed electric drive. A.C. motor drive - with variable frequency / variable speed control system. (VFD) The drive unit shall be complete with control equipment, Speedo-meter, voltage, amp., frequency indicators, operator's control cubical local (lockable) and remote (control room) etc. The electric system to be complete with all electrical protections & control devices. Both the ID and FD fans should be interlock so that FD fan can be started only when ID fan is running.
192
2.1.17 Performance requirements for Fans Noise and vibration All equipment and their accessories shall perform continuously with the levels of noise and vibration as specified below: a) All equipment shall provide acceptable and not excessive back ground acoustical level. Measured noise level produced by any rotating equipment or a group of equipment closely located shall not exceed 85 db (A) at a distance of 3 m from it in any direction. b) Vibration isolation of proven design shall be supplied by the Tenderer for preventing transmission of vibration from the equipment to other neighbouring equipment and structures for all fans. 2.1.18 Secondary / Primary / Cinder Recovery Fan The Secondary Air or cinder re-injection fan & Primary Air Fan shall be two (1SA + 1 PA) in number shall be of constant speed, horizontal, radial, backward curved or aerofoil bladed and electric motor (squirrel Cage TEFC) driven. The fan flow control shall be with inlet guide vanes with manual control. The fan shall be direct driven, with speed not exceeding 1440 RPM and shall be supplied complete with motor, base plate for fan and motor, coupling, control driven etc. The supply of SA air to the furnace should be through flexible SS tubes. The SA / PA / CR fan is to be designed for a minimum discharge capacity of 15% higher than required at peak load capacity. The SA / PA / CR fan shaft shall conform to C40. The SA / PA / CR fan shaft shall be both end supported, directly driven type and complete with drive equipment etc. The SA / PA / CR fan maximum speed shall not be more than 1440 rpm. The blade of the fan rotor should be fabricated out of minimum 5 mm thick mild steel plate.
193
Variable inlet vane control dampers in the sanction of the SA fan should be provided. A thick welded mesh screen shall be provided before the damper to avoid accidental entry of foreign material, in case of ambient air suction. The direction of rotation of the SA / PA fan shall be same where more than one fans are provided. The rotor of the SA / PA fan shall be dynamically balanced and tested for its parameters at their works and test certificate and inspection certificate to be provided. The rotor shall be dynamically re-balanced at site if the vibration levels exceed limits.
2.1.19 Blow Down Arrangements Continuous blow down equipment as per I.B.R. /I.S.O. complete with all piping, fabricated blow down tank, located at a suitable distance from the steam generators (Approved by the Owner / Consultant). Tenderer in accordance with IBR will provide one intermittent and one continuous blow down tank. All blow down piping shall be as per I.B.R. and provided with supports and slope etc., Adequate slope from the pressure parts outlet connections and minimum nos. of bends shall be provided to ensure that the system remains free from the blockages. Flash steam to be recovered from blow down tank to de-aerator with required piping, NRV, supports etc.
2.1.20 Soot Blowing Equipment Steam operated and auto controlled soot blowing equipment with adequate number of soot blowers for the steam generator at appropriate places to cover bank of steam generator tubes and super-heater elements shall be provided. Additional soot blower (s) shall also be provided for the economiser. In super heater area, the soot blowers should cover 100% of the tube area.
194
All soot blowers will be motorised and logically controlled. All steam piping for soot blowing to be provided A suitable pressure reducing valve & system shall be provided for required steam for soot blowers. The steam will have at least 500C superheat, as being used for soot blowing. The steam generator shall be provided with a complete system of soot blowers to effectively dislodge deposits from the heat transfer areas. The soot blowers shall be motor operated with steam, taken from the steam generator, as the cleaning medium. The required pressure reducing station with pressure controller and pneumatically operated control valve and downstream safety valve shall be provided. The supply shall include all piping, fittings, valves, traps etc. In the zones where the gas temperature exceeds 7000C only long retractable soot blowers shall be given. For the blowers located in zones where the gas temperature exceeds 4000C, the material shall be a minimum of stainless steel type 304. The entire soot blowing system will be auto controlled and operated with all controls from its independent PLC or through the DCS.
2.1.21 De-aerator & De-aerated Water Storage Tank Spray and Tray type de-aerator having auto control of temperature, flow and level etc. mounted on de-aerated water storage tank of 45 m3 capacity and suitable for maximum flow rate of 150 m3/hr shall be provided, to obtain a temperature of feed water of minimum 1150C by using exhaust steam at 2 kg/cm2. All internals of de-aerator wetted part should be of stainless steel 316 materials. The design inlet water temperature to be 45C. Level & pressure control valves to be provided, to sustain & maintain the design quality of DA water. The maximum dissolved oxygen in the de-aerator water shall not be more than 0.007 ppm. at 105C temperature.
195
The de-aerator storage tank shall be installed as per requirement of NPSH from the feed water pump suction. The water outlet (suction line of pumps) to be provided with all perforated pipe inside the tank along its full length or with suitable vortex breakers. The over flow from the de-aerator water storage tank shall be connected to feed water storage tank through a suitable sealing arrangement. The drain valves for feed and de-aerated water tank shall be at elevation of + 2000 mm from F F L and terminated at the common drain (factory drainage system.) A full range plate type level gauge glass is to be provided. The water level in the de-aerator tank gauge glass should be visible to the steam generator control room/ operator working platform. The high and low water level indicator and alarms shall be provided. Auto control is required from plant DCS. Main FW control valve shall be pneumatically operated, by pass valve will be motorised and pneumatic control valve for lower sizing (30%)
2.1.22 Boiler Feed Water Pumps Electrical Driven Feed Water Pumps Nos. of Pumps: 3 x60% with VFD Each multistage electrical driven pumps set shall be suitable for pumping hot water from de-aerator to steam generator. The BF water pump to be designed by taking HP heater into consideration. Auto circulation valve (with required arrangement) to be separately provided for each pump. The ARC valve will be of Schrodehal make. On the suction side, one operating and one isolation valve shall be provided. The balancing chamber relief line shall be provided with the pressure gauges for each pump and pipe line laid separately for each pump. Only, mechanical seals to be provided.
196
Each pump should be provided with in-line strainer in the pumps suction line. The pump and the drive (Electrical Motor) shall be placed on RCC foundation at a foundation level of +500 mm. The steam generator feed water pumps should be sized to include the flow need of the steam generator, 3% blow down, 1% losses/unaccounted and 6 8% margin for volume. Head to be sized as per Tenderers design with at least 5-10% margin. Pumps to be sized for 110% MCR at design pressure level. 2.1.23 HP Feed Water Heaters Tenderer to supply suitably designed (as per ASME / equivalent code) heat exchanger to preheat the de-aerated water from 115C / 125C to 220C at MCR conditions. Tenderer to provide steam at 25 & 8 kg/cm2, as per requirement to the heat exchanger. Scope to include required control valves, I&C and piping as required. All control valves to be motorised or pneumatically controlled. All level controls to be through DCS. Vent line to be given to de-aerator. Feed Water Heater Design Requirements Type Location Shell & Tube Type with U tube Between Boiler feed water pump and economiser Application To heat feed water using low Pressure Steam Code of Design & A] TEMA, Class C construction B] IBR 1950 with all latest amendments C] ASME SEC.VIII DIV I D] HEI Process data (for HP heaters 1 & 2) Shell Side Tube Side Medium Steam Feed Water Inlet Pressure,kg/cmg 25 & 8 110 135 Temperature Inlet / As per design 165 & 220 Outlet, C
197
Steam quality The steam for feed water heaters shall be supplied from turbine extractions during normal operation Additional requirements a) Provision shall be kept for adding 10% heating surface on tube side. b) Tenderer has to provide level switch to control the condensate level. Hence suitable storage volume to be considered.
Material of Construction: Shell/Skirt : Tube Plate/Water Box Channel/Cover Pipes : Fasteners : Tubes : SA 516 Gr 70 : SA 266 Cl 2 SA 106 Gr.B SA 193 B 7/ SA 194 2 H SA 213 TP 304 (U Tubes)
2.1.24 Pressure Reducing cum De-superheating Station (PRDSH) Tenderer to include pneumatically controlled pressure reducing & de-superheater of 50,000 kg/hr capacity, to reduce pressure from 110 kg/cm2 to 8 kg/cm2 & 8 kg/cm2 to 2.5 kg/cm2. The outlet temperatures required are 10C above saturation temp. PRDSH to be capable of supply of 0 to 20000 kg/hr steam at 8 kg/cm and 0 to 30,000 kg/hr at 2.5 kg/cm. PRDSH to be placed on the roof of the control room with minimum required tapping from the main HP steam line. All bypass valves of the PRDSH will be manually operated. 2.1.25 Feed Water Chemical Dosing System Steam generator shall be provided with a tri- sodium phosphate based High Pressure (HP) dosing system and a hydrazine and ammonia based Low Pressure (LP) dosing system.
198
The HP dosing system shall add the chemical to the steam generator water to take care of the ingress of the hardness salts and to increase the steam generator water pH. The LP dosing is done to the feed water preferably at the outlet of the de-aerator to scavenge the last traces of oxygen and to increase the feed water pH. Each dosing system shall include a stainless steel mixing tank with an electric motor agitator. Each system shall have 2 x 100% capacity, motor driving positive displacement type pumps, with wetted parts made of stainless steel, with facility to vary the feed rate. The HP and LP dosing systems shall be mounted on individual skids with their respective tank, pumps along with all required piping, valves, fittings, supports etc. The complete piping for both the HP and LP dosing system from the skid to the respective admission points to the steam generator water circuit shall be SS 304. 2.1.26 Instrumentation 2.1.26.1 General The entire I&C package will be in Tenderers scope and will be interconnected to the plant DCS. Instrumentation shall be complete in every respect and liberal to the extent of providing data on all operation variables sufficient for the safe efficient, easy operation, start up and shut down of the plant. The complete steam generator & auxiliaries packages will be normally operated only through the DCS in the control room, except for manual drain valves. Normal start-up operation should also be accomplished through the DCS. Hence, start / stop of all drives, speed regulation where required, operation of actuators / dampers / solenoid valves, operation of all motorised valves, operation of sub-systems like soot blowers, SWAS, etc. should all be interconnected through the DCS with appropriate & required I/Os.
199
All instruments and equipments shall be suitable for use in a hot, humid and tropical industrial climate in which corrosive gases and / or chemicals may be present. As a minimum, all instruments and enclosures in field shall be dust proof, weather proof to NEMA 4 (IP:55) and secure against the ingress of flue, dampness and vermin. All external surface shall be suitably treated to provide anti-corrosion protection. The instruments like control valves, thermo wells, orifice flanges, level instruments etc. coming on pipes and vessels under IBR shall be certified by IBR. Location of tap off connections shall be either from the side or from the top of the steam generator equipment but not from the bottom. This requirement is applicable to both pipes and vessels. The location of lower side connection shall be high enough to prevent plugging due to dirt or other suspended solids. In addition, the connections shall be short, vertical or horizontal and without any pockets. Materials of construction of instruments shall be consistent with temperature, pressure, corrosion conditions and other steam generator requirements. The design of control panel shall incorporate provision for expansion by installing space capacity. Each panel shall be designed to accommodate 10% minimum additional equipment including 10% spare cable/ tube entry points. Instrument power circuits shall employ an isolation transformer and individually protected from fault with the help of MCBs and fuses. Power supply to the individual instrument shall be disconnect able with the help of switch and protected with the help of fuse. Ranges for instruments shall be selected, in general, such that in normal process operation the indication on the indicator or chart is between 40% to 60% of span for linear and 60% to 90% of span for square root. The complete instrument system shall be designed for safe operation, by using normally closed contacts which open on fault conditions.
200
Adequate alarms shall be provided to give audible and visual warning of malfunction . The Tenderer shall also provide alarm contacts for the operation of parallel alarms, common pre-alarm and shut down alarm by the Owner wherever indicated. All lamps shall be provided with lamp test facility. Gauge glasses shall be provided for all level measurements requiring automatic or manual control or monitoring. They shall have at least the same pressure and temperature rating as that of equipments on which they are to be installed. They shall have ball check auto shut off valves. Isolation and bypass valves shall be installed with all control valves. Hand wheels and air lock valves shall be considered for all control valves. Control valve sizing formula shall, in general, be as per ISA-75, 07. Control valves shall be sized for the available pressure drop at normal flow and shall permit up to 110% of the maximum flow. The Tenderer shall submit the sizing calculations for all control valves. DP shut off shall be 10% more than upstream pressure for actuator sizing. Orifice plate calculations shall in general, follow BS 1042. Orifice diameters shall be selected so that d/D ratio is between 0.2 to 0.7 for gases and steam and up to 0.75 for liquids. Tenderer shall submit the sizing calculations for orifice plates. Main steam generator stop valve & air vent valve will be motorized and shall be designed in accordance with ASME code for valves (ASME B 16.34) and Indian Boiler Regulations. All transmitters shall be provided with output meter/output gauge at the transmitters end. All transmitters will be smart type. The Tenderer shall ensure that the packing of instruments and associated equipment is adequate to prevent damage from such contingencies as rough handling, weather, condensation, dew, vermin and vibrations. All solenoid valves shall be universal type and continuous rated type.
201
Analysis for PH, Conductivity, Silica and Oxygen (SWAS) shall be complete with sampling system and shall be supplied with complete calibration kit including zero and span samples or buffer solution and special tools required for the maintenance. SWAS analyser will conduct online monitoring of FW quality at FW control station, drum water and superheated steam. The SWAS panels to be located in the powerhouse building. The annunciations and results of the SWAS to be communicated to DCS. The steam generator shall be provided with a three Elements Automatic Feed Regulator (thru. transmitter and controllers). One pneumatic operating and one standby pneumatic / motorised control valve (located such that its operator can see water level in steam generator gauge glass) capable of passing the required amount of water, shall be provided. The steam generator shall have two water level gauge glasses at one end of the top drum independently connected. 30% manual bypass valve to be provided. De-aerator Automatic Level and Pressure Controller Remote Water Level Indicator (hydra-step type) for steam generator to indicate the water level in the steam drum and visible at the operating floor. Furnace draught control system will be provided to automatically control the ID dampers to maintain design furnace pressure. 2.1.26.2 Instruments The DCS shall be employed for the following and will be suitably interconnected for: a. Closed loop controls of parameters for operation of boiler and turbine. b. Open loop controls. c. Sequence and shut down logic of boiler. d. Continuous monitoring of process parameters and drive running status. e. Mimic graphics f. Trends g. Report generation h. Alarm logging i. Event recording
202
Following closed loop controls shall be implemented in DCS: i. Three element control ii. Level control iii. Combustion control iv. Superheated steam temp. control v. Furnace draft control De-aerator level and pressure control vi. vii. Steam vent during start up viii. CBD/IBD level control ix. HP heater level control Pressure reducing and de superheating temp. control x. Open loop control Operation of Motorized control valves and dampers for i. Boiler feed water pump ii. Main steam stop valve and its by-pass valve iii. Air vent valve ID, FD, SA fan inlet damper iv. v. By-pass valves of PRDSH station vi. All valves of HP heater station Start/stop critical drives Monitoring of following process parameters of boiler : Flow : i. ii. iii. iv.
Boiler outlet steam Boiler feed water Attemperator spray water Combustion air
Pressure : i. Boiler outlet steam ii. Drum iii. De-aerator
203
Draft : i. ii. iii. iv. v. vi.
FD fan outlet ID fan 1&2 inlet SA fan 1&2 inlet Furnace Flue gas at boiler outlet Economiser outlet
Temperature : i. Feed water at de-aerator inlet & outlet Feed water at economiser inlet and outlet ii. iii. Boiler outlet steam iv. Steam at de-super-heaters inlet and outlet v. Steam temp. of PRDS vi. Flue gas at boiler outlet vii. Flue gas at economiser outlet viii. Flue gas at air heater outlet Flue gas at ID fan inlet ix. Current : i. ii. iii. iv. v. vi.
ESP ID fan 1&2 FD fan 1&2 SA/PA fans Boiler feed pump 1,2 &3 FW transfer pump
Positions : Positions of all MOVs (FW control station, HP heater, de-aerator, FW tank pumps, vents, MSSV, PRDSH, etc) Level : i. ii. iii. iv. v.
Drum De-aerator IBD CBD HP heater level
%O2 in flue gas
204
Speed : i. ii. iii. iv.
ID fans FD fans Rotary drum feeders Bagasse screw feeder
Conductivity : i. Feed water v. Condensate water vi. Blow down vii. Drum steam viii. Superheated steam PH : i. ix. x. xi. xii. Feed water Condensate water Blow down Drum steam Superheated steam
Dissolved oxygen in boiler feed water Silica for superheated steam, feed water & drum water The I & C to provide for the following recording to occur in the plant DCS. Parameters to be measured for recording in DCS : a. b. c. d. e. f. g. h. i. j. Steam Flow (also indicating & integrating) Steam Pressure (also indicating) O2 % (also indicating) Steam temperature (also indicating) Feed Water Temp. of Eco. inlet (also indicating) Feed Water Temp. of Eco. inlet (also indicating) Drum Water Level (also indicating) Feed Water Flow (also indicating & Integrating) Flue Gas Temp. at APH Outlet (also indicating) Feed Water Pump Outlet Pressure (also indicating)
205
Alarms to be interconnected to plant DCS : a. b. c. d. e. f. g. h. i. Drum Water Level Very High & Very Low Alarm-Audio & Visual Drum Water Level High Alarm - Audio & Visual Drum Water Level Low Alarm - Audio & Visual High Steam Temp. Alarm - Audio & Visual Low Steam Temp. Alarm - Audio & Visual ID, FD, SA Fans Trip Alarm - Audio & Visual BFW Pump Trip Alarm - Audio & Visual Bagasse Feeders Trip Alarm - Audio & Visual Low De-aerated Storage Tank Level - Audio & Visual for Air
Temp. Indicator (simultaneous indication of all the points) & interconnected to plant DCS. a) APH - Inlet b) APH Outlet c) + 2 Spare Point
Temp. Indicator (simultaneous indication of all the points) & for Flue Gas interconnected to plant DCS. i. ii. iii. iv. v. vi. vii. viii. Furnace - Just above the grate Furnace - Combustion zone Furnace - Super-heater flue entry zone Steam generator Outlet APH Outlet ESP Outlet I.D. Fan Outlet + 3 Spare Point
Temp. Indicator (simultaneous indication of all the points) and for Water interconnected to plant DCS i. ii. iii. iv. v. Steam generator feed water tank De-aerated Steam generator feed water storage tank Eco - inlet Eco - outlet + 2 Spare point
206
Draft indicator (simultaneous indication of all the point) and for Draft interconnected to plant DCS i. ii. iii. iv. v. vi. vii. Furnace Steam generator Outlet Eco Outlet APH Outlet ESP Outlet ID Fan Outlet + 2 Spare points
AMP. (CURRENT) Indicator & Recorder interconnected to plant DCS i. ii. iii. iv. v. vi. ESP ID Fan Drives FD Fan Drives SA Fan Drives BFW pump drives FW transfer pump
AMP. (CURRENT) Indication All other motors in Steam generator Station - individual indicator at respective MCC ON - OFF Indication of the Soot blowing operation showing individual location of Soot blowing, interconnected to DCS, with logic control for auto time based operations. Bagasse Feeder Speed Control Units, interconnected to DCS. ON/OFF - Push Button Units for all rotary Air Lock Valves Any other required for the proper and efficient combustion control and operation of the Steam generator. Local Instruments The steam generator shall complete with the minimum following local instruments.
207
Steam Pressure indicator
One on each side Steam generator drum. One on each side of Super Heater and one at Steam generator Firing Floor One on each side of Super Heater (with additional thermo-wells), and one at Steam generator Firing Floor One near the Flow Meter and one at Steam generator Firing Floor One each at Eco inlet and Outlet One near Feed Water Control system and One at FWP. Outlet One each at Eco Inlet and Outlet One near Feed water control system One at Feed Water Pump Delivery. (common line). One at Delivery. of each FW. Pump Delivery. One near the Flow control system
Steam Pressure indicator
Steam Temp. indicator
Steam Flow indicator
Feed water indicator Feed Water indicator
temp.
press
Feed water indicator
flow
Flue Gas temp. indicator at
Furnace - 3 places a) Steam generator Outlet - Eco Outlet b) ESP Outlet c) ID Fan outlet a) APH - Outlet b) APH Outlet (level gauge) - 2 Nos. independently connected to the Drum on each side of the stream Drum. One remote type at Firing Floor Level.
Air Temp. indicator at
Drum Water indicator
level
208
Instrument to measure O2 in flue gas. (zirconium oxide or equivalent), interconnected to DCS for the combustion control loop. Necessary tapping arrangements with thermo wells to measure the temperature of air, gas, steam and toppings to measure draft with manometer shall be provided. Steam generator to be provided with auto-combustion control, based on O2% measurement by electrochemical or infra-red gas analysers and linked to air supply drives to retain low excess air levels from 50 to 100 % of MCR. 2.1.26.3 Other General Points All required safety interlocks shall be incorporated in instrumentation system. All control valves power cylinders for dampers shall have airlock facility. The following drives shall have start / stop facility from the DCS. Illuminated push buttons shall be used. FD Fans a. b. ID Fans c. SA Fans d. Bagasse Feeders e. BFW f. FW transfer pumps g. Hydraulic drive of grate In addition to the instrumentation recommended, whatever additional instrumentation is required to prove the performance of their equipment shall be included. a. Material of Construction & General Instructions Each steam generator shall be complete with necessary tubes, manifolds integral pipe work, mountings and fittings with valves, gauges high and low water alarm, drum level control with three element system.
209
Maintenance tools consisting of tube expanders, mandrills, ratchets, two grease guns, a set of spanners, water gauge glass assembly with glasses, and chemical injection valves etc. The integral pipe work shall consisting of blow off bends, high and low pressure drains, water gauge piping, water and steam connections to feed water regulator, feed pipe work from feed control valve to economiser inlet manifold, feed pipe work from economiser outlet manifold to the steam generator steam pipe works, safety valves escape pipe works etc. All the bends, elbows, ducts shall be suitably designed for to avoid the draft losses. The Air & Flue duct will be provided with Man Holes, Cleaning holes for internal inspection, Cleaning & painting. The entire ducting for Air as well as Flue shall be designed to achieve minimum bends, minimum change of cross section. If change in cross section is unavoidable, it must be very gradual. No dust accumulation should occur where ash hoppers to be provided. All ash hoppers including hopper below Dust collector, APH, Holders, Drum, etc., shall be provided with steep angle (60 Deg.). All the ash hoppers except for Furnace ash hoppers shall be provided with rotary air lock valves. Ash hoppers having Rotary air lock valve shall have side cleaning inspection Doors / Main holes etc. Available galleries and ladders with gratings or open steel flooring for affording access to the essential levels of the steam generator plant complete with hand railing curb angles and supports shall be provided. The marking in the pressure parts for measuring tramp expansion shall be provided. All the details of tramp expansion details shall be provided. All supporting steel work, hangers thrust brackets and castings for the furnace would be provided for each steam generator.
210
All the necessary temporary lifting arrangements for drums, economiser etc., shall be supplied. If any re- calibration required for the steam generator instruments, the same shall be calibrated by the steam generator Tenderer. Tenderer will be responsible for obtaining all IBR certifications up to provisional certificate for the steam generator and auxiliaries. Buyer will pay the necessary statutory fees. b. Refractory All refractory materials including standard and high grade refractory tiles and bricks. Adequate quantity of high grade refractory cement, special shaped refractory tiles, castables refractory bricks for furnace and high temperature zones should be as per I.S:8. quality. c. Insulation High grade insulation materials suitable for out door Steam generators shall be supplied, ceramic blanket with mineral wool of multilayer with aluminium cladding of 22 SWG, water proof lagging and protected from rain water, wind and Dust etc. for the exposed portion of the steam and mud drums, steam generator furnaces, integral pipe work from the feed pumps to the steam generators, steam & exhaust piping, hot air & gas dusting, condensates pipes, valves having high temperature fluids & hot water / condensates feed water tank, de-aerated water tanks, and other steam generator accessories to be provided. Glass wool materials is used should confirm to I.S. 3690 - 1974 type 2 mineral wool shall confirm to I.S. 5696 - 1970. The thickness should be to suit the diameter and temperature of pipes. The wire mesh should be of galvanised wire and lugs/pins used should be galvanised. The detailed tramp expansion of the steam generator pressure parts corresponds to temperature from 30C to the maximum designs working temperature shall be furnished. It has to be confirmed before safety valves testing to the Owner.
211
d.
Staging, Galleries and Ladders The complete steam generator & the auxiliaries structural steel supports including the roof over the steam generator and side cladding from the top to the drum operating floor, all foundation bolts, base plates & insert plates for the structural shall be the responsibility of the Tenderer. The entire civil works including preparation of finished floor, foundations and all required structures, supports, ladders, etc. are in Tenderers scope. The required structural columns, frame for the economiser, air pre-heater ducting and piping equipment, stair cases to steam generator drum level, soot blower locations, de-aerator & feed water tank, access openings shall be provided with liberally sized stairs, handrails and walkways. In addition, pipe supports, hangers, duct supports etc., shall be provided for the complete systems covered in this specification. The steam generator and its accessories will be provided with steel supporting structure made from rolled steel sections, having adequate strength for the loads imposed by the steam generator and associated equipment. These will be including supporting columns, integral floor structure, with gravity or open steel flooring stair cases / ladders, hand railing, curb angles supports etc., for affording access to the essential levels of the steam generator plant. All supporting steel work, hangers, thrust brackets etc., shall be provided. All gangways, passages, stair cases / ladders, working platforms and railing shall be provided. A clear working platform of minimum 2000 mm to be provided for the steam generator at all levels. All statutory requirements regarding staging, platform/stair cases, safety devices etc. should be observed.
212
An interconnecting platform from steam generator top working platform to steam generator de-aerator water tank shall be provided. An approach ladder from steam generator operating floor (+ 3500 EL or as confirmed during detailing) to feed and de-aerator tank working platform shall be provided. Interconnecting steel platform from boiler operating floor to the control room operating floor in the power house to be provided with handrails and steps. The centre of the steam generator front steel supporting columns shall be minimum 2500 mm away from the centre line of bagasse carrier. The steam generator operating floor/working platform shall be minimum 10 meters wide from the steam generator front support columns in front of the steam generators and the control room. An approach ladder shall be provided from bagasse working platform to bagasse carrier working platforms at both sides. The steam generator control room shall be located to avoid obstruction while furnace cleaning etc. The front wall of the control room shall be minimum 10 meters away from the steam generator furnace doors. Two staircases on either side of the steam drum to be provided with suitable platform on the drum. e. Platforms and Walkways Platforms, walkways, staircases and landings shall be provided for safe operation and maintenance of the steam generator and auxiliary equipment and in general conform to an acceptable and proven standard. Arrangement of platforms, walkways and landings shall provide safe access to all openings for inspection and cleaning purposes, permanent and test measuring points, control devices, local instruments, vents and drain valves, soot blowers, safety valves etc. Wherever possible platforms, walkways and stair cases shall be supported from unheated structures of steam generator or building and shall never be supported from pressure parts or other moving parts of the steam generator or other plant. Platforms & walkway panels and stair treads shall be made of structural steel open bar gratings.
213
Minimum width of platforms and walkways shall be 1000 mm. Minimum headroom above the top of platform or walkways should be 2200 mm. Members supporting floor panel shall not deflect by more than 1/325 of the span. f. Stairs and Ladders All stairs shall have a minimum clear width of 750mm and the slope shall not exceed 45 0C with the horizontal. Minimum width of tread of staircase shall be 22 mm and the rise shall not exceed 200mm. 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 15mm and shall have a slip resistant nosing not less than 25mm wide. All roof tops will be accessible by suitable staircase. Fixed ladders shall be provided to platforms/roofs, which do not require frequent access by the operating personnel. All roof tops will be accessible by suitable staircase. Ladders should preferable of a sloping type with a maximum inclination of 15 0C to the vertical. Clear width between strings shall be 450 mm. Minimum thickness of strings shall be 10mm. Rungs shall be MS rounds of 20mm diameter, spaced at 225 mm (min) and 275mm (max). Minimum clear space of 230mm shall be provided behind each rung to allow foot room. Wherever the height of the stair exceeds 6.0 metres an intermediate platform shall be provided. Safety cages shall be provided if the height of ladder exceeds 4.5 meters. The cages may start at a high of 2.5 meters from the lower level. The diameter of the cage shall be 700mm (min) with 5 Nos. of 50 x 6 flats for vertical and 50 x 6 flat at a spacing of 900mm (max) for rings. g. Grating For Platforms, Walkways And Stair Treads Gratings shall be of structural steel with a minimum depth of 25mm and a minimum width of 750mm and shall conform to BS;4952 Part I. Minimum thickness of load bearing and spare bars shall be 3mm. Thickness of other binding bars shall be minimum 6mm. Clear distance between the load bearing bars shall not exceed 40 mm. for diamond pattern and 30mm for rectangular pattern. The deflection of grating panel shall not exceed span/200 or 10mm whichever is smaller.
214
h.
Handrails Top rail, knee rail and vertical post shall be 32mm NB (medium) tube conforming to IS:1239. The spacing of vertical post shall not exceed 2.5 meters. The height of handrail shall be 2.5 metre with rail at mid height. At platform and landings toe guard of 100 x 5mm shall be provided.
i.
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. The sellers designs are acceptable for structures, platforms, galleries, etc. provided this has to be approved by the Owners/Consultant.
j.
Checking of foundations The Tenderer shall as a first field activity check the foundations for the correctness of the same as per relevant drawings & and certify the same for concreting and the same may be rechecked for its correctness after concreting, such as levels, location of bolt holes, sleeves, pockets, openings, fixture plates and other embedment in RCC works, etc. All the structural fixtures required shall be supplied by the Tenderer.
k.
Steam generator Integral Piping The steam generator integral piping consists of all the interconnecting piping between the economiser inlet stop valve and the super-heater outlet header. The number of size and the arrangement of these integral piping shall be based on the permissible pressure drops in these pipes and the distribution required in the respective headers of the various sections of the steam generator. These piping shall be properly supported and provided with the required tapping, stubs and thermo wells for measurements.
215
l.
Sampling Facility Sampling Facility with sample coolers as required shall be provided for feed water, superheated steam, saturated steam and blow down water. There shall be individual sample coolers for each of the above applications with associated sampling lines, valves, cooling water lines etc. These shall be provided complete with drain tray, drain piping up to nearby drain trench.
m.
Ducting For Air and Flue Gas Necessary Mild steel ducting of 5 mm thick. plate in case of air duct and 6 mm thick in case of flue gas duct with stiffeners shall be provided for each steam generator comprising of cold air ductings extending between the forced draft fan discharge and air inlet to air pre-heater, hot air ducting from the air pre-heater outlet to the common duct and branches there from to the furnace through the blowers. The flue ducting connecting the steam generator with its accessories to the chimney. The minimum design pressure for the ducts will be 200 mm WC. Necessary regulating and isolating dampers at suitable points are to be provided for the efficient operation and maintenance of the steam generator. All the dampers shall have an effective area not less than that specified for the ducts they control. Suitable galleries and ladders with grating of open steel flooring for affording access to the essential levels of the steam generator plant complete with hand railing curb angles and supports shall be provided. All supporting steel work hangers, thrust brackets and castings for the furnace shall be provided for steam generator. The air and flue gas ductings shall be straight, with necessary long radius bends shall be provided. Sharp radius bends, diverging, converging in ductings shall be avoided. All air and flue gas ductings shall be leak proof to avoid pressure losses and atmospheric air entry etc. The details of air and flue gas velocity, draft and temperature at various points shall be provided.
216
All ducts shall be rectangular in cross section and will be of welded construction, properly stiffened and reinforced. All the air ducts, shall be fabricated from steel plates of minimum 5 mm thick, and all flue ducts shall be of minimum 6 mm thick. The duct plate material shall conform to IS 225/IS 2062 . The duct corners shall be stitch welded internally and full welded on the outside. The ducts, exceeding 600 mm width or depth, shall be suitably stiffened and reinforced on the outside and designed to withstand the pressure encountered, but however the minimum design pressure for the ducts shall be 200 mm WC. The internal struts wherever required for the ducts shall be of tubular (ERW) construction. The ducting system shall be complete with all required expansion joints, mating flanges, dampers, supports, access doors, platforms insulations etc. The top of the ducts and /or the outer cladding shall be cambered to facilitate drainage of water. Ducts will be sized considering a maximum velocity of 14 m/ sec for hot air and flue gases and 8 m/sec for cold air. The duct design consideration shall include the operating internal pressure, medium temperature , dead loads, ash loads, live loads, seismic loads, expansion joint reactions etc. The ducting expansion joints are provided to take care of the duct expansions and shall be of saw-tooth square corner type. The number of expansion joints required shall depend on the ducting thermal movement considerations. For the critical ducting sections, to be identified by the Owner/ Consultant after the submission of the ducting layout drawing, the Tenderer shall provide the calculations for the flexibility analysis and the expansion bellows selection for approval. Dampers, in the ducting system, shall be provided as called, for the proper operation of the steam generator. All dampers shall be of the louver or butterfly type with the necessary frames, shafts, blades, bearings, linkages, seals, etc.
217
ID fan shall be located such a way to provide sufficient space to construct ID fan shed to protect the drive motors, local panels etc., if any ID fan drive motors shall be free from heat radiation from steam generator chimney etc. The steam generator will be top supported type or suspension type. The steam generator shall be provided with a steel supporting structure from rolled steel sections and designed with adequate strength for load imposed by the steam generator. The steam generator shall be complete with necessary tubes, manifolds, integral pipe works. All ducting etc. must be located above 2500 mm level to clear off the man and material movements. All the steam gaskets as joints with a pressure of 7 kg/cm2 (g) and above, shall be metallic grafted, high pressure steam gaskets suitable to twice the working pressure and temperature. Spare gaskets for all joints in HP steam line shall be supplied. Adequate supports shall be provided for the roof tubes to avoid sagging of tubes in the hot conditions due to the weight of the refractory materials etc. n. Temporary Supports The necessary temporary support of steam generator pressure parts such as top (steam) drum, bottom (mud) drum, headers, steam generator tubes, super-heater elements, economiser shall be supplied by steam generator Tenderer only. o. Safety Valves The safety valves shall be semi nozzle full lift, and open bonnet type and the selection and sizing of the safety valves shall conform to the provisions of the IBR. In IBR and addition to meeting these requirements, the steam generator safety valves shall also meet the stipulations of ASME with regard to the blow-down and over pressure requirements. The steam generator safety valves and all other safety valves shall be with butt welding end connection.
218
The valves shall be supplied with lifting level, test gag, cap and spring cover and silencer for superheater safety valves and start-up vent. The capacities of the safety valves provided downstream of pressure reducing stations shall be the maximum flow permissible through the control valves under 100% valve opening with the rated full upstream pressure. S/V exhaust to be taken out from the roof of building with silencer. p. Control Stations All control stations shall be provided with a bypass with a motorised regulating globe valve for DCS control and isolating valves on either side of the control valve. The control valves shall be sized to have the maximum flow at a maximum of 90% of the valve opening. The noise levels at a distance of one meter from the control stations shall be less than 85 dB. All control stations shall be located in easily accessible areas with adequate space around for maintenance. Feed regulating station shall have two bypasses one with 100% MCR capacity the another with 30% MCR capacity. The feed regulating valves shall be capable of being operated in auto manual regimes from the control room. It is preferred to have the operating valve as pneumatic, standby as pneumatic and manual valve at 30% capacity. q. Cladding Cladding for boiler roof will be meta-poly sheet.
219
2.2 2.2.1
STEAM TURBINE GENERATOR & AUXILIARIES Scope of Work The Tenderer will be responsible for providing an efficient, reliable and state of art technology steam turbine, generator of triple extraction cum condensing type. The Tenderers scope of work includes designing appropriate turbine / generator sizing for maximizing power export from the cogeneration plant after meeting the energy needs of the adjoining sugar mill. The detailed specifications given below, attempt to define the Tenderers scope and specifications. However, the onus of providing the appropriate steam turbine generator and auxiliaries rests with the Tenderer. The scope of work for the Steam Turbine, Generator & Auxiliaries covered under the specification will include but not limited to the following. a) Supply Engineering, Design, fabrication, manufacture, assembly, shop testing and inspection at manufacturer's works. Providing all labourers, materials and equipment for testing at shop as required. All spare parts required for the commissioning of the Steam Turbine, Generator and auxiliary systems. Recommended spare parts of the Steam Turbine Generator unit and auxiliaries. Special tools and tackles required for operation and maintenance, inspection, and repair of the equipment / systems offered.
220
b)
Erection and Commissioning Unloading, handling and storage at site, pre-fabrication/assembly if any, erection, testing, commissioning, trial operation, final painting and guarantee performance testing of one (1) No. Steam Turbine & Generator of rating as specified in this tender document with all necessary accessories and auxiliaries as well as associated electrical and instrumentation and control equipment, as specified.
2.2.2
Scope of supply and services of basic equipment Scope of supply and services for One number Turbo-generator with auxiliaries are indicated below. Components and services not specifically mentioned here but necessary to complete the stipulated work in all respects, regardless of any omission in this specifications or drawings, is deemed to have been included in this tender. Scope of supply a) Mechanical One (1) No. Turbine and auxiliaries comprising of, i. Triple extraction cum condensing, multistage, impulse & reaction type or impulse type steam turbine, complete with casing, rotor, blades, bearings and glands. ii. Provisions for three extractions at 25, 8 and 2.5 kg/cm2. The 2.5 kg/cm2 extraction needs to be internally controlled. The 25 and 8 kg/cm2 bleeds will be externally controlled to maximise power generation iii. Heavy duty reduction gear box (double helical type) capable of continuously transmitting the maximum power generated by the turbine.
221
iv. High speed coupling between the turbine and the gear box, and low speed coupling between the gear box and the alternator with coupling guards. v. Emergency trip cum stop valve with steam strainer throttle valve, governing valves, etc. vi. Microprocessor based Electro-Hydraulic or Electronic governing system including speed changer, capable of operating in parallel with the grid and also independently in case of islanding. Woodward 505E digital governor with required actuator & accessories. Governing console to be provided. Digital AVR of approved make with auto power factor adjustment capability to maximise power exports. One standby AVR of similar make also required. vii. Vibration monitoring system. viii. Air cooled condensate system complete with required vacuum breaker, rupture disc, tube bundles, fans with VFD, drains, vents, structures, air ejectors, condensate collection tank, CEP, condensate controlled station, etc. ix. Interconnection between the turbine and the inlet of air cooled condenser. x. Gland sealing steam system consisting of gland steam condenser, valves, steam jet ejectors etc. GSC to have CS tube sheet, SS / admiralty brass tubes with shell, water box, foundation bolts, sole plates, primer coating, 2 x 100% SJAE, water relief valve, stand pipes, isolation and drain valves. All gland sealing steam to be recovered & returned to hot well. xi. Lube and control oil system common for turbine, gear box and alternator. xii. One oil reservoir complete with filters and oil vapour extractors.
222
xiii. Two 100% oil coolers with necessary three way switching valves. Coolers to have tubes of SS / brass, removable tube bundle, CS shell, water box & tube sheet, bolted end covers, sole plates, coating, valves for change over & isolation, mating flanges. xiv. Two 100% oil filters for the lube and control oil. Oil mist fan (1 no.) xv. One main oil pump driven by the turbine shaft or A.C. motor , one auxiliary oil pump driven by A.C. motor and one emergency oil pump driven by D.C. motor. Jacking oil pump with AC motor. xvi. One centrifugal type oil purifier. xvii. Bolt heating equipment, shaft grounding device. xviii. Automatic exhaust hood spray system. xix. Overhead emergency oil tank (SS lining) of adequate capacity duly interconnected to lube oil system, with SS piping. xx. A.C. motor driven barring gear system with manual engagement and automatic disengagement. xxi. Main hydraulic stop & emergency valve suitable for manual opening & emergency shut down, with internal strainer. Main isolation valve, flow meters in throttle & extraction lines, temp. & pressure transmitter, safety vales, QCNRV, control valve in uncontrolled & controlled extraction. xxii. 3 x 50% capacity motor driven vertical condensate extraction pumps. xxiii. Base frame for turbine, gear box, and alternator with necessary foundation bolts or sole plates. xxiv. Trip system for safe operation of turbine during abnormal steam, vacuum or oil conditions.
223
xxv. Electric drive barring gear, to drive the turbine in-case of shutdown or start-up to prevent thermal distortion. xxvi. Safety devices for speed, lube, displacement & steam parameters. xxvii. Set of removable hot insulation xxviii. Complete piping with valves, fittings & insulation as required along with pipe supports associated with turbine, HP heater, lube, drains & control oil system. Set of QCNRV (Quick close non return valve), control valve, isolation valve and flow relief valves for the three extractions. Set of diaphragm type regulating valve and pressure transmitter for external control of bleed. Set of matching flanges for all interconnections. xxix. Adequate system of drainage from all steam spaces with in the unit. xxx. Flash tank for connecting all high pressure drains. xxxi. Special lifting tackles and special tools required for the normal maintenance work. xxxii. Acoustic hood. xxxiii. EOT crane of adequate capacity to lift the heaviest component during maintenance, along with all electrical, rails, girders, etc suitable for erection. xxxiv. PRDSH for auxiliary steam needs from HP line and steam piping thereon up to the auxiliaries.
224
b) Electrical One (1) no. Three Phase Synchronous Generator i. The complete excitation system consisting of the brush less exciter with PMG and thyrister driven type AVR mounted on the generator shaft and the excitation panel housing the automatic voltage, VAR / power factor controller etc. Including field breakers and field dischargers. In either case, voltage regulation of + 1 % and adjustment of +10% to 12.5% is needed. AVR to be digital type with auto and manual channel, along with PF controller. One EOT crane of required capacity along with electrical, rails, girders, etc ready for erection (capable of meeting all erection loads). One additional standby AVR to be added. ii. Stator with output leads taken from sides, rotor suitable for overhang, bearings, base frame, built-in RTDs. iii. Local panel gauge to give all important inlet and outlet steam parameters, major electrical parameters and oil / cooling water temperatures. iv. Auto & manual synchronizing system, with panel. v. The closed air circuit water (CACW) cooling system for the generator with ducting and coolers. vi. Space heaters, CTs, PTs, LA and SP equipment. vii. Generator protection panel. viii. Metering and control panel. ix. Neutral grounding resistor cubicle with connection from neutral. x. Lighting arrestor and surge protection. xi. Relays as required and as described in the specification.
225
xii. Current and potential transformers for protection and metering and voltage regulation. xiii. Lightning arrestor for STG building up to earth mat. xiv. Starter for EOP motor along with DCDB. xv. Complete CO2 based fire-fighting system, if applicable. xvi. Generator air coolers to be side / bottom mounted, tube sheets, frame, water box, sole plate, anchor bolts, primer coating and valves. xvii. Special tools for the Generator and accessories and sling for lifting. xviii. All AC and DC motors required for the successful operation of the plant. The motors shall be suitable for the equipment/area specified and supplied as a complete unit with its driven equipment. The terminal box of motor shall be complete with cable gland and lugs. xix. All pipe / equipment mounted local gauges as required. xx. All pressure test points complete with root isolating valves (bonnet less) and temperature test points complete with thermo wells and screwed plugs and chain for performance measurements. xxi. Local gauge board at Turbine floor or in control room, complete with gauges and accessories. xxii. Local instrument panel or turbine control panel xxiii. Safety devices and shut down systems. xxiv. Complete I&C system to connect to DCS.
226
xxv. One set of special tools and tackles required for operation maintenance, inspection and repair neatly packed in steel boxes complete with instructions for the Turbine, Generator and all other Equipment covered in this scope of work.
2.2.3
Correction Curves The results of the performance test shall be corrected to the specific conditions by correction factors, which shall be defined by means of correction curves. All correction curves shall be submitted by the Tenderer. A certified copy of the correction curves, giving the corrections to the steam turbine generator unit performance for variations in the inlet steam conditions, power factor, ambient conditions etc. as will be applicable to the plant shall be submitted.
2.2.4
General Specifications This specification is intended to cover the design, manufacture, delivery, erection, testing and commissioning of one (1) Number turbo generator unit with gear box, air cooled condenser and all other auxiliaries, with a nominal power output of 20 MW (or best at given steam flow parameters) at the generator terminals at the site conditions with 40C ambient and at 0.8 PF, 11 KV and 50 Hz. The unit will be operated in parallel with the local Electricity Board Grid with the frequency variation of +/- 5% and voltage variation of +10% to 10%. The steam turbine shall be a triple extraction cum condensing type with extractions at 25, 8 and 2.5 kg/cm2 The supplies and services within the scope shall be rendered inclusive of all appliances and interconnecting arrangements with other supplies, necessary for installation of all accessories and for satisfactory maintenance and repair. The scope of supply and services shall include all necessary work and supply of equipment and material whether mentioned in these specifications or not, but which are necessary for the satisfactory, reliable and safe operation and maintenance and required for achieving guaranteed performance of the plant.
227
Any equipment, device or material even if not included in the original bid but found necessary for the safe and satisfactory functioning of the unit under the bid, shall be supplied, erected and commissioned by the Tenderer at no extra cost to the Owner, as though, such equipment, material or work were originally specified and formed part of the scope of work. Scope of relays, metering & protection will necessarily meet BSEB standard requirements.
2.2.5
Design Basis The Turbo - Generator and the Auxiliary Equipment covered under this specification shall be designed to achieve maximum power generation as per normal steam flow rates from the double extraction cum condensing set. Part of the generated power will be fed to the sugar complex plant and the rest will be exported to the grid, after stepping up the voltage to EHV and transporting the power through transmission lines to the nearby sub-station of the BSEB. The extractions from the turbine provides the sources for the medium and low pressure steam for the use in the sugar mill & power plant auxiliaries & de-aerator. The steam will be available at the turbine isolation valve at 105 + 2 kg/cm2 and 535 + 5C. All equipments shall be designed to operate continuously for 8000 hrs per annum. The turbo alternator shall be designed taking into consideration all possible electrical parameters affecting the choice of the machine, assuring stable and reliable operation in a rural network. The selection, if necessary, shall be based on the complete study of the electrical system, including transient stability study, short circuit study, load flow and reactive power short fall study etc. For this tender the Tenderer shall offer his standard micro-processor based controls and instrumentation system with panels etc, for the start up, shut down and operation with all standard features.
228
2.2.6
Performance Parameters 2.2.6.1 Steam flow at the Turbine : normal : 100,000 kg/hr Up to 110,000 kg/hr (max) Min:15,000 kg/hr 105 2 kg/cm2
2.2.6.2 Steam pressure at the turbine stop valve 2.2.6.3 Steam temperature at the turbine stop valve.
5355 0C Performance guarantee 0.1 ata
2.2.6.4 Exhaust pressure with air cooled : condenser 2.2.6.5 Extraction steam requirements Bleed at 25 for HP heater no.2 kg/cm2
Season 7,000 kg/hr
Off-season 5,300 kg/hr
Bleed at 8 kg/cm2 for HP heater no.1 and process
up to 35,000 kg/hr, Normal 27500 kg/hr, min: Nil
up to 20,000 kg/hr, Normal 16000 kg/hr, min: Nil
Controlled extraction at 2.5 kg/cm2 for deaerator and process
up to 45000kg/hr, Normal 36000 kg/hr, Min: 5000 kg/hr Min : cooling steam Flow Normal : as required to generate 20 MW
up to 10,000kg/hr, Normal 5600 kg/hr, Min :Nil As required to generate, alternator capacity
Flow through condenser
229
Note :1) The steam flow figures given above are typical of the proposed cogeneration plant and have included normal operation of various power cycle components like de-aerator, auxiliary cooling tower etc. Also, these values correspond to the normal crushing rates of cane. It is hence, to be understood by the Tenderer that the operating values of steam flow may differ from those given as normal above but will generally be within the specified ranges. However, in event of malfunctioning or outages of any of the power cycle equipment or decrease in cane crushing rates, the extraction and condensing steam flows will change. The Tenderer should optimise the turbine design to maximise power generation anticipating the possible fluctuations in extraction and condensing steam flows. Tenderer to give power generation at alternator terminals for all above conditions, with normal being guarantees points. Condensing pressure as achieved by Tenderers design, with given cooling water temperature. For evaluation purpose, the same to be 0.1 ata Tenderer to submit power generation at normal flows during season and off-season. Turbine to be designed for continuous operation at 105 kg/cm2 and 5350C 2.2.6.6 The economical steam rate required at percentage load Nominal Generator Output Power factor (lagging) Generation Voltage : 80 to 100
2.2.6.7 2.2.6.8 2.2.6.9
: : : :
20 MW 0.8 11 KV 50 Deg. C
2.2.6.10 Ambient temperature for Electrical equipment design
230
2.2.6.11 Parallel operation with grid Duty requirements
: :
Required Continuous 8000 hrs per 30% (However, STG to be capable of running of operating on only auxiliary load of 1.5 MW during any grid tripping in off-season) Dusty (as prevalent in the existing sugar mill)
The minimum continuous loads : at which the TG is expected to operate as percentage of rated load
2.2.6.12 Atmospheric conditions
2.2.6.13 The maximum noise pressure level at 3.0 m distance for any equipment from the equipment surface shall be equal to or less than 2.2.7 Utilities 2.2.7.1 Instrument Air Pressure, kg/cm2 g Temperature, Deg. C 2.2.7.2 Cooling Water Water temperature Dec. C Water pressure, kg/cm2 g 2.2.7.3
85 db (A)
4.5 40
5.5 45
6.5 85
32.0 2.0 (maximum)
Low pressure Auxiliary steam Pressure kg/cm2g 2 2.5
2.2.7.4
Medium pressure steam Pressure kg/cm2g 8
231
2.2.7.5
A C Power Voltage Frequency V Hz 415 (Three Phase) 50 230 230 V
2.2.7.6 2.2.7.7
DC Power Voltage V UPS Power:
2.2.8
Conditions of Service a) b) The steam turbine will be installed in a power house. The turbine control shall be located in the adjacent control room ,whereas important indicating instruments shall be provided near the turbine in the local gauge board & local panel in addition to the control room instruments. Emergency stop arrangements shall be provided in the local panel.
2.2.9
Design and Engineering The turbine shall be preferably single cylinder, single exhaust, double extraction, condensing type. All castings and stator blade carries shall be horizontally split and the design shall be such as to permit examination of the blading with-out disturbing shaft alignment or causing damage to the blades. The design of the casing and the supports shall be such as to permit free thermal expansion in all directions. The Tenderer shall describe and illustrate by means of diagrams the method used to support the casing and to accommodate the expansion. Solidly forged and machined rotor with integral disks is preferred. The rotor after fully machined and bladed be given a over speed test. None of the critical speeds of the rotor shall fall within the range of 20 % above and 20 % below the normal running speed of the rotor. The turbo generator Tenderer, with the unit responsibility, shall analyse the complete couple train for both lateral and torsion vibrations, and ensure proper separation margins. The rotor shall be designed to withstand the maximum shock loading that may occur during any power system disturbance.
232
Such shock loading values shall be taken for the design of the gear box and the generator rotor. The Tenderer shall clearly describe in his offer, the construction of the rotor, the heat treatment proposed and the procedure for inspecting the shaft to ensure soundness and homogeneity of the material. The material of construction shall be consistent with proven practices and standards. The blades shall be designed to withstand all vibrations, thermal shocks, and other loading that may be experienced during service and system disturbances. The blades shall be machined from forge bars or die forged and the materials used shall be chromium steels consistent with proven experience and standards. Any blade coating used to improve performance or resistance to erosion shall be described. The Tenderer shall clearly indicate the type of fastening of the blades on to the wheels and also give the specific advantages of the particular fastening method. The rotating blades are either shrouded or tied with lacing wires depending on the stresses and the excitation frequencies, and the offer shall indicate the arrangement. The details of the seal strips used to control the steam leakages shall also be indicated. The glands shall preferably of labyrinth type and sealed with steam. The complete piping, valves, pressure gauges, regulators etc., required for the end seals shall be provided by the Tenderer. A vacuum system if required by the design shall be provided. All piping and components of shaft seal and vacuum system, if provided, shall be sized for 300 percent of the calculated new clearance leakages. Steam leaving the glands shall be condensed in seal steam condenser and recovered in the hot well. It shall be possible to inspect and replace the end seals without opening the casing and without damaging the thermal insulation. The Turbine shall be provided with liberally rated hydrodynamic radial and thrust bearings. The radial bearings shall be split for ease of assembly, and of the sleeve of pad type, with steel shell backed, babbitted replaceable pads. These bearings shall be equipped with anti-rotation pins and shall be positively secured in the axial direction. The thrust bearings shall be of the steel backed babbitted multiple segment designed type, designed for equal thrust capacity in both directions. A liberal flow of lube oil under pressure shall be supplied to all the bearings for lubrication and cooling.
233
It is required that : a) All integral piping for steam, water air, lube oil etc to be supplied in pre-fabricated condition to the site to avoid delay in E&C. b) Supply of cooling water to STG auxiliaries like SJAE, GSC, etc. to be from CEP. c) Condensate from cogeneration auxiliaries like SJAE, GSC, etc. to be returned by Tenderer to the de-aerator. 2.2.9.1 Lubrication and control oil system a) A pressure lubrication and control oil system shall be furnished for the turbo generator unit to supply oil at the required pressure to the steam turbine, gear box, generator and governing system. Oil in the reservoir shall be maintained at appropriate temp when TG set is idle by providing suitable electric heaters and temperature controls. For the hottest ambient conditions to be encountered at the site oil outlet temperature at any bearing shall neither exceed the maximum permissible temperature for the bearing metal nor the maximum safe operational temperature of the oil. b) The oil system shall include the following: i. ii. Main oil pump preferably driven by the turbine shaft /motor driven. A 100% capacity A.C. motor driven auxiliary oil pump arranged to cut in automatically if the oil pressure falls to a preset value. This pump shall also meet the requirements during the start up and shutdown. A D.C. motor driven emergency oil pump of sufficient capacity to provide adequate lubrication in the event of a failure of the unit A.C. motor driven pump. This pump also shall cut in automatically at a pre set value of the oil Pressure. Two 100% capacity (one working and one standby) water cooled oil coolers.
iii.
iv.
234
v.
vi.
vii.
viii. ix. x.
Two 100 % duty oil filters arranged in such a way that it is possible to clean one oil filter while the other is in continuous flow transfer valves. An accumulator to maintain sufficient oil pressure, during transients conditions and while standby pump acceleration from idling to full speed. Oil storage and settling tank (can be part of main oil tank) with adequate reservoir capacity, duplicate strainers, level indicators with float switches and alarm contacts, vent and oil mist eliminators. Overhead oil tank for gravity flow to the system in case of emergency. Flow and temperature indication for oil from every bearing. Centrifugal oil purifier. Supply of the flushing oil and the first fill up of lube oil for turbine and accessories shall be the responsibility of the Tenderer and preferably from the Indian market.
c) Oil coolers The oil coolers shall be water cooled with a duplicate arrangement and changeover valves. The coolers shall be of shell and tube type with removable tube bundle. The coolers shall be constructed in accordance with TEMA class C. The provided surface area shall be adequate to cool the oil with 32 Deg. C inlet cooling water temperature even with 20 % of the tubes plugged. The sizing of the coolers shall consider a tube side (water side) fouling factor of 0.0002. The water velocity shall be not less than 1.5 M/sec. The material of the cooler will be ERW SS or admiralty brass and shall conform to the requirements of ASME or API or HEI. The coolers shall be amenable for easy inspection & maintenance and cleaning of one cooler while the other one is in service shall be possible. The Tenderer shall indicate any emergency cooling water requirements in his offer.
235
d) Filters Full flow oil filters shall be used downstream of the coolers and shall be piped in a parallel arrangement with a continuous flow transfer valve. Filtration shall be 10 microns nominal. Filter cartridges shall have a minimum collapsing differential pressure of 3.5 ata The minimum design pressure for the filters shall be the maximum discharge pressure of the oil pumps. e) Oil reservoir The interior of oil reservoirs shall be desalted and rust proofed with a permanent coating. Reservoirs with top mounted equipment shall have sufficient rigidity. All openings for piping shall be made dust and water proof. The oil reservoir shall be so located to permit draining of the contents by gravity and shall be equipped with fine coarse mesh strainers. f) All necessary piping, valves and fittings for the complete oil system shall be provided by the Tenderer. The lube and control oil piping from the outlet of the filters and up to the user point shall be of stainless steel. The piping from the reservoir to the filters and the return oil piping shall be of carbon steel. The complete piping shall meet the requirements of ASME / API. All piping from overhead tank will be SS. All governor oil piping to be of SS. g) Oil purifier A centrifugal type oil purifier shall be provided for the removal of water, sediments and other oxidation products. The purifier shall be a separate complete package. The capacity of the purifier shall be at least one (1) percent of the rate of normal flow through the reservoir. Feed to the purifier shall be from the drain end of the reservoir and it's operation shall be independent of the oil systems.
236
h) Steam Turbine Governing System The turbine governing system shall be electro-hydraulic designed for high accuracy, speed and sensitivity of response. The electrical / electronic and hydraulic component of the control system shall be selected on the basis of reliability over a wide range of operating conditions. All components used shall be well proven to assure overall system reliability and shall be designed for easy and quick replacement when necessary. The governor shall ensure controlled acceleration of the turbo generator and shall prevent over speed without tripping the unit under any operating condition or in the event of maximum rejection. The governor (Woodward 505E) shall have linear droop characteristics with a suitable range for stable operation and shall have provision for adjusting the droop in fine steps. The governing system shall have the following important functions: Speed control Over speed control Load control Extraction steam pressure control 2.2.9.2 External Forces and Moments The Tenderer shall furnish the allowable forces and moments on the turbine nozzles. The Tenderer shall furnish the stress analysis of the piping to meet the same. 2.2.9.3 Thermal Insulation and Lagging : The steam turbine and the other high temperature parts, including piping supplied, shall be insulated with low conductivity insert material, where required, reinforced by stainless steel wire net between applied layers.
237
The insulation shall be so arranged that it can be removed for access to the flange bolting, control valves and other parts that require periodic maintenance. MAT / blanket type removable insulation for the turbine is required. 2.2.10 Performance Requirement 2.2.10.1 Controlled extractions The bid document calls for three extractions at 25, 8 kg/cm2 and 2.5 kg/cm2. The low pressure extraction is to be internally controlled. Tenderer to provide externally controlled system for the 25 and 8 kg/cm2 bleed. Tenderer will need to supply all control valves, as required after the uncontrolled extraction. The system to be complete with the necessary control valves, relief valves and non return valves included in the Tenderer's scope. 2.2.10.2 Economic Load The specific steam consumption shall be the lowest for operating loads between 80 to 100%. 2.2.10.3 Over Loading The Generator shall be suitable for an over load of 10% for 1 hour in every 12 hour and 50 % over load for 30 Seconds as per IEC. 2.2.10.4 No load and Minimum load operation The turbine shall be capable of operating under no load condition during loss of load for a maximum period of 15 minutes. The minimum load at which the turbine is required to operate continuously shall be 30% of the designed capacity.
238
2.2.10.5 Specific steam consumption This guaranteed specific steam consumption / heat rate shall be for a load range of 80 to 100 percent of rated capacity and the testing shall be as per ASME PTC 6-S. 2.2.10.6 Governing Characteristics When the machine is operating with rated steam conditions and at rated speed, and the maximum load is thrown of, the operation of the electronic speed governor shall prevent the speed rising to a value at which the over speed trip is set to operate. The speed governor droop i.e. permanent speed variation from no load to rated output etc., shall be within the limits specified in IEC Recommendations Publication 45 2.2.10.7 Parallel operation The characteristics of the turbine shall be such that the turbine generator set can be run in parallel with the State power grid and / or with a machine to be added later on and possess no abnormal features either individually or collectively. 2.2.10.8 Speed adjustment The turbine speed at no load shall be adjustable between 5% below and 5% above rated speed. Means are to be provided whereby the speed of the turbine at no load can be raised in a controlled manner for the purpose of testing the over speed trip mechanism and provision made to ensure that such means do not interfere with the action of the speed governor in normal. The device to raise speed at no load must incorporate limiting means to Prevent it from reaching a dangerous speed. During emergency condition, the turbine may be operated at speeds as low as 98% of the rated speed.
239
2.2.10.9 Over speed trip In addition to the speed governor, the turbine and generator shall be protected against excessive over speed by a separately actuated over speed device which operates the trip system. In the event of sudden load rejection, should the speed governor fail to meet the requirements the over speed trip shall operate to prevent any damage. The over speed trip setting shall be stated by the Tenderer in his offer and in the operating instructions. 2.2.10.10 Trip system The turbine shall be provided with a system for the complete and rapid closure of steam valves effectively preventing all steam admission to the turbine independently of the closure of the governing valves. In order to avoid sudden re-admission of steam to the turbine the trip system shall be fitted with interlocking devices so that trip resetting cannot take place until steam admission can be achieved as per normal operating procedure. Essential trip circuits to be provided are: a) b) c) d) Steam inlet pressure falling below / above pre-determined level. Steam temperature falling below / above pre-determined level. Condenser vacuum falling below / above pre-determined level. Lubricating oil pressure falling below / above pre-determined level.
2.2.10.11 Maximum speed An over speed test of the turbine rotor shall be carried out preferably at the Tenderer's works. The over speed tests shall be at a speed exceeding by 2% of the maximum calculated over speed that would occur if the governor failed and if the maximum over speed was limited by the action of the over speed trip device only. The duration of the over speed test shall be less than 2 minutes. The over speed shall not be more than 20% of the rated speed.
240
2.2.10.12 Vibration Vibration measuring and monitoring systems shall be provided for the bearings and the shaft. This system shall include the generator bearings also. The maximum allowable vibration under specified operating conditions shall be indicated by the Tenderer. Minimum two nos. vibration probes to be provided at each bearing of turbine, generator and gearbox. 2.2.10.13 Critical speed The critical speed for the combined turbine and generator shall be sufficiently away from the rated speed to avoid any adverse effect of the operation of the unit over the range of operating speeds. 2.2.10.14 Materials of construction The selection of materials for parts of the machine shall be based on the experience of the Tenderer and experimentally determined data and shall conform that under conditions of stress temperature and time the components will not fracture or deform to a greater extent than is permissible. The materials selected shall be clearly indicated in the turbine and auxiliary data sheets. 2.2.10.15 Variation of steam pressure and turbine The turbine shall be capable of accepting variations from the rated conditions within the limits specified by IEC Recommendation Publication. 45.
241
2.2.11 Safety a) All controls shall operate in a fail safe mode. b) All coupling and gears shall be provided with adequate guards. c) Piping shall be arranged in such a manner as to avoid tripping or overhead problems. d) Piping or tubing of insufficient mechanical strength which is standing or hanging shall be protected from personnel traffic. e) Surface temperature on any point shall not exceed 60 Deg.C. f) Very high standard of safety shall be built into the set with high degree of redundancy.
2.2.12 Condenser a) The condenser shall be of non-contact surface type condenser designed as per the requirements of Heat Exchange Institute Standards for Steam Surface Condensers. The condenser shall sized to condense the maximum quantity of exhaust steam (i.e. when there is no extraction to process and the only extractions are for HP heater and deaerater) with the inlet cooling water temperature at 32 Deg. C and outlet temperature of 40 deg. C. to generate power of 100% alternator rating. The temp. rise on CW side will be 8 0 C The cooling water for the condenser will be supplied from the cooling tower basin through cooling water pumps and the water will be treated. The water velocity through the tubes shall not be less than One (1) meter per second and the cleanliness factor on the tube side shall be 0.85. The pressure drop on CW side not to exceed 6 mwc.
242
b)
The condenser design and supply shall be complete with the neck, expansion joint, condensing chamber and tubes, tube sheets, epoxy coated hot well, water boxes, air removal system and accessories, atmospheric relief valve, bellows, surge & stand pipes, water expansion relief valves, vent & drain valves, sacrificial anodes & baffles. The condenser neck shall be suitably designed to reduce the inlet steam velocity to ensure low pressure drop and to protect the tubes from impingement of steam. The condenser shall be adequately designed for the external pressure and stiffeners and bracings wherever required shall be provided. The tubes shall be provided with supports to eliminate any serious tube vibration problems and sagging. The tubes shall be expanded into the tube sheets at both the ends and flared at the cooling water inlet side. The condenser neck shall be connected to the turbine exhaust hood with a properly designed stainless steel expansion bellow, as applicable, which allows free expansion of the condenser unit without exerting undue thrust on the turbine exhaust hood and facilitate independent supporting of the condenser on the foundations without resorting to springs. The hot well at the condenser bottom shall have a minimum capacity of 2 minutes storage while handling maximum quantity of exhaust steam. The hot well shall be provided with level gauges and connections for condensate extraction and drain. A suitably designed level control system shall be provided. No make up will be added in the condenser hot well. Condensate of STG auxiliaries will be returned by Tenderer to the hot well.
c)
The condenser shall be of divided water box design and the water boxes shall provide easy accessibility to the tubes. It shall be possible to clean one section of the tubes with the condenser load suitably reduced. The circulating water inlet and outlet connections shall be of adequate size to reduce the waterside pressure drop to the minimum.
243
The water boxes shall be coated with epoxy resin, internally to prevent corrosion from the cooling water and shall be provided with sacrificial anodes. The condenser water boxes and the tubes shall be designed for a pressure corresponding to the full shut-off head of the cooling water pumps which will be about 4 ata. d) The condenser shall be provided with an atmospheric relief valve sized as per the recommendations of HEI standards with water seal around the valve disc to ensure proper sealing. The material selection for the various components of the condenser shall be as per the Tenderer's standard and adequate to meet the duty requirements. Condenser tubes to be of admiralty brass or SS 304 welded. Tube sheet & shell to be of IS 2062. The Tenderer's offer shall furnish the complete data on the condenser including the material of construction for the various components. The foundation bolts for the condenser shall be included in the scope of supply. f) Condenser Air Removal Equipment One steam operated hogging ejector (1 x 100%) of single stage shall be furnished for the initial pulling of the vacuum in the system. The capacity shall be so as to reach 60% vacuum in 20 minutes time. Ejector shall be without any condenser, discharging to the atmosphere through a suitably designed silencer (1 x 100%) Two steam operated main ejector of two stage single element type with inter and after condensers shall be provided. Cooling medium in the inter and after condensers (2 x 100%) in the ejector system shall be condensate from CEP discharge. Condensate after CEP control station will be taken to deaerator. Condensate piping from hot well to ejector & other auxiliaries in Tenderers scope. Condensate from auxiliaries to be returned to hot well by Tenderer.
e)
244
Both the ejector systems shall be complete with piping, valves, rupture disk etc. Valves to include isolation for steam supply individual ejector elements, expansion relief, vent & drain, etc. The tenderer shall provide the complete details of the ejector systems with material of construction and the steam consumption. 2.2.13 Condensate Extraction Pumps Three numbers 50% capacity vertical condensate extraction pumps to pump the condensate from the condenser hot well shall be provided. Both the pumps shall be driven by electric motors and the flow shall be controlled by discharge throttling and auto cut-in / cut-out of the pumps. The pumps shall be of centrifugal, vertical, multistage type and shall be supplied compete with all valves, inlet and discharge piping with manifolds. The pump shall be designed to have a minimum discharge head considering friction losses, deaerator head, pressure drop across deaerator nozzles and control valves. However, the required head will be finalised during the technical kick-off meeting with select Tenderer, based on design of boilers deaerator.
2.2.14 Barring Gear The turbine, shall be provided with a barring gear of mechanical type driven by an A.C. motor, to rotate the turbine and generator after shutdown to prevent thermal distortion of the rotor. The barring gear shall be capable of starting the rotor from rest and run it continuously at low speeds. The barring gear shall be interlocked with the lubrication system to prevent it's operation without lubrication. If provided, the system shall be capable of manual engagement and automatic disengagement when the turbine speed goes above the normal barring gear speed.
245
The system shall also have facility for manual turning in case of A.C. supply failure. The turbine panel shall be provided with necessary push bottoms, alarms and switches for the operation of the barring gear.
2.2.15 Base Frame Suitable base frame or sole plates either common or individual shall be provided for the turbine, generator and the gear box. Provisions shall be made to level each piece of equipment separately and as a package.
2.2.16 Control System for Steam Turbine In case of any failure of the DCS system, there should be a DCS bypass to start the essential equipments of the STG & auxiliaries in manual mode. All intelligent devices should be monitored and controlled through the DCS. All intelligent devices should be realized in the DCS. This specification outlines only the broad requirement of the controls for the turbine. It is the responsibility of the turbine Tenderer to provide all the controls, instrumentation and gauges required for the safe and efficient operation of the turbine system. The inputs and outputs are to be protected against polarity reversal. All inputs to be potential free contacts. Outputs to be short circuit proof and provided with fuses. The basic requirements are as follows. The complete steam turbine generator & auxiliaries package will be normally operated only through the DCS in the control room. It is not envisaged to have any operator or workman in the field. Normal start-up operation should also be accomplished through the DCS. Hence, start / stop of all drives, speed regulation where required, operation of actuators / dampers / solenoid valves, operation of all motorised valves, operation of all sub-systems should be interconnected through the DCS with appropriate & required I/Os.
246
The starting and stopping provision for steam turbine shall be provided at the remote control panel in the control room. All instruments and controls shall be supplied by the Tenderer and tested along with the turbine / generator. All sequential start-stop, shutdown / interlocking and other auxiliary equipment shall be located within the remote control panel and shall be through DCS. The turbine shall be supplied with a self-checking solid state fully automatic sequential start system designed to provide reliable programmed starting, acceleration, synchronization and loading to selected loads, operatable through the DCS. The control system shall provide redundancy for key functions by use of separate sensors, monitors, control valves, converters, etc. The control system shall include all the standard control monitoring and alarming. Control panels shall be supplied fully wired and complete with all a necessary special wiring for interconnection of panels. Vibration detector/proximity meters/axial position detectors monitors shall be provided for all bearings including the bearings of the turbine, gearbox and the generator and for turbine axial displacement, shaft vibrations at gearbox high & low speed shafts. Annunciation scheme will be given as part of DCS. Hard wired recorders shall be provided for critical service. Control shall have suitable facilities for ON-line testing / trouble shooting through provision of diagnostic lamps, bypass lamps / switches, test switches, etc. Remote on/off indication & control of all drives of lube oil system & CEP should be available in control room.
247
The control panel must realize required annunciation & alarm windows.
2.2.16.1 Turbine Control System : The turbine control system has to be capable to provide the following inputs to the DCS system : Centralized monitoring of turbine mechanical parameters (rotor axial shift, relative expansion, relative shaft vibration, rotating frequency) Control of control valves Provides turbine protection against rotor rotating frequency rise above the permissible limit. 2.2.16.2 Protection System : Following protections are to be provided for turbine : Over speed protection Electronic (2/3 logic with 100% redundancy) Low lubricating oil pressure Increase of backpressure in condenser Increase of condensate level in condenser All other TG protections such as High / low control oil pressure High axial shift High shaft vibration Low steam temperature Provision is made for the relay blocking the possibility to start-up turbine during shaft turning device being in operation and automatic start of start-up oil pump at turbine shutdown.
248
2.2.17 Local Panels a) Local panel shall be supplied for the Turbo Generator set with suitable full size opening doors to provide access to all equipment. The local panel shall contain as minimum the following : Steam inlet pressure and temperature Steam extractions pressure & temperature Steam turbine / generator speed indicator Lube oil pressures at all headers Steam turbine / generator stop push button Run light Control oil pressure Emergency shutdown push bottom Local horn for audible alarm and horn silence push button. KW, pf, frequency Pr. at CEP suction and discharge Condensate pr. before & after SJAE, GSC, level control station etc
b)
2.2.18
Controls & Turbine Control Panel 2.2.18.1 Controls All control signals will be supplied to the DCS for safe, efficient, start up, monitoring, control and shutdown operation of the steam Turbine. The minimum supervisory instruments to measure the following shall be provided, with provision of all signals to DCS : Speed, load, inlet & extraction steam pressures & temperatures, turbine wheel case pr., emergency and control valve lift, control fluid pressure, journal bearing metal temperature, thrust pad metal temperature, axial position of thrust collar relative to its own housing, differential expansion between shaft and casing at any critical point, axial expansion of casing from anchor point, shaft eccentricity, bearing pedestal or shaft vibration, especially with a view to ensuring safety during starting operations and under transient conditions.
249
2.2.18.2 Control Panel Control Panel shall house the following: a. Electronic governor with keyed-in operating program for control of speed, load, inlet & extraction pressures. b. Relay based hard wired turbine safety interlocks and trip logic c. Remote controls comprising of selector switches, ammeters, push buttons & indicating lamps for ; AOP motor i. ii. EOP motor iii. Barring gear motor d. Push buttons for turbine speed raise and lower e. Turbine remote trip/reset push buttons. f. Temperature scanner for Monitoring turbine and gearbox bearing temperature g. Alarm annunciator for Turbine fault monitoring. The panel shall be complete with AC supply & DC supply on / off control switches, indicating lamps and space heater. 2.2.19 Lube Oil System (with connectivity to DCS system) a) Level gauge in main oil tank b) Bearing temperature gauges for turbine + gear box and alternator 8 no. total c) Bearing temperature RTD for turbine gear box + alternator d) Alternator hot air and cold air temp gauge e) Alternator hot air and cold air temp RTD f) Alternator winding temp. 6 RTD g) AOP & EOP discharge pressure gauge h) Temperature gauge before filter i) Temperature gauge after filter j) Temperature element after filter k) DPIS for lube oil filter l) Pressure transmitter control oil m) Pressure transmitter lube oil header pressure n) Pressure switch for lube oil pressure o) Lube oil pressure switch for auto start of auxiliary oil pump and emergency oil pump p) Pressure switch for barring gear interlock
250
2.2.20
Control Oil System (with connectivity to DCS system) a) b) c) d) e) f) g) h) i) PDIS across control oil filter Pressure gauge after filter Pressure gauge after oil pr. Regulator Pressure gauge control oil pressure to ESV Pressure switch control oil pressure to ESV Pressure gauge control oil pressure to Trip device Vibration probes for turbine & gear box bearing (8 points) Axial movement sensor (1-point) Pressure transmitter after CPC
2.2.21 Protection (with connectivity to DCS system) Turbine Protection with interlocks, trip logic & annunciation a) b) c) d) e) f) g) h) Over speed protection (high / very high) Governor emergency trip Axial shift protection, vibration high Lube oil pr - low Lube oil pressure too low Manual trip Remote trip Bearing temperature hi (turbine front / rear, thrust, gear box bearing, generator front journal) i) Live steam temp low j) Live steam temp hi k) Live steam pressure low l) Live steam pressure hi m) Generator / Electrical Faults : Differential fault n) Extraction pressures & temp. - high o) Extraction pressures & temp.- too high p) Control oil pr. low trip and alarm q) Thrust wear high trip and alarm r) Hot well level low, very low high, very high
251
2.2.22 Gear Box The reduction Gear Box between the turbine and the generator, shall be of proven design of double helical arrangement with proven performance on STG of 18 MW and above. It shall be capable of transmitting the maximum rating of the set and be able to withstand 10% over speed over a period of minimum five minutes. The gear box shall also be designed for the short circuit condition of the generator. All bearings of the gear box shall be readily renewable and it shall be possible to inspect the bearings and the gears readily without disturbing the shaft alignment. Non-Illuminated sight glasses shall be provided to inspect the lube oil drain from each individual bearing. The gear box design shall be as per the requirements of AGMA. The flexible couplings between the turbine and the gear box and between the gear box and the generator shall be of reputed make. The power rating of the coupling shall be at least equal to the turbine rated power times the service factor in accordance with AGMA 514. Easily removable coupling guard shall be placed over each of the exposed coupling. The service factor of gearbox to be 1.4
2.2.23 Specification for Generator 2.2.23.1 General The equipment shall include one (1) No. Horizontal Shaft Three Phase Alternating Current, synchronous generator of nominal capacity 22,500 KVA or higher as per Tenderers recommendation based on normal steam flows, 11 KV, 50Hz at site condition of 50 Deg. C ambient, brushless exciter, automatic voltage regulators.
252
Neutral grounding cubicle, lightning and surge protection panel, 11 KV Switchgear, protection relay and metering panels, cooling water system, instrumentation control and safety devices and other accessories, spares and special tools that will be required for satisfactory erection and efficient operation of the Station, including periodic maintenance. The generator to be coupled to the turbine matched in respect of speed, over speed, moment of inertia, overload capacities, coupling and other relevant requirements. The generator to be designed to be operated with the expected variations in power generation. Tenderer to give loading vs. efficiency curve. Sizing of the generator to be done keeping in view the maximum and minimum power generated by the turbine as per specified steam conditions. The generator shall be of closed circuit air cooled type housed in a IP54 (CACW) enclosure and driven by steam turbine through a speed reducer, if necessary. The necessary coupling bolts shall also form part of the supply. The Nominal output of the unit shall be sufficient to deliver the maximum output of the turbine obtainable under any conditions of operation at 0.8 pf., 11 KV, 50 Hz, at site conditions. Unit shall be capable of continuous operation at 10% overload subject to permissible temperatures of the windings. The excitation system shall be suitable for maintaining the voltage for a grid voltage variation of 10 % with a combined voltage and frequency variation of 10 %, and shall have a control accuracy of 0.5 %. Generation voltage of the unit shall be 11 KV, 3 Phase R,Y,B in anticlockwise rotation. The voltage within specified limits at generator terminals shall be maintained. The Generator is to be connected to 11 KV Switchgear including all metering and protection. The rating and specification of all the required accessories should be suitable for 11 KV rated voltage.
253
Synchronous speed, short circuit ratio and the inertia constant shall be specified by the Tenderer. The selection of the critical parameters of the generator shall be to operate the machine parallel to the rural grid The generators shall be suitable for operation in all respects and shall deliver rated output over a range of voltage variation and operate satisfactorily under system conditions stated earlier. The generator shall remain stable on the sudden application of maximum load or sudden loss of maximum load and during momentary short circuits or sustained ground faults. The generator shall be star connected and the main and neutral leads shall be brought out of the stator frame for insertion of current transformer for protection, metering and surge protection apparatus. The generator shall be suitable for grounding through grounding resistor. The Short Circuit Ratio (SCR) shall be optimized to ensure stable parallel operation with a rural grid and to ensure minimum voltage changes under fluctuating loads. The selection of the SCR value, within IEC specifications, shall be fully justified for the operation of the machine in a rural network and the calculations shall be provided with the offer. The generator shall be capable of withstanding without damage a stator current of 150 % for a period of 30 seconds. The generator shall be capable of withstanding without damage a three phase, a line-to-line, a line- to-earth or two line-to-earth short circuit for a period of three seconds, when operating at the rated speed and with an excitation corresponding to a 5 % over voltage at no load. The maximum line charging capacity at rated voltage that can be obtained without negative excitation and with stable operation of the generator may be indicated, which shall not be less than 43 % of rated KVA. The rated direct axis transient reactance of generator should be guaranteed without any tolerance and shall not exceed 30 %.
254
The moment of inertia of the generator shall be so selected that it meets the requirement of over speed. The machine shall be capable of operating continuously on an unbalanced system such that, with none of the phase current exceeding the rated current, the ratio of the negative sequence component of current (1/2) to the rated current (I/N) does not exceed 0.1 and under fault conditions shall be capable of operation with the product of (1/2 L/M) 2 and time (t) in seconds not exceeding 20 or as per IEC. In the design of generator, each part shall be so proportioned that the maximum unit stresses therein resulting from any continuous operating conditions specified shall not exceed one third of the yield point or one fifth of the ultimate strength of the material whichever is less. The design of the generator structure and housing in which resonance might become objectionable shall be so proportioned as to avoid the possibility of resonance with higher rated frequency or within the frequency variation. The synchronous generator shall be designed and constructed so as to facilitate easy repair / replacement of generator stator bars and rotor poles. Suitable provision shall be made in the base frame of the Generator to facilitate easy removal of the stator body by sliding on the bed plate. The equipment offered shall be suitable for manual and auto control from the machine control panels located near the machine 2.2.23.2 Over Speed The generator shall be designed so as to be capable of running at over speed of the turbine, and all parts of the generator and other equipment shall fully and safely withstand stresses resulting from over speed operation. The mechanical run test will done for 109% MCR turbine speed for 15 minutes.
255
2.2.23.3 Insulation a) Detailed drawings shall be submitted during engineering showing the arrangement of conductors and the thickness and nature of all materials used both for insulation and mechanical protection in the slots of the stator. Insulation of only 'F' class as specified in I.E.C., specification of the latest issue shall be used for stator, rotor and exciter. The quality of the insulation must be such that it is nonhygroscopic and no deterioration will take place when subjected to the maximum, specified operating temperatures nor must it be permanently injured when exposed as the machine is to operate in a most tropical climate. c) The end turns and coil connections, shall have not less than full insulation, equivalent to, and of the same construction as the coil insulation in the stator slots. The coil and end turns shall be impregnated with high grade insulating varnish. Provision shall be made for tightly wedging the coils in the lot with the wedges which shall not shrink or buckle. Care shall be exercised that the blocking of air passages shall not occur. d) The insulation and taping of the coils shall be such as to prevent permanent injury from exposure to dampness to provide adequate corona shielding, to withstand high temperatures without injury, to prevent the entering of magnetic particles and to prevent formation of zones.
b)
2.2.23.4
Temperature Rise a) Even through insulation of 'Class-F' must be used, when operating continuously at the maximum continuous rating at its rated 0.80 PF at any working voltages and any frequency in the range stipulated, the temperature rise shall not exceed the limits specified for 'Class-B'.
256
The temperature of the bearing shall be measured by means of mercury in steel dial thermometers in the bearings metal. The thermometers shall have alarm contacts, apart from the dial thermometers. The bearing metal temperatures shall be detected by resistance type temperature scanner and realized at the DCS in the control room. b) Measurement of temperature shall be made as specified in IEC. The maximum temperature of ambient air shall be taken as 40 Deg. C and the maximum cooling water inlet temperature as 35 Deg .C and the guaranteed temperature rises in the windings for the rated and 110 % loading shall be furnished. These shall be within the Class 'B' insulation Temperature rise limits. c) The machine shall further be capable of operating continuously at full load at 0.80 power factor at 11 KV at frequency 5 % below normal, satisfactorily and without undue heating. The machine shall be capable of generating more KW than the rated KW during operation of the machine from 0.8 to 0.95 lagging power factor but within the KVA rating of the machine.
d)
2.2.23.5 Efficiency & Output Guarantees a) The guaranteed overall efficiency of the generator at rated terminal voltage 0.80 PF lag and 75 Deg .C winding temperature, for the percentage rated output of 100%, 80% and 60% shall be furnished in the data sheet. The efficiencies shall be determined by summation of losses method as specified in the latest edition of IEC Publication No. 34.2 or IS4889 or equivalent standards. A tolerance will be permitted in the determination of efficiencies as per IEC Code 34.2.
257
b)
The generator shall be guaranteed to be capable of giving its rated output under the conditions described earlier without exceeding the temperature rise as specified and without tolerance. The equipment shall be rejected if the temperatures exceed the given limits by 15 Deg. C. Guaranteed maximum temperature rise, for the stator and rotor windings of the machine above the inlet temperature of the cooling air, when operating under rated load conditions with all coolers in service shall be as follows: i. Stator winding by embedded temperature detectors : 86 Deg. C ii. Rotor winding by resistance: 90 Deg. C
c)
2.2.23.6 Cooling a) Each generator shall be provided with adequate cooling systems based on air circulation principles complete with fans etc., depending on the capacity of the units. The air passages in the stator, rotor fans, coolers, etc., shall be designed to give a smooth and quick flow of air. The Tenderer should explain in detail the cooling system he proposes for his equipment so that it meets the requirements of the Owner as stipulated earlier. The Tenderer shall give a detailed description of the cooling system taking note of the class of insulation and maximum permissible temperature, size of the unit. Justification for the adequacy shall be given in the description of the cooling system. b) Dial type thermometer or RTDs shall be provided in air coolers for indication of inlet and outlet air temperatures and to provide alarm in case of high temperature of inlet / outlet air. Thermostats shall also be provided in the cold and hot air passages.
258
c)
The coolers shall be constructed out of seamless stainless steel tubes or admiralty brass and shall be located clear of the stator at a lower level. Any leakage from the cooler shall be drained safely and properly and there shall not be any chance of the cooling water finding it's way to the stator / rotor windings. Suitable moisture detector device shall be used to detect and warn accidental leakage of water into the cooling air stream. The coolers shall be designed for the shutoff head of the cooling water pumps which will be about 4 ata and tested for two times the design pressure. The cooler shall be sectionalised and designed to be suitable for shutting off sections by section for cleaning. The design shall be such that the generator can deliver its rated output even with one section out of service.
2.2.23.7 Construction a) The generator shall be of synchronous type. The Tenderer has to clearly specify the type of bearing arrangement provided, with proper recommendations for its suitability. All parts of generator shall be designed and constructed to safely, withstand maximum stresses during operation, over speed, short circuit conditions, out of phase synchronizing. The pedestal of each generator will be supported on the concrete foundation. All necessary accessories like shims, dowel etc., shall be furnished by the Tenderer. All sole plates shall be interchangeable and suitably machined and prepared for use at site with minimum amount of work. c) The Tenderer shall give full particulars of the extent to which the generator will be assembled for purpose of shipment and the work to be done at site.
b)
259
2.2.23.8 Stator The stator frame shall be a single piece to consist of a cylindrical casing of welded plate construction, reinforced internally in the radical and axial direction by stationary web plates making the entire frame perfectly rigid. Light non magnetic alloy end shields shall be made Up of segmental, annealed punching of high quality silicon steel to give minimum electrical losses. The stator winding shall be of the double layer lap type with Class 'F' insulations. 2.2.23.9 Rotor a) The generator rotor shall be forged from a single piece ingot of special alloy steel carefully heat treated to obtain excellent mechanical and magnetic properties, a comprehensive series of ultrasonic examinations on the rotor body shall be done to ensure that absolutely no inadmissible internal failures are present and that the material meets the quantity standards. The design and construction of the rotor shall be in accordance with the best modern practice and shall be fully described in the offer. The factor of safely on yield point of material shall not be less than 1.5. The insulation between turns of field winding shall consist of special epoxy impregnated asbestos paper / equivalent. The rotor spider shall be of steel constructions. To facilitates synchronization a shorted damper consisting of several round copper bars in each pole head shall be provided. The field poles shall be provided with adequate damper windings to ensure stability under fault conditions.
b)
c)
d)
e)
2.2.23.10 Earth Terminal Two Nos. of Earth terminals shall be provided. The earth terminals shall be designed to terminate Galvanised Iron conductors. The size shall be as specified IEC 34-1.
260
2.2.23.11 Speed Regulation The moment of inertia of the alternator together with that of the turbine shall be sufficient to ensure stability and the speed regulation specified in the section covering turbine for full load rejection. The fly wheel effect shall be incorporated in the alternator and turbines as integral part and not added in the shape of separate weights, rings or other means. 2.2.23.12 Shaft a) The generator shaft shall be made of best quality forged alloy steel, properly treated. The shaft shall be of ample size to operate at all speed, including maximum over speed without vibration or distortion and shall be able to withstand short circuit and other stress without damage. To prevent the flow of harmful shaft currents damaging the bearings, suitable shaft earthing shall be provided. A complete set of test reports covering metallurgical strength, crystallographic and ultrasonic and baroscopic tests performed in each shaft during various stages of its manufacturing shall be furnished as also the complete specifications of the shaft material forging and its design parameters such as stresses and critical speed. The generator shaft shall be cylindrical for coupling to the turbine /gear box shaft. The coupling shall be forged integral with the shaft or be shrunk fit and the shaft coupling shall comply with the requirements of IEC for shaft coupling. All coupling bolts, nut and nut guards for coupling shall be furnished by the Tenderer.
b)
c)
2.2.23.13 Space Heaters Suitably rated heaters shall be installed within the enclosure of the generator. Location and the maximum temperature of the heaters shall be such that no damage can be caused to any insulation. Heaters shall be suitable for operation on a single phase 230 V AC supply. A suitable double pole switch shall be mounted on or adjacent to the stator frame for the manual switching of the heaters.
261
2.2.23.14 Excitation System a) A brush less exciter shall be used and it shall be mounted on the out board end of the generator frame. A static voltage regulator shall be included to control the voltage of the synchronous generator by varying the current supplied to the field. Details of the equipments shall be furnished along with the bid. A self excited static excitation system shall be provided. A high speed, fully tropicalised, printed circuit, draw out type, automatic digital/analog voltage regulator shall be provided. It should be complete with necessary sensing PT's, cable entries, cast resin type current transformer, adjusting rheostats, auto/manual and on/off selector switches. Excitation Control System (AVR) The excitation control system shall ensure the following operational modes and parameters : 1. Initial excitation 2. Idle run of generator 3. On-switch of generator to the power line by precise synchronizing method. 4. Operation in united (multiple STG or grid connected) and independent power systems with loads from idle run up to nominal. 5. Steady regulation of excitation at sharp alternating loads up to separate outbursts of load caused by simultaneous on-switch of a synchronous motors with short-circuited rotor of total output up to 35% of the turbo generator nominal output. 6. Maintaining of voltage at turbo generator terminals in accordance with the specified setting with accuracy of 1% relative to the specified static characteristic. The value of constant-error response of regulation shall vary from 0 to 10% in the modes of reactive power generation and from 0 to 100% in the modes of reactive power consumption. Steady distribution of reactive power between generators 7. united at the level of generator voltage. 8. Change of automatic regulator setting at the rate of 0.5% within the range for 80 to 110% of the generator voltage.
b)
c)
262
9. 10.
11. 12.
13. 14.
15. 16. 17.
18.
Limitation of the rotor overload by time depending characteristic in accordance with the generator data. Limitation of the minimal current of excitation by a value precluding the shift of generator into the mode of deep consumption of reactive power at nominal active load. Independence of voltage at generator terminals during variable frequency within the range from 47 Hz to 52 Hz. Forcing of excitation with ratio up to 2 vel. unit and duration up to 50 S during faults in the power system, causing voltage reduction at the generator bus bar relative to the specified characteristic log of control system during forcing in no more than 0.025 diameter-excitation of generator at nominal shut down. Field killing in emergency modes by breaking its excitation circuit. To ensure all specified parameters and modes during deviation of feed voltage from nominal : From 10% to 15% continuously From 20% to 45% briefly up to 50s Deviation of operative feeding from nominal from 10% to 15% To sustain voltage rise up to 140% during 1 S. To ensure the maintaining of operational mode during disappearance of operative feeding. The excitation control system shall comprise a stand-by excitation regulator and provide the following protections: Against internal short-circuits and short-circuits in the exciters excitation circuit. Against loss of excitation Against rise of generator voltage Against non-symmetrical short-circuits in circuits of rotating core of exciter (inter phase short-circuit, break-down of diodes, etc.) The excitation control system shall provide for a unified signal 4 20 mA and pro-rata for the generator active power, to be produced to the turbine governing system. The excitation control system shall have signalling system of principal modes: illumination type or Dry Control type..
263
d)
The system offered shall have the following facilities: i. Manual mode of operation. ii. Auto mode of operation. iii. Follow on mode for each operation to have bump less Transfer from each mode of operation. Auto/ Manual changeover facility shall be provided. For Manual mode Voltage lower/raise pistol grip type spring return type switch shall be provided in the control panel. Following minimum alarms shall be transmitted to the Unit control desk. The excitation system shall have diode protection relays to detect failure of the Rotating Diodes. AVR Fault. i. ii. AVR automatic changeover to manual. iii. Diode failure.
2.2.23.15 Accessory Equipment a) Terminal boxes shall be provided to enclose the leads and current transformer. The terminal boxes shall be adequately designed to accommodate termination of required busbars. The generator shall be provided with stator temperature sensors installed in the stator winding with leads, brought out to the terminal boxes. Platinum RTDs shall be provided which shall be hooked up to the temperature scanner in the control panel. Thermostats or RTDs for bearing temperature, for anti-condensation heaters and for fire detection shall also be provided. Necessary vibration transducer shall be provided which shall be hooked up to the control room. b) Adequately rated neutral grounding resistor shall be supplied and the resistor shall be of stainless steel edge wound type mounted in shielded safe enclosure. A current transformer shall be provided for ground fault current measurements for protection. The rating of the resistor shall be furnished.
264
c)
Necessary surge capacitors and lighting arrestors shall be provided for generator protection. The surge capacitors shall conform to the latest IS:2834 and shall be rated 0.25 Micro Farad. The capacitors shall be suitable for indoor mounting and shall be provided with built in discharge resistor. The lighting arrestors shall be heavy duty indoor station class gapless metal oxide type suitable for repeated operation to limit voltage surges on alternating current power circuits . The arrestors shall conform to IEC 99-4. LA will be of 11kV grade.
2.2.23.16 Electrical Controls Control and monitoring cubicles shall conform to international standards. Protective relays, control switches indicators and monitoring devices shall be mounted on the front. The relays, terminals, motor starter and control circuit breakers shall be inside the panel. The completed panel shall be factory inspected and tested and a standard simulation test shall be performed on the system before shipment in the presence of the Owners representative. The electrical panels shall consists of: Relay & Protection Panel. Synchronization & metering panel (can be part of turbine control panel) Excitation Cubicle. (can be part of turbine control panel) Auxiliary control panel for lube oil and other auxiliary system. (redundant to DCS) (part of turbine oil system) LA, SC and PT Panel / terminal box NGR Panel.
265
2.2.23.17 Unit Control System The unit control system shall basically have the following controls for sequential operations for the start and stop of the unit with Annunciation / Visual and Audible Alarm facilities. The sequential start system shall have the following minimum functions, which will be operated by the DCS system: "Turbine-Generator power on" for start up after pre start condition checks like main breaker open and MS stop valve closed. Control switches for auxiliaries etc. switched on remote control. Master relay picks up. Auxiliaries of the unit start. MS stop valve starts opening and the unit starts rotating and accelerates. At slightly below no load speed, valve position is controlled to accelerate the unit to synchronous speed at controlled speed. At 95% speed, voltage regulator cut into service. At synchronous speed, if phase sequences voltages and frequencies match unit breaker closes and synchronises. The unit should be ready for accepting the load. Adequate monitoring facilities, checks and interlocks should be provided in the sequential control, so that in the event of incomplete operations, the unit shuts down giving requisite annunciations.
2.2.23.18 Earthing The Turbo-Generators shall be earthed through neutral grounding resistors, lightning arrestors, surge capacitors, CTs and Voltage Transformers for AVR etc.
266
2.2.23.19 Protective Devices The Tenderer shall study the system conditions like voltage, frequency variations, etc. level at the location of the proposed generating units and offer suitable generating equipment with necessary accessories required for satisfactory working of the generating units. 2.2.23.20 LA, SC and PT panel a) The Tenderers shall supply 1 no. terminal cubicle for housing surge capacitor, potential transformers, current transformers, lightning arresters, cable boxes, etc., The cubicle shall be complete with necessary tapping for excitation system, etc,. The rating of the CTs for AVR shall be decided by the Tenderer taking into account the requirements of the AVR. The cubicles shall be sheet steel, suitably compartmentalised with doors and shall be furnished complete with base mounting arrangement, foundation bolts etc. The internal illumination or cubicles shall be provided with guarded lamps with on/off switch. Copper / Aluminium conductors shall be suitably insulated to make them compatible with generator temperature rise and insulation. The support insulators for the bus connection will be provided as necessary, GL earth bus of adequate cross-section will be provided in the cubicle. LA 3 nos, 11kV grade, surge capacitors 11kv low resistance grounded, PTs for protection, metering & AVR sensing 11kV, ratio: 11kV 3/110kV 3, PT for generator protection
b)
c)
2.2.23.21 Potential Transformers The potential transformers will be single phase, epoxy cast, dry type units. Potential transformer will be protected on primary and secondary side by current limiting fuses. The PT shall confirm to IS: 3152. The accuracy class for Metering will be 0.2 and protection 3P10.
267
2.2.23.22 Current Transformers a) The current transformer will be single phase, epoxy cast, dry type unit confirming to IS:2705. The current transformer shall be designed to withstand the thermal and magnetic stresses resulting from the maximum short-circuit current. The accuracy class for metering will be 0.2 and protection 5P20. The generator Tenderers shall supply suitable transformers for the protection scheme and these shall be installed in the neutral grounding and line terminal cubicles.
b)
2.2.23.23 Tests A) The generator shall be completely assembled at works and type tests as specified below shall be conducted on the assembled unit and auxiliaries as per the latest edition of IS:4722. Detailed test reports shall be furnished. i) Type Tests The following shall constitute the type tests. a b Measurement of DC resistance of stator and rotor windings. Insulation resistance of stator winding (before and after high voltage tests), rotor winding, bearings and embedded temperature detectors. Stator winding capacitance and tan delta measurement. High voltage test of stator and rotor windings at industrial frequency. Phase sequence. Determination of open-circuit characteristics. Determination of short-circuit characteristics. Over speed. Pressure test on coolers. Determination of efficiency by separation of losses method Vibration. Temperature-rise test of windings.
c d e f g h i j k l
268
m n o ii)
Instantaneous Three (3) phase short circuit test at rated voltage and speed. Voltage wave-form. Determination of reactances and time constants.
Routine Tests. The following shall constitute the routine tests. a b Measurement of DC resistance of stator and rotor windings. Insulation resistance of stator winding (before and after high voltage test), rotor winding bearings and embedded temperature detectors. High voltage test of stator and rotor windings at industrial frequency. Phase sequence. Determination of open-circuit characteristics. Determination of short-circuit characteristics. Over speed. Pressure test on coolers for close-circuit cooling. Determination of efficiency by separation of losses methods. Vibration. Impedance of the rotor winding. Stator winding capacitance and tan delta measurement.
c d e f g h i j k l
iii) TESTS ON EXCITERS AND REGULATING EQUIPMENT (FOR ROTATING EXCITERS) a b c d e f g High voltage test Temperature rise test Measurement of resistance Measurement of insulation resistance Regulation test Commutation test Excitation response ratio.
269
iv) ROUTINE TESTS ON STATION EXCITATION EQUIPMENT Additional Test:40% over voltage on open circuit excitation for five (5) minutes, voltage recovery test after fault clearance over speed of 30% for two (2) minutes B) Site test for each generator shall include the followings. a Mechanical run and vibration measurement b Measurement of stator and rotor winding insulation resistance. c High voltage dielectric test d Measurement of shaft voltage (if applicable) e Measurement of stator and rotor winding resistance f Phase sequence test g Load acceptance and rejection test at selected loads from no load to full load. h Overall response f machine and excitation system i Adjustment of AVR j Synchronising test k Checking and commissioning of various other auxiliary equipment Test on the equipment like CTs, Pts, LAs, shall comply with routine tests etc., as per relevant standards. Test report or all the type tests on the generator, CTs, PTs, & LAs carried out on similar equipment already supplied shall be furnished for approval.
270
2.2.24 Specification for Neutral Grounding Equipment 2.2.24.1 Introduction a) This specification cover the design, manufacture, testing, packing and supply of neutral grounding resistors. Rated voltage : 11kV/3 volts 10%, duty rating : 10 secs, grid type : punched steel, to restrict fault current to 100 A for 30 secs. b) Standards The resistors covered by this specification shall conform to the following and other relevant Indian Standards. Wherever Indian Standards are not available, they shall conform to relevant British or IEC Standards. IS : 3043 Code practices for earthing. BS : 162 Electric power switchgear and associated apparatus (applicable to Class-B apparatus in BS 162) Wherever the stipulation in this specification are in conflict with any of the above standards, the requirement under this specification shall be binding. 2.2.24.2 General Specifications Resistors a) Resistor element shall be made of unbreakable, corrosion proof, joint less stainless steel grids. It shall be suitable for use in monsoon tropical climate. Resistors shall be able to carry the rated current for the rated time with temperature rise not exceeding 325Deg. C over the maximum specified ambient temperature when the resistor is housed in a covered space.
b)
271
c)
Grids shall be mounted on steel rods insulated by special heat resistant micanite paper tubes. Grid washers shall be of natural mica. Porcelain insulators shall be used to used to insulate the resistor element from body of the enclosure.
2.2.24.3 Enclosure (IP 42) a) The resistors shall be housed in a metal clad enclosure totally enclosed type. It shall vermin proof, weatherproof and suitable for outdoor installation. The enclosure shall have an arrangement for fixing it on concrete foundations / floor and its thickness shall be not less than 3 mm. The terminals for neutral and earthing connection shall be housed in a separate vermin proof, weather proof compartment. A canopy shall be provided on the top. It shall cover the terminal compartment also. Hooks or handle shall be provided to lift the canopy. It shall be possible to periodically clean the resistors after lifting the top cover or canopy. It shall be possible to earth the cabinet or enclosure at two places and for this suitable size of studs shall be provided on the sides, as low as possible, to accommodate the GI strips size mentioned in particular specification.
b)
c)
d)
e)
f)
2.2.24.4 Terminals a) Porcelain insulated through terminals shall be provided for neutral and earth connection and they shall be housed in a metal clad panel. The terminals shall be suitable for terminating the XLPE cables / bus duct. Suitable washers shall be provided between grid and terminals to maintain good contact.
b)
272
c)
The two ends of the resistor shall be brought out to weatherproof bushing type terminals of adequate rating. Bolted type link shall be provided for isolating the resistor. The connection between generator neutral and NGR shall be done by means of single core XPLE armoured cable, having aluminium conductor or bus duct. The connection between NGR and earth pit shall be done by means of GI Earthing Strip.
d)
e)
2.2.24.5 Space Heater Suitable space heater shall be provided inside the resistor cabinet to prevent condensation of moisture. This shall be rated to operate from 240 V, 50 Hz supply. The terminals of the space heaters shall be brought out in a separate terminal box. The cable used for heater shall be aluminium conductor PVC insulated armoured cable. The entire arrangement shall be complete double pole switch, HRC fuse and thermostat. 2.2.24.6 Cooling The NGR shall be natural air cooled and any type of forced cooling will not be used. However, if required louvers can be provided in the enclosure. But wherever the louvers are being offered it shall be completely guarded on inside with a fine wire mesh (holes less than 0.5 mm) to make it vermin proof. 2.2.24.7 Nameplate Marking The equipment shall have a nameplate located conspicuously giving particulars, such as make, name the equipment, rating and other relevant details.
273
2.2.24.8 Painting After manufacture, all surfaces to be painted shall be thoroughly cleaned, de-scaled, made free from rust and given a priming and final coat of the paint. 2.2.24.9 Inspection & Test Inspection shall be carried out by the Owner or Owners representative and following tests shall be conducted. a) Measurement of resistance value at rooms temperature by Kelvin Double Bridge. One minute power frequency high voltage withstand test shall be as per applicable voltage.
b)
2.2.24.10 Heat Run Test The test shall be conducted by passing the rated current for rated time on the complete assembly or by any method mutually agreed Upon.
2.2.25 Specification for Erection of Mechanical Equipment specific to STG 2.2.25.1 Checking of foundations The Tenderer shall as a first field activity check the foundations for the correctness of the same as per relevant drawings & and certify the same for concreting and the same may be rechecked for its correctness after concreting, such as levels, location of bolt holes, sleeves, pockets, openings, fixture plates and other embedment in RCC works, etc. 2.2.25.2 Before starting erection job on turbine floor Tenderer shall ensure that turbine area is sufficiently enclosed against ingress of dust and wastes, and that all debris have been cleared off from the floor.
274
2.2.25.3 Where turbine holding down bolts carry washers and where these plate washer rest on concrete surface such concrete surface shall be finished and dressed true to get full surface contact between the concrete surface and the plate washers as required. 2.2.25.4 Tenderer shall provide his tool stores for special tools and instruments at a convenient location in the turbine hall. 2.2.25.5 Tenderer shall set up longitudinal and axial centrelines, and two or more level bench marks accurately on turbine floor which shall be certified by Owner / Consultant. This certified turbine centre line and datum level shall be reference for turbine and all auxiliary erection and alignment work. 2.2.25.6 Where required by manufacturers the concrete surfaces shall be chipped and finally dressed up true to obtain the required contact between sole plates and concrete surfaces. The fine dressing of the concrete shall be with Prussian blue match checks. 2.2.25.7 Tenderer shall ensure that while lifting turbines/generator. piping and other auxiliaries for transporting, slings shall be put over the points indicated on the equipment. Slings over casing shall have gunny bags or soft wood packing to avoid the scratches and nicks on the equipment. Slings / D-Shackles of proper sizes shall be used for all lifting and rigging purposes. All care shall be taken to safeguard the equipment against any damage. 2.2.25.8 Tenderer shall thoroughly clean all machine surfaces / slings, surfaces/keys, brackets sole plates etc. and apply anti-scuffing paste or other recommended equivalent before assembly of the said parts. The components whose surfaces are coated with protective coating are to be thoroughly cleaned.
275
2.2.25.9 The Tenderer shall carry out all necessary checks such as accuracy of levels, centres lines, bolt positions, of installation of all equipment covered in the scope of work. 2.2.25.10 Checking of Equipment after Grouting After the grout is set and cured, the Tenderer shall check and verify the alignment of equipments, alignment of shafts of rotating machinery, the slopes of all bearing pedestals, centring of rotors with respect to their seating bores, couplings etc. as applicable and the like items to ensure that no displacement had taken place during grouting. The values recorded prior to grouting shall be used during post grouting check-Up and verifications. Such pre and post grout records of alignment details shall be maintained by the Tenderer in a manner acceptable to the Owner. 2.2.25.11 Shaft Alignment All the shafts of rotating equipment shall be properly aligned to those of the matching equipment to the required accuracy. The equipment shall be free from excessive vibration so as to avoid overheating of bearing or other conditions which may tend to shorten the life of the equipment. All bearings shafts and other rotating parts shall be thoroughly cleaned and suitably lubricated before starting. 2.2.25.12 The Tenderer shall maintain a record in the form acceptable to Owner / Consultant of all the operations carried out on each weld and maintain a record indicating the number of welds, the names of the welders who welded the same. All site joints shall be subject to acceptance of Owner / Consultant. Any joints declared rejected shall have to be redone at the Tenderer's cost.
276
2.2.25.13 The Tenderer shall carry out the tightening of the bolts on the equipment and piping covered under this specification by using either the calibrated torque wrench method or the turn of nut method. The methods used, the tools and the equipment deployed shall be subject to the approval of Owner / Consultant. The bolting work shall be carried out by competent technicians. 2.2.25.14 The Tenderer shall install all necessary platforms, stairways and ladders required for the safe and convenient operation and maintenance of all the equipments, valves etc. covered in this specification at no extra cost. 2.2.25.15 The Tenderer shall completely erect all the equipments for the complete E & M portion including hangers and supports, valves & accessories in accordance with the approved drawings. This includes all necessary bolting, welding, testing and cleaning. Systems shall be demonstrated in condition to operate continuously in a manner acceptable to Owner / Consultant. Welding shall be used throughout for joining pipes except where flanged screwed or other type joints are lines & elevation as indicated in the drawings. 2.2.25.16 While erecting the field run pipes the Tenderer shall check the accessibility of valves, instrument tapping points and maintain minimum head room requirements and other necessary clearances for adjoining work areas. 2.2.25.17 The Tenderer shall be responsible for correct orientation of all valves so that seats, stem and hand wheels will be in desired location. 2.2.25.18 All supports & hangers for the pipes have to be fabricated and provided for approximately every three metre (3 meter.) of pipe. However in any case sufficient numbers shall be provided so that the deflection of pipe between hangers shall not exceed the limits indicated in the drawings.
277
2.2.25.19 The Tenderer shall make all necessary arrangements including making of temporary closures on piping / equipment for carrying out the hydrostatic testing on all piping / equipment with motor operated pump. 2.2.25.20 All piping flanges are required to be blue matched using surface plate to obtain at least 80% contact area before installation. 2.2.25.21 All welded joints of pipes shall be cleaned of welding slags, & burrs by hand file wire brushes and flexible grinders wherever required and using white cloth. No cotton waste shall be used while cleaning the equipment / piping. 2.2.25.22 The Tenderer shall dismantle the valves & actuator for overhauling, servicing and lubricating wherever required as advised by Owner/ Consultant. The Tenderer shall also lap or grind the valve seat for ensuring the satisfactory performances of valves at no extra cost. All consumables such as gaskets, gland packing which form the permanent part of equipment shall be in the Tenderer's scope. 2.2.25.23 The hanger assemblies shall not be used for attachment of rigging to hoist the pipes into position. Other means shall be used to securely hold the pipe in position till pipe supports are completely assembled and attached to the pipe & building structure. 2.2.25.24 All temporary rigging shall be removed in such a way that pipe supports are not subjected to any sudden load. During hydro static testing of pipes, all piping having variable spring type supports shall be secured in place by temporary pinned or blocked solid during the test. 2.2.25.25 The Tenderer shall carry out the pre-commissioning activities such as chemical cleaning of piping system, water flushing, flushing of oil systems, flushing of control fluid system. The scope of pre-commissioning activities covers installation of all temporary piping, supports, valves, tanks, pumps & all other accessories & services to complete the process.
278
2.2.25.26 The Tenderer shall carry out the edge preparation of weld joints at site in accordance with the details acceptable to Owner/ Consultant. Wherever possible machining or automatic flame cutting will be allowed only wherever edges preparation otherwise is impractical. All slag / burrs shall be removed from cuts and all the hand cuts shall be ground smooth to the satisfaction of Owner / Consultant. 2.2.25.27 Tenderer shall carry out all the electrical pre commissioning tests on the generator, excitation system, as stipulated by the relevant specification and codes. 2.2.25.28 The Tenderer shall hand over all parts/materials remaining extra over the normal requirement with proper identification tags, in a packed condition to the Owner / Consultant. 2.2.25.29 The work to be carried out is of highly sophisticated nature requiring quality precision workmanship, engineering and construction management. It should also ensure successful and timely commercial operation of equipment in stalled. The Tenderer must have adequate quantity of precision tools, construction aids in his possession. Tenderer must also have adequate trained, qualified and experienced supervisory staff and skilled personnel. 2.2.25.30 All temporary scaffolding shall be removed before the start of the commissioning activities to prevent hazards.
279
2.3 2.3.1
EOT CRANE AND HOIST Design and Construction EOT will be to Class-MS (IS:3177, 1999 & IS: 807). Clause 8.0.0 of IS : 800 1962 Code of Practice for General construction in steel shall apply.
2.3.2
Minimum Thickness of Metal For load carrying members, the component plates, bars, angles and other rolled sections shall be minimum 8 mm thick. For tubes having both ends sealed, the minimum thickness shall be 4.9 mm (6 SWG). For unsealed tubes, the minimum thickness shall be 8 mm. The chequered plates for platforms shall be minimum 8 mm thick.
2.3.3
Connections Unless otherwise specified, only welded joints shall be used Transverse fillet welds on load carrying members shall be avoided. Butt welds on structural members under tensile stress shall be checked by Radiographic examination (100%) Splices shall be designed to resist one and half times the forces and moments to which it is subjected.
2.3.4
Deflections and Camber The total maximum vertical deflections of the girders for the safe weight of working load plus the weight of the crab in central, position (without taking into consideration the impact factor) shall be considered The girder shall be cambered by an amount equal to the maximum deflection due to dead load plus one half the live load and trolley.
280
2.3.5
Bridge and Trolley Frames Bridge and trolley frames shall be of fabricated structural steel sections. Mounting shall be designed to facilitate easy removal of the wheels, bearings and journals. Buffers shall be provided on trolley and bridge frames to absorb shock of impact without transferring to the frame.
2.3.6
Hooks Hooks shall have swivels and safety latch. Locking pin shall be provided to prevent swivelling of hook.
2.3.7
Hoist rope The rope shall be of flexible steel with lubricated hemp (fibre) core construction. Suitable attachment to the rope shall be provided for fastening to the drum. Rope shall be sufficient length so that drum has two full turns when hook is at the lowest position.
2.3.8
Drums Rope and drums shall be grooved and welded steel conforming to IS 3177. Drum shall have minimum one spare groove when this hook is at its highest position.
2.3.9
Sheaves Rope sheaves shall be of cast steel or fabricated steel with anti-friction bearings. Sheaves shall be fully guarded to prevent rope coming off.
281
2.3.10 Gears Gears shall be cut from solid cast of forged steel blanks or shall be of stress relieved welded steel construction. Pinions shall be of forged carbon or heattreated alloy steel. Split gears shall not be used. Gears and pinions shall be totally enclosed for all motions and must be dust proof and prevent oil leakage. Gearboxes shall have oil bath type for lubrication. Gearboxes shall have covers split horizontally for inspection. Necessary level gauge for indicating oil level, drain plugs, lifting lugs and guards shall be provided.
2.3.11 Wheels and Rails The track wheels of bridge and trolley shall be of forged steel and double flanged with cylindrical straight tread and shall have hardness not less than 250 HB. The wheel diameter and rail sizes shall be suitable for the wheel load and duty class.
2.3.12 Stoppers Steel rail stops shall be provided at ends of rails for Bridge and trolley welded to crane girders to prevent creeping of rails and running off of trolley. Stops shall match wheel radius and buffers shall be provided as required.
2.3.13 Brakes Brakes shall be provided on the high-speed side of gear reducer. It can also be located on input shaft / extension of input shaft or gear reducer. Coupling halves shall not be used as break drums. The brakes shall be designed for 150% of rated torque.
282
2.3.14 Operating cabin The operation cabin shall be enclosed type with ample space for mounting control panel. The main control panels shall be mounted on the crane bridge. The cabin shall be designed to give the operator clear view of the equipment being lifted in the bay. The operators sea shall meet the above requirement and shall be comfortable. The cabin shall be adequately illuminated and ventilated. Necessary non-oscillating fan, audible alarm and plug points shall be provided.
2.3.15 Ladder and Platforms Ladders shall be provided for access to the crane from the walkway along the building columns and access to cabin from girder top. Platform / walkways shall be provided for maintenance with 750 mm clear insider width with 6 mm thickness non skid steel plate with toe guards of 75 mm height above the floor level and of 6 mm thick.
2.3.16 Drive Drive motor shall be of Crane duty. 15% margin on arriving at motor ratings over and above the design requirement shall be considered.
2.3.17 Testing and inspection The Owner shall conduct all tests required to ensure that the equipment furnished shall conform to the requirements of the specification in compliance with the requirements of the applicable codes. The particulars of the proposed tests and the procedures for the test shall be submitted to the Owner / Consultant for approval before conducting the tests. All materials, castings and forging shall be of tested quality & certificates made available. If mill certificates are not available, the Owner shall arrange for physical & chemical testing at his own cost.
283
The crane shall be subjected to full load, overload tests and deflection test as per IS : 3177. The tests shall be conducted on the motors as per Indian standards IS : 325 and IS : 4029 and routing test and type test certificates of the motors shall be submitted to the Owner / Consultant for review. All other electrical equipment and components thereof shall also be subject to routine tests as per relevant Indian Standards. Type test certificates shall be furnished wherever required by Owner Butt welds on structural members in tension and seams of Welded Hoist Drum shall be subjected to 100% radiography. Non-destructive test (NDT) shall comply with relevant Indian Standards and is the total responsibility of Owner for the quality of weld Reports of all shop test shall be submitted prior to dispatch for review and approval. Test for flameproof electrical apparatus if applicable, as per relevant IS standards shall be carried out and required approval / certificates shall be obtained from the authority having jurisdiction. Test certificates for the same shall be submitted. 2.3.18 SPECIFICATION CRANE ELECTRICALS 2.3.18.1 Motors The crane motors shall be of TEFC type having class B stator insulation and class F rotor insulation with temperature rise limited to class B operation. The enclosure of the motors shall conform to IP 55 degree of protection for outdoor service and IP 54 of indoor service. The hoist, long travel and cross travel motors shall be motors shall be squirrel cage type, designed for crane duty requirement of frequent starting, reversing and plugging with motor pull-out torque of not less than 2.25 times of the rated torque. These motors shall have class S4 duty class with a cyclic duration factor of 40% (CDF)
284
Motors above 30 kW rating shall be provided with 240 V AC space heaters. For motors below 30 kW the motor winding shall be suitable for continuous heating from 240 V, 1 phase, 50 Hz supply 2.3.18.2 Main Safety Disconnect Switch One (1) no. main disconnect switch shall be provided for each of the EOT cranes and hoist for feeder power to the runway conductors. This switch shall be metal clad, load-break type in IP 54 enclosure and complete with compression brass glands and lugs to suit Owners power supply connection. The switch shall be provided with visible ON-OFF inscriptions. Padlocking arrangement for locking in IFF position shall be provided for this switch. Further, the operating handle of the switch shall be mechanically interlocked with the enclosure cover and cover shall not be possible to open unless the switch is in OFF position. PVC insulated and sheathed, round steel wire armoured and overall extruded PVC sheathed power cables shall be provided by the Owner from the main disconnect switch to the runway conductors. 2.3.18.3 Runway Conductors The runway conductors shall be about four (4) in number for 415 V, 3 phase, 50 Hz supply and ground. These shall be of mild steel angle sections, liberally sized for a current density of 0.42 A/mm2. Sufficient allowance (MIN 20%) for wear and tear shall be provided over the calculated size. The runway conductors shall be supported on brackets and insulators from the crane girder with sufficient spacing in between the conductors. The collector system shall have spring-loaded cast iron / high quality carbon metallic shoes to maintain adequate contact pressure. Two (2) nos. ON LED type indication lamps rated for 240 V supply and wired through fuses shall be provided at each end of the bridge to indicate that the runway conductors are in line..
285
2.3.18.4 Cross Conductors The cross conductors on bridge shall be with PVC flexible trailing cables and shall move on the separate roller / track arrangement which will move along with the trolley. 2.3.18.5 Protection & Control Panel a) Panel Power Distribution Wiring shall be extended from the main collector shoes to a 3-pole, load-break, safety disconnect switch located on the bridge within easy reach. This shall be capable of cutting-off supply to all power driven and associated equipment of the crane excepting the auxiliary loads such as fans, etc. From the above safety disconnect switch, wiring shall be provided to a protective panel containing the following as a minimum. One (1) 3-pole incoming supply disconnect switch. One (1) 3-pole, main magnetic contactor with HRC fuses back up. ON OFF push buttons and RED-GREEN indication lamps. The duty of the main contactor shall be AC3 or higher. Suitably rated, 3-pole bus with a fault rating of 45 KA for one second. From this panel, power wiring shall be taken to the individual panels of each motion. The main protective panel and the individual motion panels may be clubbed together to form a single panel unit with barriers in between for separation. The outgoing motor feeders for each motion form the individual motion panels shall consist of 3-pole switch fuse units, contactor and thermal overload relay with single phasing preventions. The electro-mechanical brakes and electro magnetic clutches shall also be wired through separate set of fuses and contactors. 240 V, suitably rated thermostat controlled panel space heaters and fluorescent lamp for internal illumination with ON-OFF switch shall be provided for each panel. Under voltage release shall be included. The crane shall hold its position when the protection operates.
286
Contactor control gear or drum type controllers. The control supply for the panels shall be tapped before the protective panel incoming switch terminals and wired through DP switch and fuses and control transformers. The control transformer shall be rated for 415 V / 110 V. The main contactor shall be electrically interlocked so that it cannot close unless all the motor overload relays are reset and all controllers are in OFF position. The main contactor shall also be opened by means of emergency push buttons and hoist limit switches. All 230 V power requirements shall be arranged by 440 / 230 V lighting transformer mounted on crane and shall be supplied by the Owner.
2.3.18.6 Emergency switch Mushroom type emergency STOP push buttons to open the main contactor shall be furnished one (1) at each end of the bridge platform, one (1) in the protective panel and one (1) no. in the pendant push button station, the number of contacts associated with this switch shall be 2NO+2NC. 2.3.18.7 Crane Controls The long travel and main hoist speeds will be controlled by VVVF / VFD. The auxiliary hoist and cross travel speed to be controlled by conventional inching (resistor based) or VFD. All controls shall be designed for fail-safe operation on loss of power. The control circuits shall be designed for 230 V, 1 phase, 50 Hz supply complete. 2.3.18.8 Resistors The resistors shall be housed in metal enclosures with provision for arresting vibrations. The resistors shall be heavy duty; rust-proof type with stainless steel grids and time shall be rated for 10 minutes duration. The maximum temperature of the resistors at any time shall not exceed 250C. Sufficient space shall be provided around the resistance to ensure adequate cooling airflow.
287
2.3.18.9
Limit Switches Each hoist shall be provided with one (1) no. gravity operated hand reset type limit switch for back-up protection against over-hoisting and one no. lever type switch for LT & CT motions.
2.3.18.10 Illumination Crane lighting, receptacle system and space heating systems shall be designed for 240 V, 1 phase, 50 Hz supply. A separate panel with necessary dry type control transformer having isolation facility and primary / secondary fuses shall be provided for this purpose. 240 V, 5A, 3 pin industrial socket outlets one (1) no. on the protective panels, two (2) nos. on the bridge along the walkway shall be provided. All branch circuits for lighting and receptacles shall be individually protected by switch fuse units. Four (4) forty (40) watts fluorescent fixtures shall be used for lighting bridge platform. 2 X 400 W, HPSV fixtures shall be provided below bridge for illumination of working area. One (1) no. heavy-duty type industrial howler shall be provided. The howler shall be operated from pendent push button station. One (1) no. portable 40 W hand lamps shall be furnished with adequate length of flexible cable for inspection of crane components. Crane overloading warning An audible alarm shall be given when the crane is mechanically overloaded. This may be actuated by a mechanical strainmeasuring unit or by an electrical overload device. Audible Alarm An audible alarm shall be provided, operated by self-resetting push button to enable the operator to give warning at any time. Operators Cab At the end of the bridge, an operators cab shall be provided designed and located to give the operator a complete view of all operations of the crane as practicable. The cab shall provided with 230 V socket outlets for the use of portable electrical outlets.
288
2.3.18.11Wiring All wiring shall be done with 1100 V grade insulated wire, in conduits or 1100 V Grade, PVC cable. All cabling shall run between each component and shall be protected and supported to prevent mechanical damage due to vibration. The minimum conductor size shall not be less than 2.5 sq mm copper. All power, control and auxiliary circuit wiring shall be designed such as to maximise shop wiring and minimise field wiring. The cable size shall be selected taking into account the name plate rating of the motor with de-aerating applied for ambient temperature, group factors, etc. All lighting and control circuit wiring shall be routed through conduits. The conduits shall be heavy gauge, rigid steel, GI conduits with threaded and screwed, tight at all joints. All wires and cables shall be connected to any terminal 2.3.18.12Grounding The cane rails, structures, motors frames, metal enclosures of all electrical equipment conduits and tray system shall be effectively grounded in accordance with IE Rules and Regulations. Two (2) common earth conductors shall be provided along the bridge to which all earthling leads shall be connected. These common earth conductors shall be connected to the ground conductor of the runway conductors. Bonding of structures and cane rails shall be provided as required to ensure electrical continuity. The crane grounding system shall be connected to the station ground mat. For this purpose, the Owner will terminate the crane system at two locations agreeable to the Owner. The earth conductors shall be of GI Conductor, shrouded type. The grounding connection shall be suitable for accommodation of flexible aluminium cables or GI flats as follows: Motors above 30 kW up to 90 kW Motors above 5 kW up to 30 kW Motors up to 5 kW 35 X 6 mm GI flat 25 X 6 mm GI wire 8 SWG GI wire
289
2.3.18.13Gantry Girder Scope to include gantry girder and typical 90 lbs/yard rail. 25 mm diameter anchor bolts to be used. Rail to be continuous over span. Maximum span to be 8 m. Chain Pulley Block to be provided for Boiler Feed Pump, boiler fans, CW pumps, CT fans, ESP transformers, air Compressor, etc. Wherever accessible, the EOT crane in the powerhouse to be used for maintenance purposes. General Information Capacity Span Lifting height Operation Codes / standards : : : : : Minimum 10% higher than largest load As required As required Indoor / outdoor use, as per application IS: 3938, Class II
2.3.19
System Description The hoists used should be standard production hoists. The hoists should be designed and calculated in accordance with the principles of IS: 3938 Class II or according to accepted and equivalent standards. The nominal carrying capacity of the hoists and of their attachment points to be such that the heaviest objects to be lifted can be transported safely. The hoists and crabs should be equipped with squirrel cage motors. Inching control to be also provided on all electrically driven hoists and crabs. The crab power supplies should be in the form of trailing cables with cable carriers running in tubular track.
290
Electrical switchgear and control gear should be mounted directly on the hoists in cabinets. The electrical hoists should be operated by pendant control units fitted with push-buttons and should be fixed to the hoist in such a way that safe operations guaranteed. Limit switches should be fitted to all lifting and travel gear. A key operated switch and an emergency off push buttons to be provided.
2.4 2.4.1
WATER TREATMENT PLANT Primary Treatment of Raw Water This package consists of the treatment plant consisting of alum, polyelectrolyte, sodium hypo chlorite, and lime dosing systems, clarifloculator with bridge or tube settler, flash mixer, raw water pumps, auxiliary equipments for clarifier / tube settler, clarifier sludge pipes, related sludge discharge pumps, clarified water pumps etc., sampling devices, plant instrumentation, metering / measuring devices, pressure gauges, basket strainers, all piping etc., are to be included in the scope of supply.
2.4.2
Secondary Treatment Multi-grade filters / dual media filter ACF Strong acid cation unit Degasser unit and auxiliaries Anion unit Mixed bed unit Ultra filtration unit for silica removal, PLC operated. If required by the design, Tenderer may provide additional tank and pump (1 W + 1 S/b) to transfer water to UF unit. Bypass to UF unit to be provided. All associated instrumentation, piping, valves, fittings, controls, tanks, reagents, resins, injectors, metering pumps, etc. All inter connecting piping and fittings Neutralising pit of suitable size to be provided and pumps to handle the liquid should have SS 316 internals discharge pumps
291
For all regeneration system, two ejectors will be provided, one will be stand by All parameters measuring devices to be provided Vortex type electronic water meter at the plant outlet in addition to rotameter Morpholine dosing system at the outlet of mixed bed for pH correction Appropriate supporting structures / fixtures for supporting pipelines tanks, etc. All valves, piping, fittings, etc. within battery limits Instrumentation & controls MCC and all electricals including cabling, cable trays, supports, earthing, starters, push buttons, etc. within battery limits O & M manuals
2.4.3
Performance Guarantee The Tenderer should guarantee that the net output and quality of treated water from DM plant stream as given below : Output of Pre-treatment plant stream : 40 m/hr Output of DM plant stream Net output of treated water per regeneration Flow rate OBR : 1000 m3 55 m3/hr 8 m3/hr 50 m3/hr
Maximum : Minimum : Normal
Quality of DM plant water Specific electrical conductivity at 250C measured after degassing max. Total iron Total copper max. max.
us/cm : 0.2 ppm : nil ppm : nil
292
Total silica (as SiO2) pH at 25 Deg.C Permanganate Total Hardness (as CaCO3) Total CO2 Oil & Organic matter Total dissolved solids Total suspended solids Residual Phosphate 2.4.4 Codes & Regulations
max.
ppm : 0.02 : 8.5 - 9.2
max.
ppm : Nil ppm : Nil ppm : Nil max ppm : Nil
max max max
ppm : 0.1 ppm : Nil ppm : Nil
The water treatment plant shall comply with all applicable codes and regulations. In addition, following standards shall be applicable: Pressure thickness) Painting vessels (for : : : : : : : ASME Section VIII DIV. I/IS 2825 Manufacturers Standards as approved by karkhana / consultant B Table IS 2062 IS 2062 IS 4682 Part I IS 13268:1992
Type of Flanges Vessel sheet Vessel dished ends Rubber lining on vessels DM plant guidelines
293
2.4.5
Basis of Design Pre-treatment including dosing MGF & ACF DM Plant Qty. Source of water plant system, : 30 m3/hr or 600 m OBR
: : :
Normal flow No. of regeneration / day Operation of the plant Raw water inlet pressure DM water discharge pressure at Exit level Raw water analysis
: : : : : :
600 m3 OBR 1 no. River water. In case of exigencies, borewell water will be required to be used for process and boiler. Hence the water treatment plant should be designed accordingly DM plant 30 m3/hr One (maximum of 4 hours) Manual 2.5 kg/cm2g 1.5 kg/cm2g As given in Appendix XVI. Tenderer to design the water treatment plant by considering 300% higher loading than the given raw water analysis. This is to accommodate usage of borewell water during exigencies. Tenderer to also design the WTP for a total silica load of 25 ppm
2.4.6
Technical specifications of Water Treatment Plant The complete system shall preferably be skid mounted (on RCC foundation). All ladders and platforms required for assessing equipment for operation or O&M will be provided by Tenderer. All equipments shall be designed for 1.5 times the maximum operating pressure All drain points shall be led to one point and to the neutralising pit Resin traps shall be provided after every exchanger to remove fines, etc. of the resin media caused by attrition and backwash. Strainers of SS or PVC to be installed in the back wash outlet of exchangers. Back wash flow should be measured by V notch provided by Tenderer. All pressure gauges shall be provided with isolation valves
294
Polyelectrolyte dosing to be specified in the filtration system for removal of colloids. DM water pipe should be MSRL / SS 304 All degasser wetted components to be of SS / Polypropylene. Degasser pump to have auto on-off based on degassed water level. HDPE piping for acid / alkali measuring tank, MSRL / SS 304 for DM water piping All ion exchangers and acid & alkali storage tanks / measuring tanks / dilution tanks shall be of MS rubber lined construction. Piping and all flanges at battery limit shall be as per B Table Material for pumps: feed water pumps CI, acid / alkali pumps PP, DM water pumps SS 316 Online pH and conductivity meters with recorder with alarm for mixed BED outlet and online pH measurement for SBA & MBU. Flow meters of vortex type for DM water after mixed bed Rotameters with bypass rotameter at inlet & outlet of DM plant. Butterfly valves with EPDM seating are required. For smaller size, diaphragm type valves with neoprene diaphragm can be used. For corrosive applications valves will be ebonite lined or with CF8M disc. PVC ball valves are acceptable. Electrical : local push button station shall be provided for pumps and fans Painting : all exposed unmachined parts shall be painted with colour code as per relevant IS specifications Minimum resin life of five years or higher including attrition losses to be specified, quality of resin, make, type, quantity for each stream to be specified All pressure vessels thickness to be designed as per ASME Section VIII All treated water tanks and piping to be MSRL 75% of free board (void space) in all vessels of DM plant exchangers and 100% for mixed bed exchangers for expansion For internal parts of the bed, MOC of Polypropylene is required. Instrument air, if required, will be provided by Owner at 4 kg/cm2g For pipe sizing : Pump suction : 0.7 m/sec. Pump discharge : 1.5 m/sec. Compressed air : 20 m/sec. Piping materials : For water, IS:1239 / IS:3589 ERW / EFW pipes will be used. Minimum corrosion allowance of 1.6 mm to be provided.
295
2.4.7
Instrumentation List (With Connectivity To DCS) Sr. No. 1 2 3 4 Description DP for basket strainers at raw water transfer pump Level Indicator for clarified water storage tank DP for basket strainers for clarified water transfer pumps Level indicator for a) Soft water storage tank b) DM water storage tank c) Service water storage tank Low level alarms as above (4) Vortex flow meters a) softener outlet b) MB outlet c) RO outlet Float type flow meter a) inlet to MGF UFROMB line b) Inlet to MGF softener line Online pH meter a) RO outlet 2 each b) DM outlet 2 each Conductivity meter a) RO outlet 2 each b) DM outlet 2 each Level gauges - Acid & Alkali Tanks & dosing tanks Low level alarm - clarified water storage tank
5 6
10
11
296
2.4.8
Material Of Fabrication Of Equipments And Piping Wherever Applicable 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 Clarifloculator Inlet well Alum Dosing Tank NaOCl dosing tank Polymer Dosing Tank Lime Dosing Tank Mixing channels Clarifier Clarified water storage tank Multi grade filter ACF Acid Measuring Tank Caustic Measuring Tank Anti Scalant Tank Fast Flush Tank Backwash Tank Degasser Tower Degassed Water Tank Degassed Blower Degassed water pumps MB Unit ETP Pump Acid and Caustic Lye Pumps Neutralisation pit Softener Brine Preparation Tank Brine Dosing Tank Sludge Sump Sludge Pumps DM water piping Soft water piping UFRO Unit Effluent / Sludge Slurry DM water tank Soft water tank Filtered water storage tank Rotating Bridge Type RCC HDPE / FRP / MSRL HDPE / FRP / MSRL HDPE / FRP / MSRL HDPE / FRP / MSRL RCC (Through flow pipe) RCC RCC MSEP MSEP HDPE / MSRL MS / MSRL HDPE HDPE HDPE / FRP MSRL MSRL SS 316 internals SS 316 MSRL SS 316 PP RCC with acid proof tile lining MSEP RCC Bitumen MSEP / Bitumen RCC SS 304 MSRL MS SS / PVC / MSRR PVC MSRL MSEP MSEP
297
37 38 39
All dosing pumps SS 316 internals Raw water pumps CI Filtered water and clarified CI with SS 316 internals water pumps
2.4.9
Laboratory Equipments Tenderer to include all lab items required to monitor all parameters specified in the quality of DM water. Sr. No. 1. Item with description and specifications pH meter digital Range 0 -14 Accuracy 0.01 pH ORION/EUTECH make Conductivity / Salinity / TDS / Meter (Digital) Range - 0-199, 990 in 4 ranges Accuracy - 0.5 % FS ORION / EUTECH make D.O. meter Model - 850 (ORION) Range - 0-20.0 mg/2 0-200 % With salinity and barometric pressure compensation with data logging Modern water analyzer equipment to the following broad specifications (Spectrophotometer) Wavelength 400 - 900 nm preprogrammed methods for water analysis / waste water analysis. Capable of giving results in direct concentration. RS 232 link interface for down loading to printer or PC Data storage capacity. Program methods to analyze and test water for about 70 parameters including silica, chloride, phosphate, nitrate hydrazine, iron etc. To operate on AC supply or battery back up. Qty. (Nos.) 2
2.
3.
4.
298
2.5 2.5.1
AIR COMPRESSOR & DRYER System Requirements The purpose of this system is for supply of compressed air for control drives, control valves, pneumatic tools and miscellaneous control system and supply of plant air to the power plant. Service air needs will also be provided by this compressor and will be designed for minimum 40 m/hr. The system will provide a reliable supply of air that is free of water, oil or solid contaminants. The compressors are to be opposed, belt pulley driven, non-lubricating type reciprocating air compressors complete with drive guards, AC electric motors, LPBS, air receiver, intercooler, after cooler, moisture separators, air dryer, moisture traps, all interconnecting pipe work & fittings, control panel, etc. The heat exchangers shall be designed as per TEMA-C and coolers shall be mounted horizontally. The air receiver shall be fabricated from SA 515 Gr. 70 or IS : 2002 material. The internal surface shall be galvanised. Control air will be supplied to boiler and its auxiliaries, turbo generator and its auxiliaries and common plant auxiliaries like water treatment plant, fuel handling plant, ash, pump house etc. Compressed air will meet the requirements as stated below : Capacity Nos.: Pressure at receiver outlet Dew point temperature at atmospheric conditions : 200 m3/hr or higher as per plant needs : 2 nos. (1 operating & 1 standby) : 7 kg/cm2 (g)
: (-) 400C
Particulate material size (max.) : 1 micron Contaminants : No corrosive, hazardous, toxic Or flammable material : 100% Oil Free
Oil Content
299
It is proposed to interconnect the service air system with the instrument air system before the instrument air dryers. A non-return valve and a manual isolating valve will be provided in this line so that instrument air cannot be supplied to the service air system. 2.5.2 Operational Requirements It is envisaged that the air compressor, air receiver and air dryer will operate in series. However, the facility will be provided by suitable design / layout of the station air pipe-work, to operate each item in a sectionalised manner. It is proposed to have common compressed air system meeting both instrument and service air requirement. With this approach compressed air after a common air receiver, a part of air will be directed to an air- drying plant and balance will serve the requirements of plant service air. The service air will be tapped off from up-stream of the air-drying unit. Air from air-drying plant will be directed to instrument air header, which will cater the requirements of instrument air for plant operation. 2.5.3 Other Technical Requirements Each air compressor will include the following accessories a) Silencer and filter for air intake b) Inter cooler for multi-stage compressor complete with trap station with bypass arrangement. c) After cooler complete with trap station with bypass arrangement d) Air receiver of 1 m3 (water volume) or higher capacity to hold air and minimize pressure fluctuations. e) Instrumentation to monitor and control the whole compressed air system including pressure gauge, pressure transmitter, temperature gauge and temperature transmitter. f) All pipes will be ERW heavy duty, C class. g) Interconnecting valves, safety valves, NRVs and piping. h) All valves for air will be ball valves with Teflon seating. All valves for water to be ball valves designed for 5 kg/cm2(g) pressure. i) Automatic moisture traps at both compressors and at receiver. j) Water for cooling will be provided at 1.5 kg/cm2(g) to 2.5 kg/cm2(g) k) Cooling water will be available at 320C
300
Air compressor package shall be skid mounted with inter and after cooler, receiver, dryer, automatic control and monitoring system. The compressor piping shall be galvanized. The heat exchangers shall be as per TEMA C standards for heat exchanger, cooling water flow through tubes. Heat exchanger tubes shall be of copper and carbon steel surfaces susceptible to corrosion shall be hot dip galvanized. The shell material of moisture separator, after cooler shall be of IS 2002 Gr. 2. The electric motor shall be as per IS 325 and compressor is driven through flat belt-pulley. Electric motor shall be of IP 54 enclosure. All interconnecting piping shall be galvanized. 2.5.4 Air Drying Plant One no. heatless type air drying plant of 200 m3/hr capacity or as per compressor capacity with 2 nos. drying towers with Activated Alumina as desiccant will be installed at compressor outlet for producing moisture free air of instrument air quality. Re-generation shall be done using purge air. The material of absorber tower shall be of IS 2002 Gr. 2. The maximum air pressure drop shall be limited to 0.3 kg/cm2. The air dryer plant outlet air pressure shall be 7.0 kg/cm2g and the maximum air temperature shall be 400C. The mechanical design pressure of air drying plant shall be 10.5 kg/cm2 (g) 2.5.5 Air Receivers The receiver will be self-supporting cylindrical vessel. The receivers will be so sized that in the event of a compressor failure, the receiver pressure will not fall from the normal working pressure of 7 kg/cm2 (g) to 4 kg/cm2 (g) in less than 5 minutes time. The air receiver shall be designed as per IS 2825. Material of construction shall be IS 2002 Gr. 2 and the design pressure shall be 10.5 kg/cm2(g). Minimum capacity of the receiver will be 1 m
301
2.6 FUEL & ASH HANDLING SYSTEM 2.6.1 Bagasse Handling System 1 No belt conveyor (BC-1) to feed the bagasse from Elevator to Slat Conveyor (SC-2) 1 No slat conveyor (SC-2) to feed the bagasse to the boiler or to conveyor no EX BC -3 from the bottom deck. 1 No belt conveyor (EX BC-3) to carry the excess bagasse to the belt conveyor (EX BC-4) 1 No belt conveyor (EX BC-4) to carry the excess bagasse to the storage yard Belt conveyor (UN BC-5) to feed the bagasse from the yard on to Belt Conveyor BC-6. This conveyor (UN BC-5) shall be partially under ground so that it should be possible to feed the bagasse to this conveyor by pay loaders at the rate of 40 MT/Hr & partially inclined to receive the bagasse from two nos. bale breakers. 1 No over band type magnetic separator suitable for 1200 mm width belt to be mounted on inclined portion of UC-BC5 1 No belt conveyor no BC-6 to feed bagasse to the top deck of slat conveyor no SC-2. 2 numbers bale brakers of 20 TPH capacity along with 20 Mtr long feeding belt conveyor of 800 mm width. 1 number de trasher of 10 TPH capacity. 1 number wood chipper of 10 TPH capacity Since the bagasse is sticky in nature, it is necessary that the scrappers provided shall be of rotary brush type to ensure effective scrapping before the run of the return belt. The drive assembly shall include the gearbox, coupling, common base frame, guards, electric motors, local push button stations etc.
302
The technical parameters of above conveyors are tabulated below: Sr. no 1 2 3 4 5 6 7 Description Capacity TPH Material Bulk Density Kg/M3 C/c Distance Mtr Lift Mtr. Angle of Inclination No of feed points BC-1 40 150 47 21 280 1 SC-2 40 150 77 0 0 1 EX BC- EX BC-4 3 30 30 Bagasse 150 150 109 0 0 1 60 0 0 1 UN BC-5 40 150 60 5 100 Through out the length of underground portion 1 BC-6 40 150 109 27 16.50 1
9 10 11 12 13 14
No of discharge points Type of conveyor Conveyor Width mm Belt Weigher Walkway Hood Cover Special requirement
Cleated Belt 1200
Chain 1600
Belt 1200
Belt 1200
Belt 1200
Belt 1200
Required for conveyor no BC-1& BC-6 Both side walkways of 750 mm & 600 mm to be provided Hinged type hood cover (100 % dust proof) to be provided for all the conveyors 5 no rack 4 Nos. V & pinion ploughs gates are to be to be provided provided
303
2.6.2
Ash Handling System: Submerged belt type conveyor (SBC- 1) to collect & convey the ash from the boiler bed & convey it to conveyor no ABC-3. This conveyor has to be mounted in a MS trough; the belt should be submerged in water with a level of minimum 250 mm. Screw conveyor (ASC-1) to feed the ash from Economizer & Air pre heater on to the cross belt conveyor (ABC-1) Screw conveyor (ASC-2 ) to feed the ash from ESP Hoppers on to the cross belt conveyor (ABC-2) Cross belt conveyor (ABC-3) to convey ash from SBC-1, ABC-1 and ABC-2 to ash silo. Ash Silo of 50M3 capacity with the supporting structure and sector type discharge gate of minimum 350 NB size
Ash Disposal : All the ash generated in boiler bed, economizer, air pre-heater and ESP will be collected in a common ash silo through mechanical handling system comprising of submerged ash, screw conveyor and cross belt conveyor as shown in the layout. Ash is then dumped in open space of through trucks / dumpers. This open space should preferably be near to the cogen plant to minimize the transportation cost. Ash from the open yard is to be distributed to farmers or nearby brick manufacturers.
304
The technical parameters of above conveyors are tabulated below. Sr. No Description Submerge d Belt conveyor below Bed Ash Hopper (SBC-1) 1.0 for bagasse Ash 18 2.1 160 Belt S H R grade 1000 mm Screw Conveyor below ECO & APH Hopper (ASC-1) 1.0 for bagasse Ash 10 0 0 Screw 300 mm Screw conveyor below ESP Hopper (ASC-2 ) 2.0 for 1.0 for bagasse bagasse Ash Ash Bagasse / Biomass ash 13 15 0 0 Screw 300mm 3.0 60 Belt 500 mm 1.0 for bagasse Ash 15 3.0 60 Belt 500 mm 3.0 for bagasse Ash 80 10 140 Belt 650 mm Belt Conveyor (ABC -1) Belt Conveyor (ABC 2) Belt Conveyor (ABC -3)
Capacity TPH Material C/C distance, m Lift, m Angle of Inclination Type of Conveyor Width/ Diameter of the conveyor One side Walkways
2 3 4 5 6 7
Required for partial length
NA
NA
NA
NA
Required for partial length
2.6.3
Electrical All AC motors required for the conveyors. The motor terminal box shall be complete with cable gland & lugs Starters lockable push button stations MCCs, all cabling including galvanized cable trays, equipment /body earthing etc. Lightning protection for the structures, as required with necessary vertical /horizontal conductors, each earth electrodes & connection to earth pit.
305
2.6.4
Instrumentation & Controls Safety switches for the system including zero speed, pull chord at a spacing of 30 Meters. on both sides, belt sway switches at a spacing of 60 Meters, emergency switches, as applicable. Control System including control panel for the sequential operation with inter phase facility to communication with the boiler control system. Local instruments including switches, instrument cables, terminal boxes, cable trays & accessories, as required to make the system complete.
2.6.5
General: Interconnecting chutes, hoods over conveyors supporting structures, maintenance Platforms ,approach ,etc as required Any other item not specifically mentioned above but required for satisfactory performance of the fuel and ash handling system Consumable materials as required for erection & commissioning including electrodes. First fill lubricants, flushing oil, etc. Two coats of primer, one coat of finished paint & final painting at site. Performance Test.
2.6.6
Detailed Technical Specifications A) Belt Conveyor The length of the conveyors is indicated in the scope of work are drive pulley centre to discharge pulley centre (c-c) distance & they are approximate. The exact length and lift of the conveyor shall be determined by the Tenderer based on the design parameters indicated and taking into consideration the dimensions and arrangement of the equipment offered by the Tenderer. The carrying capacity indicated are the rates at which the equipment shall be guaranteed to operate continuously. The angle of inclination of conveyor belts shall not exceed 18 deg to the horizontal for standard belt. For inclination up to 300cleated type belt shall be provided. The belt conveyors and accessories shall be suitable for continuous operation under severe duty working condition. Design &construction feature of the belt conveyor shall be in accordance with IS: 11592.
306
The scope of supply shall include but not limited to the belting, idlers, (carrying, return, impact, SACI & SCRI), pulleys including head, tail/ take up, snub, bend., belt internal/ external cleaners, take up units, drive unit complete with electric motors, reduction gear boxes, flexible coupling, for both high speed and low speed sides, base frames, integral hold back device, electric safety switches, auxiliaries like skirt board, deck plates, dust seals, coupling guards, take up guards etc., structural item like stringers, short supports, take up frames, conveyor gallery, walkway, conveyor support columns and frames, hoods and all other accessories that may be necessary to make each conveyor and the system complete. The belt shall be of Nylon- Nylon type with suitable top and bottom cover. The number of plies and weight of duck shall be suitably selected with due regard to load/flexibility of troughing. Hot vulcanising shall be considered for the joints. The idlers shall be made of seamless /ERW steel tubes. The idler rollers shall be fitted with deep groove ball bearings. Troughed idlers shall be concentric and shall have 3 rolls, 20 deg. Troughing angle. All bearings shall be designed for a minimum life of 40000 working hours. The return idlers shall be single roller flat type and covered with rubber sleeve wherever required. Impact idlers shall be provided at the loading each loading point. The roller assemblies shall be designed to prevent dust accumulation. The spacing for the troughing and return idler shall be as per IS 11592.Shorter spacing shall be considered for the bends and for reasons of heavy loading. The impact idlers spacing shall not be more than 300 mm. Self aligning carrier and return idlers shall not be more than 20 Meters apart and more than 15 meters from each terminal. The conveyor pulley shall be welded steel construction with closed ends. The pulley diameter shall be designed for maximum belt life and confirm to IS specification. The entire assembly of the pulleys shall be balanced and grooved rubber lagging shall be provided for the drive pulleys.
307
The take-up shall be vertical gravity type for the inclined conveyors and screw type for short conveyors up to 30 Mt. length. The unit shall be complete with counter weights, take-up pulleys and structural frame to make the installation complete. Skirt board shall be provided at loading zones and in other places to prevent spillage. The skirt plate thickness shall be minimum 6 mm and the rubber strip thickness shall be minimum 10 mm. The deck plates shall be 2.0 mm for the entire length of the belting. The belt conveyor shall be complete with coupling guards, discharge / feed hoods, pulley guards drives supporting structure, maintenance platforms and drive platform shall have adequate space on both sides to attend to drive unit. All conveyors shall have removable type hinged hoods with industrial hinged & painting. The hood shall be fabricated from minimum 1.6 mm thick M S sheets with suitable stiffeners & clamping arrangement. B) Chain & Slat Conveyor The length of the conveyors is indicated in the drawing are from drive sprocket centre to discharge sprocket centre ( c-c) distance & they are approximate. The exact length and lift of the conveyor shall be determined by the Tenderer based on the design parameters indicated and taking into consideration the dimensions and arrangement of the equipment offered by the Tenderer. The carrying capacity indicated are the rates at which the equipment shall be guaranteed to operate continuously. The angle of inclination shall not exceed 45deg to the horizontal. The slat conveyor and accessories shall be suitable for continuous operation under severe duty working condition. Design &construction feature of the slat conveyor shall be in accordance with relevant I S Standard. The chain conveyor shall be of all steel construction suitable for outdoor duty and for the specified conveying capacity. The linear speed of the conveyor shall not be more than 25 M/ Min.
308
The scope of supply shall include but not limited to the chain, sprocket, slat, take up units, drive unit complete with electric motors, reduction gear boxes, flexible coupling, for both high speed and low speed sides, base frames, integral hold back device, electric safety switches, auxiliaries like deck plates, dust seals, coupling guards, take up guards etc., structural item like short supports, take up frames, conveyor gallery, walkway, conveyor support columns and frames, hooks and all other accessories that may be necessary to make each conveyor and the system complete. The chain shall be of forged steel with suitable attachment for mounting the slats. The chain shall be supported on the suitable guides. The minimum factor of safety for chain design should be 10. The braking strength of chain shall be minimum 60,000 Kgs. The slats should be made up of I S 2062 & the minimum thickness shall be 6 mm. The sprocket shall be of cast steel with machine cut teeth & the diameter shall be designed for maximum chain life and confirm to IS specification.. Suitable take up shall be provided. The arrangement drawing should be furnished with the offer. The slat conveyor shall be complete with coupling guards, discharge/ feed chutes, coupling guards, drives supporting structure, maintenance platforms and drive platform & shall have adequate space on both sides to attend to drive unit.
C)
Screw Conveyor The screw conveyor assembly shall include the screw flight, pipe shaft, trough, trough cover, end cover, bearings, hanger bearings , end shaft, trough end seals, saddles, inlet & outlet spouts, drive unit complete with electric motors, reduction gear box, couplings for both high speed sides, weather hood for drive box, structural items like short supports, drive platform, approach and all other accessories that may be necessary to make the conveyor complete .
309
The screw flight shall be of 6mm thickness (minimum). The trough & trough end cover thickness shall be minimum 6 mm &12 mm thickness respectively. Provision for thermal expansion shall be provided if the outlet flange of discharge point is directly connected to the screw conveyors. Necessary expansion bellows are in the Tenderers scope. Hard facing of the screw flight shall be out on the carrying side for 1 face width (minimum) Packed gland seal shall be provided at tail or drive shaft opening in the trough ends to prevent material leakage. Pitch of the screw shall be 0.8 to 1 D where D is the diameter of the screw. However, to meet the required capacity, the pitch may be maintained short, half or long. D) Submerged Belt Conveyor The submerged belt conveyor assembly shall include belt, idlers, pulleys, trough, pressure pulleys, return rollers, take-up arrangement, drive unit complete with reduction gear box, belt internal & external scrapers etc. to make the system complete in all respect. Inter connecting chutes, supporting structure, safety / indicating instruments, drive assembly, supports, maintenance platform, frames, drive base, approach etc. as required by the conveyor. Water piping, inlet & outlet drains up to the terminal points as required by the system Minimum of 200 mm water seal has to be maintained at the discharge point of chutes in to the trough of the submerged belt conveyor. The inside of trough shall be quoted with one coat of Tar paint and the trough material shall be minimum 10 mm thick. The belt speed shall be limited to 5 M/Min
310
E)
Chutes All the conveyors shall be provided with discharge /receiving chutes for the flow of material. The chutes shall be fabricated from minimum 6 mm thick M S plates. Whenever required suitable liner plates shall be provided to with stand the erosion due to falling material. The liner plates shall be bolted to the main plate. Feed & discharge chutes shall be provided from conveyor to conveyor. Sufficient number of pock holes & access door shall be provided in long chutes.
F)
Supporting Structure The complete supporting structure required for the Fuel and ash handling system will form part of scope of supply. The complete structural work above finished floor shall be of steel
G)
Fly Ash Silo Silo shall be designed for storing the quantity of ash generated at various points and the capacity shall be minimum 50 M3. The silo shall be of M S construction and the conical portion of the silo shall be lined with TISCRAL/ SISCRAL liner of 5 mm thick. Sufficient headroom & side clearance shall be provided below the silos for bulk tankers/ trucks movement.
H)
Discharge Gates/ Chutes Manually operated discharge / diverter gates shall be provided whenever required to facilitate flexibility of operation and maintenance of the system. The gate shall be fabricated from minimum 10 mm thick M S plates. The gate shall be provided with antifriction bearings with suitable seal for free movement. The gate shall be of rack & pinion type. All the conveyors shall be provided with discharge /receiving chutes for the flow of material. The chutes shall be fabricated minimum 6 mm MS plates. Whenever required suitable liner plates shall be provided to withstand the erosion due to falling material.
311
I)
Discharge Hood & Chutes All the conveyors shall be provided with discharge/receiving chutes for the flow of material. Also the discharge chute shall be designed to cover the belt scrappers at the bottom of the belt. The chutes shall be fabricated from minimum of 6mm MS plates. Wear & abrasion resistant (ultra high molecular weight polymer) liner should be provided on material sliding surface. The liner shall be fixed to MS plate by mechanical fasteners or welded washer system and discharge chutes shall be provided from conveyor to conveyor. Properly designed discharge for effective de-dusting and dust tight flexible rubber access door (min 400sq.mm) shall be provided the height of the discharge hood shall be 1500 mm from the belt top. Deflectors shall be provided in discharge hoods wherever the belt conveyors are discharging at 90 degrees. The back end of discharge chute and return belt shall be properly sealed by replaceable rubber strip to avoid dust nuisance. Sufficient number of poke holes (min 100NB pipe) and access door (min400sq.mm) to be provided in long chutes with access platform and staircase.
J)
Junction towers All junction towers shall have maintenance platforms, landings, hand rails & toe plates. All floors & landings shall be provided with minimum 2500 mm clear head room.
2.6.7
Instrumentation The material handing system (bagasse & ash) will be controlled by the DCS. The interlocks will also be provided in the MCC. The ash handing system will have all the primary sensors that are required for the sequential /safe operation of the system offered.
312
2.6.8
Specific Requirements for the System Components The reduction gear box used shall be of worm gear completely enclosed with flash lubrication. The gear box shall be rated 24 hours continuous working with a minimum service factor of 1.5 on the installed motor capacity. The couplings provided shall be of flexible type and shall have a minimum service factor of 2 on the installed motor capacity. All bearings shall be preferably anti friction type and self aligning in nature The bearings shall have effective and dust covered. The bearing shall be selected for a minimum working life of 40000 hours Effective lubrication shall be provided for all bearings and sliding surfaces . All the structural steel used shall meet the requirements of IS: 2062 and the Steel plates used shall not be less than 5mm thick. A minimum walking /maintenance space of 750 mm on both sides shall be provided for the entire length of the conveyors. The walkway shall be complete with hand railing, approach ladders etc. All the conveyors outside the building shall be covered by removable type hoods .The hoods shall be fabricated from minimum 2 mm thick by MS sheets/ Metapoly sheets with suitable stiffeners and clamping arrangement. All sprockets in the drive unit shall be of cast steel with machine cut teeth. The shaft shall be of EN8.
313
2.7 2.7.1
COOLING TOWER & AUXILIARIES Scope of supply and services of basic equipment This section details out the scope of supply and services for package cooling tower with auxiliaries as indicated Scope of supply of cooling tower a. Three cells, cooling tower, 4800 m3/hr capacity with RCC basin and all civil works (Capacity calculation to be furnished by Tenderer to include all CW needs of the cogeneration plant with minimum 10% margin, with out surface condenser temperature pick-up of 8C) Recovery stack All supporting structures Entire fills and support Drift eliminators Ladders for easy accessibility to fan deck Fans, gearbox, motor, vibration and oil level limiters / indicators / alarms and control All associated instrumentation Required partitions, supports, etc. NaOCl dosing system Following digital / analog signals to be given. A. Level indication and alarm for low level : for water in the cooling tower basin. Vibration alarm for the fan assembly. Temperature of CW inlet at CT entry and CW outlet at terminal points with annunciation for high / low level Low oil level indicator switch with transmitter to be provided for each Fan Gear Box
b. c. d. e. f. g. h. i. j. k.
B.
C.
The Tenderer further guarantees the following:
314
The total pumping head required (including static height and losses in pipes and distribution system) with respect to normal water level in the basin at Tenderers terminal point shall not exceed 25 MWC at design flow. The hot water returning from the auxiliaries is cooled in the cooling tower, designed for a cooling range of 8 Deg. C and an approach of 5 Deg. C while operating under the atmospheric wet bulb temperature of about 28 Deg. C. The structure shall be designed for wind and other loads as per IS:875 and earthquake resistance as per IS:1893. The cooling tower shall be carefully sited such that there is no re-entrainment of the vapours into the auxiliary cooling tower.
2.7.2
Features of Construction The induced draft counter flow cooling tower shall be complete with tower, basin foundation and mechanical equipment as described below, the tower shall be of double inlet flow type of construction. The tower shall be of induced draft type with the fans located on top of the tower. The Tenderer will supply asbestos free cooling tower. a. Casing Casing of field erected towers shall be of RCC. External casing as well as partition walls in between cells shall be provided with air tight access doors. b. Inlet Louvers (as applicable) The water loss in the louver openings shall be prevented with proper slope, width, spacing and tightness of louvers, RCC Louvers must be properly designed to give uniform distribution of air with minimum pressure drop and must be able to withstand corrosive atmosphere. Slip fit type louvers may be provided for access to interior of tower, as per design.
315
c. Fill and Fill Supports Modular film fill made of extruded PVC supported on RCC beams. They shall be adequately supported to prevent sagging and damaging. The tower shall be levelled so that water will be uniformly distributed over the film fill and does not cause channelling. d. Supporting Structure RCC supporting structure shall be designed to withstand the wind or earthquake loads, dead load such as weight of the tower and circulating water and line load and live load. e. Drift Eliminators The drift eliminators shall be designed to keep the drift loss to a maximum of 0.1% of the circulation rate. The air pressure drop across the eliminators shall be kept to a minimum by providing a proper number of air flow direction change across the eliminators, the water collected in the eliminators shall be returned to the tower basin and shall not mix with the discharge air stream, eliminators shall be multi-pass. Herring bone type or angular honey comb arrangement or cellular type. Asbestos materials are not to be used and only PVC or HDG materials are to be used. f. Water Distribution System The hot water shall be distributed to the fill through distribution basins through, distribution nozzles. Hot water shall be distributed to the basin by steel pipes. The water shall be equally distributed among the working cells by having control valves in the supply pipes. These shall also serve as isolating valves for the cells. The control valves shall be easily accessible for any maintenance work.
316
g. Recovery Stack Recovery stack shall be of proper shape to improve the fan performance. The height of the stack shall be sufficient to recover the velocity and discharge the humid air at a sufficiently high level to minimise recirculation. The minimum clearance between the stack and fan blades shall be maintained along the entire periphery of the stack to prevent the rubbing of fan blades while rotating. The height of the RCC stack shall be sufficient to recover the velocity and discharge the humid air at a sufficiently high level to minimise recirculation. The minimum, clearance between the stack and fan blades shall be maintained along the entire periphery of the stack to prevent the rubbing of fan blades while rotating. h. Fan Deck The fan deck should be sturdy in construction to transmit the live loads to the frame, to support a stack and act as an access plat form for the mechanical equipment and distribution system. i. Internal Walkways Walkways with platform and toe bolts and suitable handrails shall be provided inside the towers. The drift eliminators shall be easily accessible from these walkways. j. Hardware The hardware used shall be a combination of hot dip galvanised steel, naval brass, phosphor bronze, silicon bronze and stainless steel, Generally all hardware material above fan deck level shall be hot dip galvanised steel and below fan deck shall be of phosphor bronze. All bolts nuts and washers and rails shall be SS 304 and nails shall be screw shank type. All hardware items to be SS 304.
317
2.7.3
Mechanical Equipment a. Fans Fans shall be of open type, multi blade construction with the blades of aerofoil section. Fan blade shall be of cast or moulded construction. These shall be of easily removable and adjustable pitch type. Blade shanks and hubs shall be suitably insulated to prevent electrolytic corrosion. b. Fan Drives Fan drives shall be as follows : Reduction Gear Drive The gears shall be of spiral bevel, helical or worm type. The gear reduction may be of single stage or multistage. All gear drives shall be of enclosed type and shall operate in oil bath. Remote oil level indicators, fill and drain lines of SS:304 shall be provided. The service factor of the gear drive shall be minimum 2 for bevel and helical gears. For worm gear drive the service factor shall be 1.5 for more than 22 KW continuous duty and 1.2 for less than 22 KW continuous duty. Low oil level indicator switch to be provided for gear boxes. All oil piping to be in SS. The drive shafts shall have flexible coupling at both driving and non driving ends. This shall be of hollow hot dip galvanised carbon steel. The flexible, tyre coupling shall be used. Drive shafts shall be dynamically balanced. c. Prime Mover The fan driver shall be an AC electric motor of squirrel cage induction type confirming to attached specifications and Data Sheet.
318
2.7.4
Accessories The following accessories shall be provided : a. Staircase A RCC staircase shall be provided on one side of cooling tower for access to the fan deck. b. Distribution Basin Cover The hot water distribution basin, shall be provided with a suitable cover to avoid direct sun rays falling on the distribution through or basin, to minimise algae growth and to prevent choking of distribution nozzles from external falling objects. c. Hand Rail Double hand rail of hot dip galvanised steel pipe, (32 mm nominal dia) shall be provided on all open sides of the fan deck and distribution basin cover. d. Locally Mounted Instruments The following instruments shall be supplied by Tenderer : Float switches and transmitter to indicate high/low levels in the basin Tenderer shall loan all necessary instruments required for testing the cooling tower. Low level oil indicator and annunciation in plant DCS (signal cabling will be done by others)
e. Vibration limit switch to stop the fan on excessive vibrations and annunciation in plant DCS
319
2.7.5
RCC Basin Concrete cooling tower basin with a common outlet channel shall be constructed. The structure shall designed as per IS:3370. Cooling tower basin shall be provided with partition for isolation purposes basin shall be water tight without the use of any fillers, paints or sealing compounds. The blowdown system should be constructed in the RCC basin with all the necessary isolation compartments, isolation valves/control valves, as per the standard practices and good engineering practice for each cell to enable controlling the blowdown cycle of CT basin water. Drain pipes should have valves and lead to the common drain.
2.7.6
Materials of Construction All materials of construction shall be of tested quality. These shall be free from defects, imperfections, of latest manufacture and shall be of certified quality for physical and chemical properties. Materials shall be of IS, ASTM, BS or any equivalent standard.
2.7.7
Tests and Inspection a. Performance Test Field erected units after complete erection and commissioning shall be field tested for performance. The test shall be conducted a time when the atmosphere conditions correspond to as soon as possible the design conditions. The test shall be conducted in accordance with the standard procedure for acceptance test of Cooling Tower Institute USA. The performance of the cooling tower shall be guaranteed over the following ranges: a) Cooling water flow 90% to 110% of design flow b) Cooling range 80% to 120% of design range c) Wet bulb temp (+) 1.70C to (-) 3.90C of design inlet wet bulb temperature.
320
Tests shall be conducted at the works on the fans, gear reducers drives etc., for satisfactory performance. Tests certificates for these shall submitted for Owners approval. Tenderer shall include in his bid for the supply and maintenance of all instruments for the duration of tests period. For the measurement of flow, during testing of cooling towers, Tenderer shall supply pitot tubes (calibrated) for each of the risers for each tower. Dry bulb and wet bulb temperature shall be measured by three identical mechanically aspirated psychrometers or Vick type located at three equidistant stations near each tower. The above thermometer shall be with graduations not exceeding 0.10C. All water temperature shall be measured with mercury in glass thermometers with 0.10C graduations The wind velocity shall be measured by means of anemometer An approved independent or National Laboratory shall calibrate all the instruments used b. Visual Inspection After completion of work, equipment shall be offered for visual inspection by Owner and/or his representatives. Any work or component not in accordance with the specification and approved drawings shall be redone or replaced to the specification of the inspector. Stage inspection if specified shall be offered to improve the quality of the final product. c. Painting & Protections All parts which are subjected to wetting and drying alternatively shall be painted with three water proof coats as detailed below : First coating Bronze 75% coal tar 25% Second coating Bronze 50% coal tar 50% Third coating Bronze 25% coal tar 75% All exposed steel and cast iron surface shall be given one coat of red oxide anti corrosive primer and 2 coats of enamel paint of approved colour.
321
2.8 2.8.1
FIRE FIGHTING SYSTEM System Requirement The fire protection system is required to ensure protection of the facility in order to combat an outbreak of fire, so as to reduce damage and consequential losses. The fire protection system includes fire detection, containment and suppression systems. The proposed fire protection system will be designed to provide adequate safety measures in the areas susceptible to fire in the power plant in compliance with the recommendations of the Tariff Advisory Committee (TAC) for insurance companies of India, so as to enable the Owner to obtain the available rebate on the insurance premium. The entire fire fighting system will have a centralised panel housing the required electrical, mimic of the system and will be hard wired to the centralised DCS to show the mimic and provide alarms. The indicative area wise requirement of fire detection and protection system will be as given below: SR. AREA NO. 1. Transformers above 5 MVA rating in Transformer Yard 2. STG Lube Oil Storage Tanks and Purifiers 3. Cable Vault in Electrical / Control Building 4. Control Room TYPE OF PROTECTION Quartzoid Bulb Detectors Automatic High Velocity Water Spray System Quartzoid Bulb Detectors Automatic High Velocity Water Spray System Ionisation type smoke Portable Fire detector extinguisher smoke detector Portable Fire & Photoelectric extinguisher smoke detector Portable Fire & Photoelectric extinguisher TYPE OF DETECTION
5.
Addressable of Ionisation type Switchgear Room, Addressable MCC Rooms in of Ionisation Control/Electrical type Building
322
SR. AREA NO. 6. Battery Room 7. Electrical Rooms in various Plant Buildings Generator
TYPE OF DETECTION -
TYPE OF PROTECTION Portable Fire extinguisher Portable Fire extinguisher
8.
9.
Conveyors
Automatic CO2 fire fighting system, as applicable Smoke detectors will be Pressurised water installed at all junction sprinkler system. towers, at all locations of fuel transfer and at every 30 m of conveyor length with interconnectivity to a water sprinkler system
Apart from the above station building, transformer yard, boiler area, pumps, compressor and fuel handling plant will be protected with hydrant system. 2.8.2 Indicative Bill Of Material The power plant falls under ordinary hazard category. Power house building, control room, switch gear room in control and other electrical building, battery room, pumps and other area will be provided with only portable fire extinguishers. Water for fire fighting purposes will taken from the raw water reservoir and stored in a fire water reservoir in the cogen premises.
323
2.8.3
Technical Requirements Fire Water Pumps All the fire pumps will be horizontal split case centrifugal type and jockey pump end suction type. Suitable priming arrangement will be provided in case pump is under suction lift condition of operation. All the pumps will be direct-coupled type. The pumps will have the following features: a. The pumps will be designed for continuous operation at their best efficiency points, which will be same as/close to the specified duty points. Pumps will have continuously rising head characteristic from the operating point towards shut off without any zone of instability and power capacity characteristic will be preferably non-overloading type. The operating range of the pump will be between 40% of rated flow & 150% of rated flow. The pumps head capacity curves will have a steady rise from 150% to zero flow. The jockey pump and the motor driven fire-water pumps will operate satisfactorily and continuously at run out capacity conditions. The maximum speed for all the main fire pumps will be 1500 rpm. The motor will be of continuous rating type and maximum continuous rating (at 500C ambient) will be at least 15% above the maximum load demand of the driven equipment, under the entire operating range. One of the main fire hydrant pumps shall be diesel engine driven.
b.
c. d. e. f.
g. 2.8.4
Hydrant System Pressurized fire hydrant system will consist of a pipe network and hydrants positioned around the station in sufficient numbers and so located that all buildings and risks are readily protected. Necessary number of loops will be formed around various risks. The loops will be interconnected for better reliability of the system. To isolate a portion of the ring main because of damage/repair, suitable nos. of valves will be provided.
324
The hydrant network will be sized and analysed to ensure that about 3.5 Kg/cm2 pressure is available at the hydraulically remotest point in the system with the hydrant pump discharging at rated head and capacity. The velocity in the hydrant main will not exceed 2 m/sec. Hose pipes of suitable lengths along with standard accessories like branch pipes, nozzles, spanners, etc. will be provided. These will be kept in a central hose house for the outdoor hydrants. Each internal hydrant valve will be provided with individual hose box having glass front containing hose pipes, hose reel, branch pipes and nozzles etc. Minimum running pressure will be 3.5 Kg/Cm2 at the base of each hydrant. The general design of hydrant valve will conform to IS: 5290. 2.8.5 Portable Fire Extinguishers Following types of portable fire extinguishers will be provided for the entire power plant area at strategic locations. a) b) c) d) 2.8.6 2 kg capacity dry chemical powder fire extinguisher. 5 kg capacity dry chemical powder fire extinguisher. 2 kg capacity CO2 type fire extinguisher. 5 kg capacity CO2 type fire extinguisher.
Piping System And Valves Both Hydrant and spray system piping will be run underground and through Hume pipe at road crossings. Piping will be of mild Steel pipes(galvanized or un-galvanized) of Medium grade confirming to IS: 1239/ 3589 or equivalent acceptable international standard and coating and wrapping as per IS:10221. Provisions will be made for extension of hydrant and spray system piping for future extension of the project. Piping for compressed air, breaching connections, drains, down stream of deluge valves will be of heavy grade galvanized type. All firewater piping will be capable of being drained completely and provided with drain cocks / valves at low levels.
325
2.8.7
Layout Considerations The fire water pumps, jockey pumps, diesel engine drives, etc. will be located in the water pump house adjacent to the raw water cum fire water tank. The firewater tank will be of concrete construction. Indicative plant layout is provided in Appendix IV.
2.9 PIPING AND FITTINGS 2.9.1 Piping All cogeneration plant piping will be as per applicable IBR / ASME standards. All piping will be aesthetically and neatly laid on pipe racks with approved colour coding. The cogeneration plant piping will inter-alia include raw water intake from the plant water reservoir, water treatment plant to boiler & auxiliaries, cooling water circulation, auxiliary cooling water circulation, plant service water, plant potable water, plant sanitation, compressed air ring, drain piping, treated effluent piping, steam piping from boiler to turbine, steam piping from HP line via PRDSH stations to LP & MP headers, HP / MP / LP steam piping to all cogeneration auxiliaries, steam piping upto LP & MP headers. Appendices IV, XII, VII, VIII and V provides the plant layout, typical pipe material specifications, CW system, plant water system and plant steam system. HP piping to be sized for highest safety valve pressure at 110% MCR with maximum pressure drop of 5 kg/cm for the entire piping. The pipeline will be duly approved by IBR by the Tenderer on the buyers behalf. Standard fittings like expansion loops, stream traps, supports etc. are to be provided. The line should insulated to suit weather conditions and preferably of ceramic blanket with mineral wool and aluminium cladding (22 g), to achieve skin temperature of not higher than 65C. Stress analysis for the HP piping to be submitted by the Tenderer along with IBR approved steam pipe drawing.
326
Piping design will be as per ASME B 31.1. All piping required for effectively connecting the steam generator with the steam, feed water, and other systems shall be provided. The piping provided shall be complete in all respects including valves, fittings, supports etc. as required. Necessary supporting materials, towers and trestles to support and anchor the pipelines at regular intervals shall be supplied. Suitable expansion loops and hangers shall be provided wherever necessary. The correct locations of hangers and supports, with as applicable spring stiffness, shall be considered for the flexibility analysis. Suitable expansion loops restraints and anchors shall be provided so as to ensure compliance with the applicable codes and to limit the stress and reactions to within the allowable values. i) The flow velocities in pipes shall be limited to the following values: Super-heated Steam.. Saturated Steam.. Cooling water.. 30-60m/sec depending on pipe size 20 to 35 m/sec Up to 3 m/sec
ii) Drains at all low points and vents at all high point shall be provided. iii) All local instruments shall be located on pipelines so as to render them observable from the nearest available platform. iv) Oil drains shall be sized to run no more than half full when flowing at a velocity of 0.3 m / sec, and shall be arranged to ensure good drainage. All high pressure drain or vent valves or other valves to be provided with one control & one isolating valve set, to prevent any passing of the operating valve. All pipe to pipe joints shall be by butt welding only and no couplings shall be used. All flanges, when provided #300 class and above shall be weld neck type.
327
Pipe fittings like elbows, equal tees and reducers shall be as given below: a) For pipe size 50 NB and above shall be butt welded type. b) For 40 NB and below shall be socket welded type. Branch connections: a) Socket welding half coupling, as per B16.11, for size NB 40 and below. b) Welded branch connections with proper reinforcements for sizes above NB 40. All pressure tapping for pressure applications above 40 kg/sq. cm. shall be of size NB 20 with two root valves. For pressures 40 kg/cm2 and less the size shall be NB 15 with one root valve. All thermo-well boss shall be one(1) inch NPT. The design of the piping system shall be based on the ANSI B37.1 code. In addition the statutory requirements Flexibility analysis shall be made for all piping systems with operating temperatures above 100C. The correct locations of hangers and supports, with as applicable spring stiffness, shall be considered for the flexibility analysis. suitable expansion, loops, restraints and anchors shall be provided so as to ensure compliance with the applicable codes and to limit the stress and reactions to within the allowable values. Drains at all low points and vents at all high points shall be provided. All local instruments shall be located on pipelines so as to render them observable from the nearest available platform. 2.9.2 Piping Synopsis for WTP 1. Service water for miscellaneous requirement about 5 m3/hr from service water pumps and to potable water with pumps DM water to feed water tank for make up (DM storage tank pumps) Neutralised effluent from neutralization pit / pump All distribution cogeneration plant within
2. 3.
All distribution within cogeneration plant Up to ETP with PVC pipe of appropriate size
328
4. 5.
Clarifier sludge from sludge pit Up to sludge drying beds in pumps ETP WTP Integral piping Includes piping from raw water reservoir to pretreatment plant From clarified water tank to DM plant and softening plant. From DM plant to DM storage tank
2.9.3
Piping Synopsis of Steam generator Complete soot blower piping from the tap off on the primary superheater header up to the individual soot blowers including all the pressure reducing station, valves and fittings. Feed water delivery piping from steam generator feed pumps up to the economiser inlet header to the steam generating unit, via the HP feed water heater. Feed water line from feed water transfer pump outlet to the de-aerator. Piping for high pressure and low pressure chemical dosing systems. Required steam condensate and MP steam piping for HP heaters. All the drain points provided for various equipment shall be suitably piped and brought up to plant drain. The piping shall be provided with necessary fittings like trap, valves, etc. The complete blow down piping up to the drain trench including all valves fittings etc. The blow down lines from each blow down valves of the steam generator shall be drawn individually up to the blow down tank. Cooling water piping wherever necessary.
329
The steam generator integral piping consists of all the interconnecting piping between the economiser inlet stop valve and the super-heater outlet header. The number of size and the arrangement of these integral piping shall be based on the permissible pressure drops in these pipes and the distribution required in the respective headers of the various sections of the steam generator. These piping shall be properly supported and provided with the required tapping, stubs and thermo wells for measurements. Test (sample) valves shall be provided to collect water/steam samples with necessary cooling arrangements in steam drum, mud drum, superheated steam header etc. Two control valves (pneumatic and motorised) of cast steel/alloy steel (located such its operator can see water level in gauge glass) capable of passing the required amount of water shall be provided. The steam generator shall have two water gauge glass units (suitable for visibility and reliability) at the top drum independently connect on each side with isolating valves such that when one is to be attended, the other one will be in line. One remote water level indicator at the operating floor to be provided. 2.9.4 Piping synopsis for turbine All piping required for effectively connecting the turbine with the subsystem shall be provided. Condensate from condenser will be returned to deaerator. The piping will be supplied in pre-fabricated condition. The piping provided shall be complete in all respects including valves, fittings, supports, etc. as required. 2.9.5 Piping synopsis for Compressed Air, Effluent All compressed air piping for service and instrument needs from compressed air receiver within the power plant will need to be carried out. All compressed air piping will be above ground and required drains and filters will be provided. All liquid effluent from all drains, blow down, neutralisation pit, ash system, etc. will be led through below ground drains or CI / RCC pipes though the power plant ETP. Treated effluent will be discharged from the power plant ETP to the boundary of the power plant.
330
2.9.6
Hangers and supports The Tenderer shall design, fabricate and furnish erection drawings for all hangers, anchors, guides, clamps, stops and supports, auxiliary structures, etc. required for the proper installation and support of the piping. It is desirable that supports should as far as practicable, be arranged adjacent to the pipe joint. Constant load hangers/ spring hangers shall be provided wherever necessary for critical piping systems such as main steam piping and steam generator feed delivery piping. The variation between hot and cold loads, if variable spring hangers are used, shall not exceed 25% of the rated load. Lugs and additional structural members should be suitably welded to the pipes wherever necessary for hangers and restraints.
2.9.7
Valves All HP valves to be 1500 Class (or as per IBR) and glandless 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 and of a higher rating than design pressure. Globe valves shall have preferable curved or spherical seating and the discs shall be free to revolve on the spindle. All non-return valves shall have an arrow cast or embossed on the side of the valve body to indicate the direction of the 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 will facilitate closing and prevent clatter.
331
The internal diameter of all valve ends to be connected to 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. Where applicable valves shall be of the outside screw and yoke type. Main steam stop valve shall be fitted with indicators so that percentage of valve opening can be readily determined locally. 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 Steam valves shall not be fitted in an inverted position. Eye bolts shall be provided wherever necessary to facilitate handling heavy valve or part of valves. 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 2150 mm and above and the rating above 600 Psig, bevel spur gearing shall be provided to facilitate manual operation. All sampling and root valves furnished shall be of integral body bonnet type. 2.9.8 Pipe routing a. HP pipe from boiler to turbine will be routed with required loops and bends to meet the allowable forces & movements. The Tenderer will submit the stress analysis. The piping will be routed in the boiler area taking support of the boiler columns and through the pipe rack between boiler and turbine area. This pipe rack could be below the connecting platform between the powerhouse and boiler operating floor. In the powerhouse area, the PRDSH stations will be located on top of the control room slab and HP pipe will then enter the powerhouse taking support of powerhouse columns and take entry to the turbine as per the STG design. The MP & LP extractions will be connected to respective headers placed at 0m level. Balance piping will include: process return condensate and other miscellaneous piping.
332
b. Cooling water piping will be routed in trenches below ground. Trenches will be provided at inspection doors and piping will be provided with suitable pipe wrap to avoid earth attack. c. Water piping from raw water reservoir to water treatment plant and onwards to all usage points will be laid on pipe racks. d. Compressed air piping from receiver to usage points will be on pipe racks and along boiler and powerhouse columns. e. Boiler feed water piping from powerhouse BFW bay will rise along the powerhouse building and later will be supported by the HP steam pipe rack. f. Fire fighting piping will be located in trenches as per TAC recommendations. g. The integrated piping layout including locations of all pipe trenches and pipe racks will be provided by the Tenderer during engineering for approval of Owner / Consultant. The pipe racks will be essentially located for aesthetic appropriateness and ease of man / material / vehicle movement. Minimum height of the pipe rack will be 5 m. All the pipe racks will be designed for existing pipe loads with 25% additional load bearing capacity. Typical design of the pipe rack on STADPRO or equivalent software will be submitted by the Tenderer to the Owner / Consultant during engineering. 2.10 PAINTING All metal scrubber shall be chemically cleaned, degreased and pickled in acid to produce a smooth surface, free of scale, grease and rusts. After cleaning, phosphating and passivation treatment, the surface shall be given two(2) coats of zinc rich epoxy primer and backing in the oven. Sufficient quality of touch up paint shall be furnished for application at site. All parts which are subjected to wetting and drying alternatively shall be painted with three water proof coats as detailed below : a) First coating Bronze 75% coal tar 25% b) Second coating Bronze 50% coal tar 50% c) Third coating Bronze 25% coal tar 75%
333
All exposed steel and cast iron surface shall be given one coat of red oxide anti corrosive primer and 2 coats of enamel paint of approved colour. i) All metal surface shall be thoroughly cleaned and degreased to remove mill scale, rust, grease and dirt. Fabricated structure shall be pickled and then rinsed to remove any trace pf acid. The under surface shall be prepared by applying a coat of phosphate paint and a coat or yellow zinc chromate primer. The under surface shall be made free from all imperfections before undertaking finishing coat. ii) After preparation of the under surface, the relay and control panel/desk shall be spray painted with two coats of final paint. Colour shade of final paint shall be Smoke Grey and shall be duly approved by the Owner before final painting is done. The finished panel/desks shall be tried in stoving oven in dust free atmosphere. Panel finish shall be free from imperfections like holes, orange peels, run off paint etc. The Tenderer shall furnish painting procedure details along with the bids. All unpainted steel parts shall be cadmium plated or suitable treated to prevent rust corrosion. If these parts are moving element then these shall be greased. Motor external parts 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 remove and treated with one coat of primer and finished with two coats of grey enamel paint. The motor fan shall also be painted to withstand corrosion. Appendix XIV provides the typical painting summary for exposed steel
iii)
334
2.11
ELECTRICAL EVACUATION SYSTEM 2.11.1 Broad Scope of supply a. Outdoor Switchyard : - 11 KV, (UE) 3Cx300 sq.mm, XLPE insulated, aluminum conductor armored cables for Supply to 11KV outdoor kiosk - Indoor type Heat Shrinkable cable end termination kit for 11 KV, (UE) 3Cx300sq.mm, XLPE insulated, aluminum conductor armored cables - 11KV Outdoor Kiosk with VCB - Outdoor type Generator transformer 11 KV/132KV, 20/25MVA, 50 Hz transformer with all accessories including OLTC, RTCC, AVR etc. - 145KV, 3 pole SF6 Circuit Breakers - 132 KV, isolators with earth switch and without earth switch horizontal operated with operating rod. - 132 KV, current transformers outdoor duty suitable to mount on the structure for metering and protection - Potential transformers outdoor type suitable to mount on the structure for 132 KV - Bus bar arrangement with structures, insulators, Al. tubes etc. - Complete steel structure with galvanized coating for mounting current transformers, PT, breakers, lightening arrestors, HT yard compound, etc. - 132 KV Insulators, LAs with necessary hardware. - Earthing and Lightning protection system including earth mat in switchyard. - Illumination system for switchyard. - Safety equipments in switchyard. b. Co- generation auxiliary systems : - Auxiliary transformers 11KV/433V, 2000 KVA 2 Nos. - Bus bar trunking from Aux. Transformers to Cogen Aux. Panel. - L.T. Panel for cogeneration plant auxiliaries having Incomer EDO ACBs and outgoing ACB / FSU for cogen plant auxiliary systems - APFC Panels with Capacitors.
335
MCC for Cooling Tower and Water Pumps L.T. Power, control cables and cable accessories up to incomer of system panels L.T. Power and Control Cables up to motors for Cooling Tower and Pump MCC Loads Earthing system for Cogen Plant Eqpts.. Illumination system for cogeneration plant including Lighting DB, panels, cables etc complete.
c. Panels : - 132 KV switchyard metering, relay and protection panel including Islanding and line protection relays. - Transformers control and relay panel. - Battery and Battery charger system with DCDB. - ACDB with MCB incomer outgoings d. Import and Export metering : Energy Import and Export meter 4 quadrant type for check meter having approved specifications of BSEB Associated cabling system.
2.11.2 Scope of work in services a. Design and engineering : Preparation of design calculations, detail drawings for switchyard and allied work. Preparation of cable layouts, Earthing Layouts and Lighting Layout drawings Preparation of cable schedule, interconnection schedule and detail BOQ. Preparation of foundation drawings and structural designs for switchyard equipments. Preparation of inspection plan and schedule. Preparation of schedule for site testing and commissioning. Preparation of relay co ordination schedule and synchronizing with generator protection relays including islanding scheme.
336
b. Erection and Commissioning : Inspection of civil work in foundations, trenches and allied jobs. Unloading, unpacking, shifting to locations, positioning, aligning and fixing of equipments. Pre-commissioning checks. Commissioning , testing and trials Completion of documentation and records.
c. Statutory approvals : Obtaining approvals on drawing and designs from BSEB, local Electrical Inspector and Chief Electrical Inspector authorities. Liaison with BSEB authorities for testing, tie up and commissioning of switchyard equipments. Arranging inspections and approvals for commissioning of total cogeneration plant electrical from Local and Chief Electrical Inspector PWD Liaison with TQ & A as well as O & M division of BSEB authorities for obtaining approvals on drawings, arranging inspections for metering CTs, PTs and other equipments, interlocks etc.
d. Inspections Making the arrangements for periodical and final inspection of all major equipments in the system at manufacturers works
2.11.3 Data Required Along with Bid All data sheets included in the tender should be duly completed and submitted along with bid. Single line drawing of the proposed electrical system to be submitted along with the bid. Plan and elevation of 132 KV HT switchyard to be submitted along with the bid. List of manufacturers of the major equipments like transformers, circuit breakers, meters, relays, panels, etc. to be submitted along with the bid.
337
The letter from transformer manufacturer confirming the transformer losses quoted by Tenderer. List of all shop and site inspection tests. The No Load and Full Load losses and regulations at 25%, 50%, 75% and 100% load and 0.8 and Unity P.F. on Generator and Aux. transformers.
2.11.4 Bill of Materials Sr. No. Particulars Indoor type, 11 KV, 40KA for 1 sec. switchboard in Cogen Plant comprising of Vacuum Circuit Breakers (VCB), having suitable CTs, PTs, metering and protective relays etc for following application, 1 No. Incomer VCB to receive power from 20 MW, 11KV Generator with metering and protection 2 Nos. Outgoing VCBs to cater Sugar Plant Load with metering and protection 1 No. Outgoing VCB for export power with metering and protection 2 Nos. Outgoing VCB to cater for cogen plant aux. power with metering and protection 1 No. Outgoing VCB with metering and protection as spare H.T. Outdoor Switchyard equipments Outdoor type Generator transformer of 11/132KV,20/25MVA,50Hz,ONAN/ONAF transformer with all accessories OLTC, RTCC and AVR Panel (including oil filtration at site) Outdoor type 11 kV,,2000A,40KA for 1 sec. VCB Kiosk with CTs, Relay, Load Manager etc complete 145kV, 40KA for 3sec.,1250A, 3 Phase SF6 Circuit Breaker with standard accessories Quantity
No.
1. a.
No. 1 2 1 2 1 No Nos No Nos
b. c. d.
e.
2. a.
No.
b.
No.
c.
No.
338
Sr. No. d.
e.
f.
g.
h.
j.
k.
l.
m.
n.
Particulars 145kV, 40KA for 3sec.,1250Amp. Double Break, Center Rotating Isolator with earthing switch having motorized operation with insulators base channel, aux. contacts etc. 145kV, 40KA for 3sec.,1250Amp. Double Break, Center Rotating Isolator without earthing switch having motorized operation with insulators base channel, aux. contacts etc. 132kV , 40KA current transformers, 5 core out door duty 150/1A suitable to mount on the structure for metering and protection 132KV potential transformers outdoor type 3 core, 132KV/V3 / 110V/V3 suitable to mount on the structure 132kV,40KA current transformers, out door duty 150/1A suitable to mount on the structure for check metering & tariff meter 132KV potential transformers outdoor type, 132KV/V3/110V/V3 suitable to mount on the structure for check metering and tariff meter Station class, Gapless type MO outdoor pedestal mounted Lightning Arrester with surge counter suitable for nominal system voltage of 132 KV, effectively earthed system having rated voltage of 120 KV and discharge current of 10 KA 145kV,40KA string insulators and suspension type insulators with required hardware suitable to mount on the structure for ACSR conductor Galvanized steel structure complete with hardware for mounting current transformers, PT, breakers, Lightning Arrestors, insulators, gantries and columns. etc. Switchyard chain link fencing and gates
Quantity 1 No.
Nos.
Nos.
Nos.
Nos.
Nos.
Nos.
Sets
Lot
Lot
339
Sr. No. o. p. q.
r.
Particulars Junction box for CTs, PTs secondary side connections Bay Junction box for CTs, PTs secondary side connections Rigid Aluminum tubular bus bars and ACSR ZEBRA conductor for line tapings supported on post /string insulators for interconnection between equipments with hardware etc complete Power Transformer protection Panel fabricated from 3 mm thick CRCA sheet steel duly painted / powder coated having all the control and protection equipments including but not limited to the following, a. Metering section with Voltmeter, Ammeter with selector switches, Frequency meter, Load Manager (Multi Function Meter) with KW, KWH, KVA, KVAR, P.F.,KVAH parameters with communication facility through RS 485 port and MODBUS protocol. b. Transformer Protective relays including Inst. Over Current and Earth Fault relay, IDMT Over Current and Earth Fault relay, Transformer Differential protection relay including ICT if needed, Transformer Restricted Earth Fault Relay, Under Voltage and Over Voltage relay, Annunciation, High speed Trip relay, Stand by Earth Fault Relay in Neutral circuit, etc. c. Line Protection and Islanding relays including Frequency relay, Rate of change in frequency (DF/DT) relay, Vector Surge Relay, Annunciation, High speed Trip relay etc. complete d. Control wiring complete for metering, protection section with control fuse fittings, terminals etc.
Quantity 10 Nos. 1 1 No. Lot
340
Sr. No. s.
t.
u.
v.
3. a.
b.
Particulars Indoor metering panel with check metering (export and import metering Electronic 4 quadrant type) SMF Lead Acid Battery, Float and Float cum Boost Battery Charger 40A and DCDB with 110VD.C.,150AH rating with stationary, tubular Battery set, stand, charger and standard accessories including 18 way 16 A, DCDB. Fire fighting equipment Fabricated stand with 4 Nos. Sand bucket of 13 Lit, Capacity filled with sand, cover etc complete CO2 fire extinguishers 22.5 kg capacity trolley mounted type Erection / commissioning of all the electrical equipments as per specifications given and good engineering practices Equipments in Cogen plant auxiliary Two winding step down Transformer for cogen auxiliary load outdoor application with rating of 2000KVA,11KV/433V,ONAN, Connection Dyn11, with OCTC with +5% to 10% in steps of 2.5% taps, having all standard accessories including but not limited to Buccholz Relay, WTI, OTI,MOG, Neutral CTs for Inst. Earth Fault and REF relay. Transformer to be supplied duly routine and heat run tested 415V,3200A, TPN, aluminium Bus bar trunking between 2000 KVA Transformers and L.T. Panel for cogen plant aux. supply with enclosure fabricated from 2 mm thick CRCA sheet with canopy for outdoor portion, duly painted /powder coated. The trunking shall have bends, flex. copper connections at transformer end, zinc passivated hardware etc. complete
Quantity 1 Set
Set
set
4 1
Nos. Lot
Nos.
set
341
Sr. No. c.
Particulars (Approx. Length of 15M each.) 415 Volts, Cogen Plant Auxiliary Panel fabricated from 2 mm thick CRCA sheet steel and painted/ powder coated as per shade 632 of IS 5, with following major components, a. 2 Nos. Air Circuit Breakers 3200 Amps, 4 pole, EDO with shunt trip & earth fault release for incomer cubicles for 2000 KVA transformers 1 No. Air Circuit Breaker 3200 Amps, 4 pole, EDO with shunt trip & earth fault release as Bus Coupler & and 630 Amps, 4 pole, EDO with S/C, O/C shunt trip & earth fault release for incomer cubicle for 250KVA DG b. 5 Nos. Outgoing feeders with TP, MDO Air Circuit Breakers 2000 Amps, 4 Nos. with 1000A TP,MDO ACB with shunt trip release, 2 Nos. Outgoing feeders with TPN, FSU 400 Amps, 2 Nos. TPN FSU 250A , 9 Nos. Outgoing feeders with TPN, FSU 125 Amps c. Bus bar sections with epoxy insulator supports and Al. bus bar sections suitable for 433V, TPN, 3200 A, 50KA for 1 sec. rating d. C.T.s for metering, protection having suitable accuracy class e. Metering section with Voltmeter, ammeter with selector switches, multifunction meters (Load Managers) f. Protective relays with 3 Phase IDMT over current, Earth fault relay complete g. Control wiring complete for metering, protection section with control fuse fittings, terminals etc
Quantity 1 set
342
Sr. No. d.
Particulars 415 Volts, MCC s for Boiler, Turbine, Cooling Tower , Water Pumps , Fuel & Ash handling and all cogen auxiliaries fabricated from 2 mm thick CRCA sheet steel and painted/ powder coated as per shade 632 of IS 5 a. 1 Nos. Air Circuit Breakers of required capacity, TPN, MDO with shunt trip & earth fault release for incomer and b. Outgoing feeders with TP, MDO Air Circuit Breakers of required capacity, Outgoing feeders with TPN, FSU of required capacity with starters as specified. c. Bus bar sections with epoxy insulator supports and Al. bus bar sections suitable for 433V, TPN, 1000 A, 50KA for 1 sec. rating d. C.T.s for metering, protection having suitable accuracy class e. Metering section with Voltmeter, ammeter with selector switches, multifunction meters (Load Managers) for incomer and Ammeter with Selector Switch for outgoing feeders. f. Control wiring complete for metering, protection section with control fuse fittings, terminals etc g. Local Control Station Al. die cast with ON, OFF Push Buttons and suppressed scale Ammeter of suitable range for the motors Self Standing Self Supporting VFD Panels with SFU, 6 Pulse Conv / Inv system, including required components for maintaining harmonic distortion within limits as per IEC
Quantity 1 set
e.
Set
343
Sr. No. f.
Particulars APFC panel with 400KVAR (8 x 50KVAR) APP type L.T. capacitors operated through digital APFC relay, individual FSU, capacitor duty contactor, PBs and indicating lamps aux. contactor, selector switches etc complete Cables and accessories Cross linked Polyethylene (XLPE) insulated, PVC sheathed,11 KV (UE), 3C x 300 sq. mm. Power cable having Aluminum conductor for connection between 11 KV switchboard and transformers Heat shrinkable indoor cable termination kits for 11 KV, 3C x 300 Sq. mm XLPE (UE), Aluminum Cable 1.1KV Grade, XLPE insulated, Aluminium conductor, armoured, Power Cables for inter phasing of all panels in the system, switchyard equipments, lighting etc. 4C x 6 sq. mm 4C x 16 sq. mm 3.5C x 35 sq. mm 3C x 50 sq. mm 3.5C x 50 sq. mm 3C x 120 sq. mm 3C x 185 sq. mm 3.5C x 185 sq. mm 3.5C x 300 sq. mm 1.1KV Grade, XLPE /PVC insulated, Copper conductor, armoured, Control Cables for interfacing of panels in the system, switchyard equipments and Lighting 3C x 1.5 Sq. mm 4C x 1.5 Sq. mm 7C x 1.5 Sq. mm 12C x 1.5 Sq. mm
Quantity 2 Sets
5. a.
3300
Meter.
b.
30
Set
c.
i ii iii iv v vi vii viii ix d.
1700 1400 350 800 250 450 1400 300 1400
M M M M M M M M M
i ii iii iv
350 900 900 750
M M M M
344
Sr. No. v vi vii e.
Particulars 3C x 2.5 Sq. mm 4C x 2.5 Sq. mm 7C x 2.5 Sq. mm Termination of all sizes of cables with single compression brass cable gland crimping type copper / Aluminum lugs ferrules consumables etc complete, as required GI, Ladder type prefabricated cable trays and accessories of suitable sizes for supporting the cables in tier formation to be laid in built up cable trenches with required MS angle supports having following sizes 600 mm. Width 450 mm. Width 300 mm. Width 150 mm. Width Earthing System Earthing arrangements for Entire cogen plant as per IS 3043, IS 2309 and IEEE 80, including earthing pit having 150 mm dia. CI pipe electrode funnel, CI chamber cover charcoal etc. 75 x 10 GI flat for switchyard earth mat and risers and main earthing grid 50 x 6 Cu flat for 20/25MVA power transformer and other transformer neutral earthing 50 x 6 GI Flat for earthing of various switchyard equipments 25 x 3 GI flat for lightning protection and lightning down comers 8 SWG GI wire 12 SWG GI wire
Quantity 4600 M 600 M 450 M Lot
f.
i ii iii iv 6. a.
750 200 150 150
Meters. Meters. Meters. Meters.
75
Nos.
b. c.
2500 125
Meters. Meters.
d. e. f. g.
600 250 400 400
Meters. Meters. Meters. Meters.
345
Sr. No. h. i. 7. a.
b.
c.
d.
e. f. g. h.
i.
8.
Particulars Lighting Ariel terminals with globe and spikes Test Link Boxes for lightning down comers Illumination system Main Lighting Panel with 125A MCCB Incomer and 8 Nos. 32 A 4P ELMCB outgoing feeders. Sub lighting DBs with 32 A 4P, ELMCB incomer and 18 Nos. 10A, SP outgoing MCBs Lighting poles welded construction 9m long with cross arm and hardware for mounting 150W HPSV street light fixture Lighting fixture 150W, HPSV Pot Optic Light fixture with lamp, control gear box etc complete Industrial High Bay Lighting fixture 250W, MH Lamps Industrial well Glass integral Lighting fixture suitable for 125W,HPMV Lamps Industrial Fl. Lighting fixture 2 x 40W, Lamps Control Panel for outdoor lighting with 32A,4P, ELMCB, Contactor 24 hr. timer and 6 Nos. 16A outgoing SP MCB with wiring etc complete Concealed Point wiring with PVC copper wiring of 1.0 sq. mm. and sub mains of 2.5 sq. mm. for office areas including molded switchboards and accessories (Average length from switch to fixture 10 m) High mast lighting fixture with 30 m high tower including cradle, motor operated mechanism, 8 nos. 400 W metal halide lamps Design, Detail Engineering and drawing preparation for the complete package
Quantity 10 Nos. 10 1 Nos. No.
10
Nos.
50
Nos.
50
Nos.
50 150 100 1
Nos. Nos. Nos. Nos.
150
Nos.
Nos.
lot
346
Sr. No. 9.
Particulars Miscellaneous items as per statutory requirements including but not limited to the following, a. Rubber mat of 12 mm thick with suitable length to be provided in front of all Panels, 11 KV switchboards, 415 V ACB Panels etc. b. Shock Treatment Charts in Marathi , Hindi and English in Glass frame. c. Sand Buckets 4 Nos. mounted on fabricated stand in switchyard. d. First Aid Box with necessary medicines, ointments etc. e. Rubber Hand Gloves suitable for 36KV system voltage, for operation of Isolator in switchyard. Liaison with BSEB and Electrical Inspector for drawing approval and Inspections including grid synchronizing etc complete
Quantity
100
Meters.
4 2 2 2
Nos. sets sets sets
10.
The quantities indicated above are as estimated and for bidding purposes. Tenderer will also provide unit rates for all above equipments for any variations in actual as build quantities 2.11.5 Technical Specifications : 132KV Switchyard equipments : The power evacuation arrangements from the cogeneration project is proposed to be done at 132KV Sub Station which is proposed within sugar mills campus at a distance of 500 meters from TG set building. The key single line diagram of electrical installation is enclosed with this document which shall be referred for the ratings of equipments.
347
132 KV Isolators : a. The isolators shall be outdoor, manually operated, horizontal, double break, center rotating type and suitable for mounting on structural members. The isolator operating mechanism shall be twist and turn type. The isolators shall be designed with suitable short circuit current rating of 40KA for 3 sec. The design shall permit breaking the charging current of 132KV transmission line. The isolators shall be suitable for operated on no load condition. The mechanical and electrical interlocking arrangements shall be made with circuit breaker to prevent the operation of Isolator on load condition. The ratings shall be as given in data sheets and key SLD. Creep age distance for insulators in Isolator shall be . 31 mm./ KV
b. c.
d.
e. f.
Lightning Arresters : a. Lightning arresters are proposed to be installed in switchyard at the locations given on Single Line diagram as per the ratings given. b. The lightning arresters shall be single phase, station type gapless construction, outdoor type. c. Suitable mounting structure shall be provided for lighting arresters. KA rating 10 KA, d. Creep age distance for insulators in Isolator shall be . 31 mm./ KV Current Transformers : a. 132KV Current Transformers shall be provided as per the ratings and locations given in data sheets and key SLD. b. The Current transformers shall be single phase, outdoor type, oil immersed dead/ live tank design. c. The current Transformers shall have the core arrangements as given in data sheets.
348
Potential Transformer : a. The potential transformer shall be of electromagnetic type to suit the functional requirement. b. The ratio and burdens shall be as given in data sheets and SLD. c. The PT shall be single phase, outdoor type oil immersed design. Bus bar system : a. The bus bar system comprising of insulator supports and bus bar sections. It is proposed to use tubular Aluminum conductor and post insulators for connection between equipments. b. For interfacing all the equipments with strain insulators with ACSR ZEBRA conductor shall to be used. Suitable type and number of connectors are to be provided in both the cases. c. The bus bar size shall be suitable to carry the normal and short circuit currents as specified. d. Clamps made from aluminum alloy shall be used for end terminations. Supporting Structures : a. The supporting structures shall be provided for insulators, CTs, PTs, Isolators, LAs etc. b. The structures shall be of bolted type construction and fabricated from GI material. c. The structures also include towers and beam structures required for 132KV incoming lines. d. The structure designs shall be made considering the minimum ground clearance of 4.6 M required as per IE rules. e. The structure designs shall be suitable for the wind pressure of 150 Kg / mm2, Wind Velocity of 50M/sec. and site temperature of 50C. f. The design calculations for structures shall be submitted for approval.
349
2.11.6 Generator Transformer : This transformer is generator transformer proposed for power export to 132KV grid. However, the transformer shall necessarily be suitable for bidirectional operation. The OLTC design in transformer shall be modified to this requirement. Sugar Complex and Cogen Plant auxiliary power in the tune of 10MVA will be made available by BSEB grid through this transformer. The transformer shall have following specifications, a. Construction : Transformer tank shall be of welded sheet steel construction and provided with gaskets steel cover plates. Base shall be suitably reinforced to prevent any distortion during lifting. Base channels shall be provided with skids and pulling eyes to facilitate handling. All covers and seals shall be oil and air tight and shall not be affected by mineral oil or synthetic oil action. Detachable radiators equipped with air vent drain plug and lifting lugs shall be provided with cut off valves to permit removal of any radiator unit without emptying the tank. Radiators shall be securely braced to prevent undue vibration. All fasteners and bolts etc. shall be galvanized or zinc passivated. All surfaces to be painted shall be thoroughly cleaned, descaled, made free from rust and given a priming coat of rust resisting paint followed by two finishing coats of approved shade. Paint shall be suitable to withstand specified atmospheric conditions. b. Terminals and marshalling box : Windings shall be brought out and terminated on terminal bushings and cable box. - Cable end box shall be supplied with cable lugs & glands. The lugs shall be non-soldering, long barrel, crimping type - Terminal chamber for cable box shall have gasketed cover plate bolted to it.
350
Marshaling box shall be weatherproof, waterproof with IP 55 enclosure. All protective devices and neutral CTS shall be wired by means of PVC insulated armored cables up to the marshaling box. Terminals shall be bolted type only. Removable gland plate with compression type glands of non-magnetic material shall be provided.
c. Cooling : The cooling of the transformer shall be ONAN / ONAF. The operation of forced air circulation fans shall be controlled automatically by temperature in oil tank.
d. Oil : The Transformer shall be supplied with first filling of oil. Additional 10% quantity of oil shall be supplied in sealed drums. The cost of the additional oil shall be included in tender. e. Accessories : Following minimum accessories shall be necessarily included in the scope of supply in addition to the accessories required as per CBIP guidelines. Oil conservator complete with oil filling plug & cap. Oil drain valve & magnetic oil level gauge . Silica Gel Breather It shall be mounted such that the silica gel shall be visible from the ground level and the breather is removable from the ground. Shut off valve between conservator & main tank. Explosion relief vent mounted on the tank with double diaphragm & equalizer pipe. The explosion vent shall be rotatable in all directions. Air release plugs. 150 mm dia. magnetic oil gauge with low level alarm and trip contact.
351
150 mm dia. oil temperature indicator with maximum reading pointer and a set of contacts for alarm and trip. 150 mm dia. winding temperature indicator with maximum reading pointer and set of contacts for alarm & trip. Thermometer pocket with mercury in glass thermometer (0-120 C) Bottom drain valve- with pipe nipple. It shall be possible to drain off 90% of the oil within 10 minutes. Sampling valves with plug. Filter valves with threaded adapter top & bottom. Inspection cover on top plate. Two grounding (Earthing) Pads placed on opposite sides with tapped holes, M-12 Bolts and spring washers. Jacking pads, hauling lifting lugs. Bidirectional Flanged Wheels. Rating plate. terminal marking plates & name plates. Double Float type Buccholz Relay with Alarm and Trip contacts. Cable disconnection chamber for LV side. Neutral CT on HV side for Restricted Earth Fault and Stand by Earth Fault. Forced air Circulation Fans with required control gear and support structures.
g. Core and winding : Transformer shall be double wound, core type with cold rolled grain oriented lamination perfectly insulated and clamped to minimize vibrations and noise. Care shall be taken to insulate core fastening bolts to reduce losses and avoid hot spot. All parts of the magnetic circuit shall be bonded to earth. Windings shall be of copper and shall be designed to withstand the specified thermal and dynamic short circuit stresses.
352
h. Tapping : On Load Tap Changing arrangement shall be provided on High Voltage side of the transformer. The OLTC mechanism shall be provided with Oil surge relay, Automatic Voltage Relay and RTCC panel. Under conditions of external short circuit, the tap changing equipment must be capable of carrying the same current as the winding.
i. Inspection and testing : Owners representative shall be given free access in the works from time to time for stage inspection & progress reporting. Tests shall be carried out at manufacturers works at his expenses in presence of the Onwers representative. All routine tests as specified in IS 2026 shall be conducted. Heat run test and type tests as per IS 2026 shall be conducted on the transformer at manufacturers works. Impulse Test shall be carried out on all three phases of H.V. winding of the transformer.
j. Packing and transport : The main tank shall be oil filled during transportation. All accessories shall be packed separately during transportation. Care shall be taken to pack the radiators such that radiator fins are not damaged during transportation. Packing dimension shall be furnished much in advance of transportation. All accessories shall be wrapped with polythene sheets before packing. All valve flanges including those for the radiators shall be closed by blank flanges.
353
2.11.7
Earthing : Earthing arrangement in 132KV switchyard shall be strictly as per the statutory regulations. The earthing shall include, Provision of earth electrodes for LAs, switchyard equipments, body earthing, T.G. set Alternator , D.G. set Alternator Neutral and Body earthing, Transformer neutral earthing, earthing of structures, earthing of Boiler ESP transformers earthing to motors in Cooling tower and Pump motors etc. Provision of earth mat as per IEEE 80. Provision of lightning conductor over 132KV switchyard. Provision of earthing grid conductor as per fault level considered. Lightning protection of Cogen Plant buildings including Earthing Electrodes for Lightening, Down comers, Test Link boxes etc.
The measurement of soil resistivity shall be done by Tenderer after award of the assignment. For design purpose, the soil resistivity value of 100 meter shall presently be considered. The earthing in switchyard shall have following specifications, a. The entire earthing installation shall confirm to IS 3043 b. Earthing electrode shall be CI Pipe type. c. The earthing electrode shall be 150 mm diameter 3M long C.I. pipe buried under ground up to the level of 2.5 mtrs. d. Earthing terminal shall be complete with watering pipe, funnel screen & earthing bus bars. e. Earthing pipe buried under ground shall be surrounded by 300 mm thick homogeneous layer of charcoal and salt..
354
f. Earthing chambers shall be provided with CI covers of size 450mm x 450 mm or with circular cover having 600 mm dia. e. All the material required for the earthing system shall be supplied and installed by the Tenderer. The main grid conductor shall be hot dip G.I. strips of 75 mm x 10 mm size. f. All the material required for making earthing stations/ pit like plate, charcoal, salt etc. shall be supplied by the Tenderer. g. The entire earthing installation shall be done in accordance with IS specifications and standard engineering practices. h. The entire earthing system shall fully comply with Indian electricity act and rules, The Tenderer shall carryout any changes desired by the electrical inspector & state electricity board authorities in order to make the installation conforming to I.E. rules at no extra cost. i. The main earth grid shall be laid at a depth of 600 mm below Ground level. In case of built in trenches, earth strip shall be laid along the trench and shall be firmly cleated to the wall or cable supports. It shall be protected against mechanical damage. Joints and tapping in the main earth grid shall be made in such a way that reliable and good electrical connections are permanently ensured. All joints below grade level shall be welded and suitably protected by giving two coats of bitumen and covering with tar tape. j. When the earthing strips are joined together minimum overlap of 100 mm shall be provided. To have better joint, the overlapped portion shall be properly welded and covered with tar tape o. Conduits in which cables have been installed shall be earthed bonded and earthed. Cable amour shall be earthed at both ends by providing GI/ copper clamp and PVC wire of suitable size near each cable gland. p. The electrodes shall be tested for earth resistance by means of standard earth tester. q. A disconnecting facility shall be provided for individual earth pit to check earth resistance. r. Earthing system includes provision of earthing to switchyard equipments, structures, panels etc. with suitable earthing conductor.
355
s. All paint, scale and enamel shall be removed before earthing connection are made. t. Anchor bolts or fixing bolts shall not be used for earthing connections. u. Entire earthing system and lighting protection system shall be tested for continuity by earth testing equipment after completion of the installation. v. Earth resistance value shall be checked and verified. If it is high then corrective measures such as addition of earth pit shall be taken to obtain desired value. w. The record of earth resistance and test results shall be maintained for future reference. 2.11.8 132KV Control and Relay Panel : Scope of Work The scope of design, manufacture, testing and supply of equipment covered under this specification shall include but not necessarily be limited to the following: a. Design, engineering and fabrication of panels / desks as per the specifications. b. Supply and mounting of all the equipment and auxiliary equipment like auxiliary relays, test switches, test blocks, plugs, timers, indicating instruments, etc., necessary for satisfactory functioning of the control and protection of the turbine generator systems. c. The protection system shall be provided with additional auxiliary contacts for the purpose of Data Acquisition system. d. All internal wiring between all equipment up to the terminal blocks and the inter panel wiring. e. Preparation and furnishing of all date /drawings/ documents as per the tender requirement and specifications. f. Testing at works of the panels and the mounted equipment.
356
Design Requirements a. Constructional Features The control panels shall be 'Simplex' type for the relay and metering panel. Panels shall be sheet steel enclosed dust and vermin proof floor mounting, free standing, formed on a framework of standard sections. The enclosure shall be of cold rolled sheet of 2mm thick. Panel supporting structure shall be so designed to form a rigid structure. All doors and openings shall be provided with neoprene gaskets. The panels / desks shall be suitable to be installed on a base frame supplied in one-piece along with foundation bolts. These base channels shall be despatched 3 months in advance to the despatch of panels so that they can be buried and grouted in the concrete floor. Amply dimensioned oblong holes shall be provided at the bottom of all the panels for their installation on base frame in addition the panels shall have an additional base channel at the bottom with smooth surface. A suitable removable un drilled gland plate shall be provided for cable entry from bottom. Suitable double compression type cable glands for control cables of sizes, quantity and material shall be included in the scope of supply.
b. Mounting All instrument and control gears and relays shall be mounted on the front. All equipment shall be flush or semi-flush type. Checking and removal of components shall be possible without disturbing the adjacent equipment. It shall be possible to set all the measuring relays 'insitu'.
357
All mounted equipment inside the panels /desks shall have "identification tags of self sticking Engraved tapes, in addition identification numbers shall be pained on panel wall to give permanent identification mark. The mounting of terminal blocks and any other auxiliary equipment such as transducers, interposing CTs etc, shall be done in such a way so as to be readily accessible but without impeding the access to internal wiring and components. The centre line of switches, push buttons and indicating lamps shall be not less than 750 mm from the bottom of the panel. The centre line of relays, meters, and recorders shall not be less than 450 mm from bottom of the panel. All switches, push buttons, indicating lamps, relays, etc., shall be neatly arranged in a matching manner. The control panels/desks shall be matched with other panels/desks in dimension, colour and mimic.
c. Wiring All wiring shall be done with PVC insulated, 650 V grade, single-core multi strands (minimum 3 strands) annealed copper conductors suitable for temperature and humidity specified. The cross sectional of the wires for voltage, current and control circuits shall be 2.5 Sq.mm. and that for the alarm circuits shall be 1.5 Sq.mm., the wires shall be vermin proof and shall be laid in plastic gutters. Each wire shall be identified at both ends with wire numbers by means of PVC ferrules. Colour coding for the wires shall be as per IS:375. The terminal boards shall be set at 45 Deg. to the side panels for easy access. Minimum 20 % spare terminals shall be provided on the panels. The bolted type terminals shall be suitable to receive crimped wires to give positive connection. All terminals shall be properly shrouded against accidental contact.
358
Sufficient terminals shall be provided so that not more than two wires are connected to each terminal. The terminal blocks shall be 600 V grads 10 amps rated, one piece moulded complete with insulated barriers, stud type terminals, washers, nuts and lock nuts and identification strips. Clip on terminals shall not be used in this panel. Terminal blocks for the CT and PT secondary leads shall be provided with test links and isolation facilities. Also CT secondary leads shall be provided with short circuiting and earthing links. d. Painting All metal surface shall be thoroughly cleaned and degreased to remove mill scale, rust, grease and dirt. Fabricated structure shall be pickled and then rinsed to remove any trace of acid. The surface shall be prepared by applying a coat of phosphate paint and a coat or yellow zinc chromate primer. The under surface shall be made free from all imperfections before undertaking finishing coat. After preparation of the under surface, the relay and control panel/desk shall be spray painted with two coats of final paint. Colour shade of final paint shall be Opulence Green and shall be duly approved by the Owner before final painting is done. The finished panel/desks shall be tried in stove oven in dust free atmosphere. Panel finish shall be free from imperfections like holes, orange peels, run off paint etc. The Tenderer shall furnish painting procedure details along with the bids. All unpainted steel parts shall be cadmium plated or suitable treated to prevent rust corrosion. If these parts are moving element then these shall be greased.
359
e. Panel illumination Compact Fluorescent Lamps working on 240 V AC, operated by door switches shall be provided for internal panel illumination. A 240 V, 1-Phase, 5Amp, 3 Pin Socket shall be provided in the panel corridor or interior of each cubicle with on-off switch for connection of hand lamps. This socket shall be metal clad type with a spring loaded flap.
f. Earthing A continuous 25mm x 3mm copper (tinned) shall be provided running along the full lengths of the panels. Suitable arrangement shall be provided at the two ends for connection to the plant earthing system. Each panel and the equipment mounted on each panel shall be securely connected to the earth bus. For this purpose, the earth wire shall be looped from equipment to equipment and both ends of the earth wire shall be connected to the earth bus.
g. Space Heaters Panel space heaters shall operate off 240 V AC and shall be supplied complete with on-off switch, fuse and thermostat. A common thermostat shall be provided for the entire panel. The thermostat shall maintain the internal temperature above the ambient temperature to prevent moisture condensation.
h. Mimic Mimic diagram shall be provided on panels. Mimic diagram shall be screwed on to the panels / desks and shall be made of anodised aluminium or plastic of approved fast colour. The mimic shall be 10 mm wide for horizontal run and 5 mm wide for vertical run.
360
Semaphore indicators used for isolator positions, they shall be so mounted in the mimic that isolator (or breaker) closed position shall complete the continuity of the mimic. The mimic diagram shall incorporate red and green lamps for isolator position indication and controlling switches with indicating lamps for breakers. The lamps will remain steady where the hand operated semaphore position correspond with the breaker position. The lamps shall flicker with a time delayed alarm if the semaphore position does not correspond with the breaker position.
2.11.9 Equipment Specifications a. Instruments All instruments shall be switchboard type, back connected, flush mounted, dust tight and tropical zed. They shall be of square pattern and comply with IS:1248 and shall be of accuracy class 1.0. They shall have 90 Deg. scale range. Zero adjustment for pointers shall be accessible from the front of the instruments. All auxiliary equipment such as shunts, transducers, interposing C.T./V.T. etc. that are required shall be included in the scope of supply. All instruments shall be subjected to an applied potential test of 2.0 KV for one minute. Whenever specified, digital meters shall be proved to indicate frequency and power factor parameters. Frequency Meters The Frequency Meters shall be long range, calibrated for 45-5055c/s. These shall be digital type and shall operate off 110 V AC.
b. Indicating Lamps These shall be multiple LED type of low power consumption, lamps shall be supplied complete. Lamps shall be provided with screwed translucent covers to diffuse light. The lamp covers shall preferably be unbreakable, moulded, heat resistant material and shall be provided with chromium plated bezels.
361
c. Control Switches All control switches shall be rotary, back connect type having cam operation contact mechanism. Phosphor bronze contacts shall be used on switches. The handle of control switches used for circuit breaker operation shall turn clockwise for closing and anti-clockwise for tripping and shall be spring return to natural from close/trip with lost motion device. Each switch shall be provided with external red and green indicating lamps. Ammeter selector switches shall be with make before break feature and shall have 3 - position, suitable to read phase voltages. d. MCB for Control circuits All control circuits shall be provided with suitably rated MCBs. These shall generally be mounted on the top half of the panels. All MCBs shall be provided with suitable identification labels. e. Annunciation Facia type static annunciations shall be provided on the control panels/desks wherever called in the equipment list. There shall be one translucent window for each alarm for point with engraved inscription. Number of windows shall be as per the equipment list. Unless stated otherwise, the annunciations shall be suitable for operation with normally open fault contact which closes on a fault. One common audible alarm, one common acknowledge push button, reset one push button and one 'all lamp test' push button shall be provided common to all annunciations. On occurrence of a fault(s) one of the following alarm sequences shall be followed.
362
D. C. supply failure indication shall be provided separately with DC under voltage relays. On failure of DC supply to the panel, a lamp and a horn operated off AC shall operate. There shall be provision for cancelling AC horn. The DC bell and AC horn shall have distinctly separate tones. Standard Alarm Sequences A. Flashing Alarm with manual reset Alarm Indicating Visual Module Audible Condition Contact Lamps Alarm Normal Off Alert Abnormal Flashing On Accept Abnormal Steady-on Off Return to Normal Steady-on Off normal reset Normal Off B. First out sequence with flashing alarm & manual reset Alarm Indicating Visual Module Audible Condition Contact Lamps Alarm Normal Off Alert First out Abnormal Flashing On Subsequent Abnormal Steady-on Off Accept Abnormal All steady-on On New Alarm Abnormal Flashing On Subsequent Abnormal Steady-on On Accept Abnormal All Steady-on Off Return to Normal All Steady-on Off normal Reset Normal Off
363
C. Relays All relays shall be switchboard pattern, back connected draw out type suitable for flush mounting and fitted with dust tight covers. The relays confirm to IS:3231 or BS:3950 and BS142. The relays shall be of Microprocessor based and communication type with RS 485 port. A set of test block and test lead for necessary secondary injection tests shall be included. All relays in draw out cases shall have suitable spring loaded contacts for inserting test block. Relays shall be provided with hand/auto reset type contacts and flag indicators. The flag indication shall be suitable for external hand resetting and mechanically interlocked to prevent falling when relays is subjected to vibration. The rating of the auxiliary contacts shall not be less than 5 amp at 240 V AC and 1.5 amp for 110 V DC.. All the circuit breakers controls shall be supplied with trip circuit supervision relays. D. Name and Identity Plates All instruments, relays and other electrical devices mounted on the control panel shall be provided with plates bearing the manufacturers name, serial number and the electrical rating data. Plastic plate at least 10 mm wide bearing suitable identification marks shall be fixed in the interior of the switchboard, at the test blocks, at the fuse blocks and the cable terminals. Similar plates shall be fixed to the exterior of the switchboard in appropriate places to indicate the functions of control switches, push buttons, lamp and other equipments not incorporated in the mimic diagram.
364
Brass or plastic plates bearing respective circuit designation of 50 mm width etched in 40 mm high letters shall be mounted on the front side and back side of each panels shall be supplied and fixed in a such way that these can be removed and refitted when desired. Instrument Tagging Each equipment shall have a rust proof metal tag permanently attached to it with the tag number.
E. Auxiliary PT & CTs Necessary auxiliary potential transformers for open delta potential polarisation and auxiliary current transformers, wherever required, shall be included in supply. Auxiliary CTs required for summation of two or more feeders and auxiliary PTs required for galvanic isolation of different synchronising inputs shall be included. The instrument transformers shall have the following accuracy class Potential Transformer Measurement Protection Current Transformer Measurement Protection Differential F. Load Managers Load managers shall be provided to indicate all operating electrical parameters in single unit. These Load Managers shall have a communication port with Modbus / Universal protocol for communication with PLC/ SCADA system. Necessary hardware and protocol shall be included in the cost of this panel.
3P
0.2
0.2 5P20 PS
365
f.
Inspection and Tests Following tests shall be carried out on the control panel desks in the presence of Owner or his authorised representative : - Checking of correctness of wiring of circuits and continuity. - Electrical control, interlock and sequential operation test. - High voltage test 2000 volts to earth for one minute. - Insulation resistance of the complete wiring with all equipment mounted on the panels/desks. - Routine tests according to the standards followed by the manufacturer on the instruments, relays and other devices. - D.C. tests. Certified copies of all routine test certificates shall be submitted to the purchase before despatch for review by the Owner.
2.11.10 11KV Switchboard and L. T. Panels : a. General technical specifications : The panel shall be self supporting, free standing, floor mounted, modular type with construction having degree of protection of IP 54 as per IS 2147. 11KV Switchboard shall be fabricated from 2.5mm thick CRCA sheet steel. L.T. panels shall be fabricated from 14 SWG CRCA sheet steel for frame & load bearing surfaces. Partitions may be fabricated from 16 SWG CRCA if no components are mounted on them. The panel shall be painted with 2 coats of primer after pre treatment and 2 coats of Polyurethane / epoxy paint with shade 631 of IS 5. Alternately epoxy powder coating shall be done in place of paint. Stiffeners shall be provided at corners & between modules to make panel rugged. The stiffeners will necessarily be required for relay compartments or doors where heavy components are mounted. The open able covers shall be provided with lift off type hinges, quarter turn door locks and flexible copper wire for earth connection.
366
The panel shall be dust and vermin proof. Synthetic or neoprene gaskets shall be provided at all openings The panel shall be of dead front construction suitable for front operated and back maintained functioning. Panel shall be provided with fl. lamp of 20 w capacity operated by door operated limit switch. Panel shall also have space heaters and thermostat arrangement. Panel shall be provided with 3 pin switch socket combined unit of 5 Amp capacity. Lifting hooks shall be provided at the top of the panel. The hardware components used in the panel shall be hot dipped galvanized. The control components shall be fixed on mounting plate by drilling & tapping. Aluminum anodized legend plates shall be provided for all the components. For components mounted on front fascia, legend plate from inside shall also be provided. Pretreatment by 7 tank process shall be done before painting / powder coating the panel. Panel shall be have provision of drawing pocket. The panel shall be designed to ensure maximum safety during operation inspection, connection of cables and maintenance. Inside panel, checking and removal of components shall be possible without disturbing other units. Cable entries will be from bottom. The opening of cable entry shall be covered by 3 mm thick gland plates. The panel shall be provided with all necessary components / devices and instruments as per the enclosed schematic diagram and functional requirements. The components such as protective relays, auxiliary relays, push buttons, switches, instruments shall be flush mounted on the front side of a panel. The control wiring shall be done with PVC insulated flexible copper wire. For CT secondary circuits 2.5 sq.mm. wire shall be used. For control wiring 1.5 sq.mm. wire shall be used. Earthing bus bar of suitable cross section shall be provided throughout the length of panel.
367
The panel shall be fully wired All the terminals shall be brought out for cable connections. 10 % spare terminals shall be provided on each terminal block. Separate terminal block shall be provided for different voltages. All wire shall have P.V.C. ferrules as per wiring diagram. Proper shrouding to incoming and outgoing terminals shall be provided to ensure safety during operation, inspection and maintenance. Indicating lamps shall be with multiple LEDs & shall be suitable for the voltage specified . All the components in the panel shall be properly labeled. The labels shall be made of non rusting metal or engraved PVC material properly fixed by screws. The panel layout shall be made in such a way that it will always facilitate easy removal and reconnection of control cables without disturbing other wiring. Centre lines of control switches, push buttons and indicating lamps shall be matched so as to give neat appearance. Similarly top lines of indicating instruments and relays shall also be matched. The panel shall be provided with electrolytic grade aluminum bus bar of suitable cross section so as to maintain max current density of 0.75 AMP/ Sq. mm. Bus bar sizing calculations shall be submitted along with drawings for approval. Bus bars shall be provided with color coded heat shrinkable sleeves. The bus bar joints in 11KV switchboard shall be provided with shrouds. Bus bars shall be supported by high quality epoxy insulators provided at specified distances so as to withstand to the given short circuit withstand current.. The bus bar chambers shall be provided with suitable ventilation arrangements so as to limit the maximum temperature of 85C while carrying rated current. Proper clearance of minimum 25mm shall be maintained between phase bus bars and between bus bars for L.T. panels. For 11KV switchboard minimum clearance of 125mm shall be maintained.. The panel shall be inspected at manufactures works before dispatch to site.
368
All routine tests shall be carried out on the panel in presence of Owner or his representative. These tests shall include following, a. Verification of components ratings and operation. b. High voltage measurement test. c. Insulation Resistance measurement. d. Control testing. Approval on following drawings shall be obtained before manufacturing the panels a. General arrangement drawing. b. Wiring Diagram. c. Detail bill of material. d. Type test certificate
2.11.11 Battery, Battery Charger cum DCDB : Battery, Battery Charger cum D.C.D.B. shall have following specifications, a. Construction : The specifications for construction of Battery Charger cum DCDB panel shall be same as that of LT panel given in earlier section of this document. b. Component Specifications : (i) Batteries : Batteries are the main component in this panel. The batteries shall be Sealed Maintenance Free (SMF) type. Batteries shall be free from orientation constraints, eco friendly, and ready to use. The same shall be long service life and shall have low self discharge. The battery used in this panel shall have excellent charge retention capability. SMF battery used shall have high rate of discharge and is expected to have highest functional reliability.
369
In addition to the above requirements, batteries shall have following specifications a. b. c. d. e. Type:- Lead Acid Stationery sealed type, storage battery set. Rating 110V D.C., 150 AH at 8 Hr rate of discharge. Standard: IS 1651 1979, Performance as per JIS C 8702 Container : Plastic Resin , ABS or PP Terminal posts : Designed to accommodate external bolted connections suitably.
(ii) Battery Charger : The battery charger unit shall have following specifications, - Charger shall be of Constant Potential type with current limiting facility. - Charger shall have provision to change the charging voltage on the front panel. Normal charging voltage shall not exceed 2.25 volts per cell. - MCB of suitable rating shall be provided as incomer to charger. The rating shall be suitable for battery short circuit current. - D.C. output voltage during float charging shall be stabilized within 1% of the set value of D.C. bus voltage for variation in parameters as follows, Input A. C. voltage : 10% Input Frequency : 5% D.C. Load variation 0 to 100% - The ripple contents shall be within 3% of the nominal D.C. rated voltage. - Load Limiting feature of charger shall be designed for short time overload to take care of intermittent loads coming on D.C. bus. - All PCBs shall be of plug in type, If more than one PCBs are to be provided in panel then the same shall be interlocked to prevent insertion in wrong slot. - Normal operating condition shall be indicated by LED mounted on PCB.
370
The boost charging voltage shall be adjustable between 70% to 100% of max. value of 2.45 volts per cell. Boost charge current shall have provision for adjustment between 30% to 100% of its maximum value. Battery charger panel shall be provided with one potential free contact for collective trouble in battery charger system. This contact shall be wired up to terminal block for interfacing with Master Control Panel. Following minimum protections shall be provided in charger, Charger shall go in current limiting mode if battery current or charger current exceed the set value. Charger shall trip in case input voltage decreases beyond set value. Charger shall trip in case of D.C. voltage is increased. D.C. current is increased beyond set value. Following indications, metering and protections shall be provided on battery charger unit, A.C. input supply ON, D.C. supply ON, Charger ON, Battery on LOAD, Battery under voltage and over voltage, Battery Charger Failure, Input A.C. supply Voltmeter with selector switch, Input A.C. Ammeter with selector switch, Output D.C. supply Voltmeter with selector switch, Output D.C. Ammeter with selector switch, Under voltage Relay to isolate battery from load when voltage drops less than 80 % of set value. Fault annunciation such as control card failure, thyristor failure, fuse failure etc. Charging voltage and current adjustment potentials.
371
c. Panel Wiring : All the components discussed in earlier section of this document shall be supplied completely wired and in ready to interface condition at the terminal strip. The wiring inside panel shall be carried out with 1.1 KV grade P.V.C. insulated stranded copper conductor wires. Minimum conductor size for wiring shall be 1.5 sq. mm. For control wiring. For D.C. circuits 4 sq. mm. Wires shall be used. Wire terminations are to be made with crimping type tinned copper lugs which firmly grip the conductor and insulation. Each wire shall be terminated with separate lug. Engraved P.V.C. ferrules shall be provided for each wire corresponding to the approved wiring diagram. The ferrules shall be firm and shall not come out on disconnection of wire from the connector. Clip on type connectors shall be used for all terminal blocks with suitable barriers end clips, terminal studs and hardware. All terminals shall have identification marks/ nos. Not more than two wires shall be terminated on any terminal. The rating of terminal block shall be suitable for current rating with minimum size of 6 sq. mm. Separate terminal blocks shall be provided for different voltage levels. 2.11.12 Bus bar trunking : The bus trunking shall be suitable for 3 phase 4 wire, 433 V 50 Hz, 0.8 power factor and rating as given in SLD. The bus trunking shall be connected between LT side of transformers to the L.T. Panel and between L.T. Panels as per SLD. The bus bars shall be EC 91 E grade Aluminum as per relevant standards. The earth bus bar of GI Strip 75 X 10 mm shall run through out the length of the bus trunking. All the above bus bar shall be mounted on epoxy type insulators at equal intervals The bus trunking shall be fabricated from 2mm thick CRCA sheet steel with angle supports where necessary. The sheet structure shall be carried out by 7 tank process and stove enameled type with grey color shall be applied Set of flexible copper joints shall be provided at transformer end. For the outdoor portion of the bus trunking canopy over and above the bus trunking shall be provided. The necessary supports also be supplied along with bus bar trunking.
372
2.11.13 H.T., L.T. Power and control Cables : a. H.T. cables are to be considered from 11KV Switchboard in TG hall to 132KV switchyard and for transformer b. The cables shall be provided as per the details given in data sheets. c. The cables shall be considered for all the equipments given in battery limit of this contract and specifically mentioned for other items in this document. d. The H.T. cables shall be with XLPE insulation and suitable for the functional requirements. All other cables shall be 1.1KV grade PVC/ XLPE insulated. e. The cable sizing calculations shall be submitted by Tenderer as per the fault level of system. The cable sizing shall be done with 40KA fault current for the duration of 0.5 sec. f. The necessary derating factors as recommended by manufacturers shall be considered while deciding the cable size. These shall be mainly comprising of, Derating for temperature Derating for depth of laying, Grouping factor, g. The instructions given for erection of the cables shall be followed as per manufacturers recommendations. 2.11.14 Illumination System : The illumination system shall consist of Lighting panels, lighting fixtures, cables, junction boxes etc complete a. The illumination system shall be provided as per the recommended lux levels and good engineering practices followed in industry today. Following lighting sources are considered, TG Hall Industrial type High Bay MH lamp for normal lighting Industrial type High Bay HPMV lamp for Emergency Lighting (About 25% of total lighting) Control Room - Mirror Optic Fl. Lamps Outdoor Lighting in switchyard HPMV and MH Flood light fittings Boiler and Other outdoor plant areas Well glass fixtures with HPMV lamps.
373
b. Following lux levels are recommended, Control room - 300 Lux TG Hall - 200 Lux. Switchyard - 100 Lux. c. The illumination system shall be comprising of following main equipments, Main Lighting Panel Lighting MCB DB. Lighting Fixtures with junction box. Cabling / point wiring 2.11.15 Auto controller and islanding scheme : Islanding scheme : Tenderer to supply a suitable islanding scheme to trip the circuit breaker connecting the plant with the grid in event of high grid disturbances. The same will be with voltage and frequency relays, VECTOR SURGE RELAY reverse power relay with timer and lock out. Suitable annunciation scheme to be included. 2.11.16 L.T. Capacitors a. Construction Features : The Capacitor bank shall be complete with the required capacitors along with the supporting post insulators, steel rack assembly, copper bus bars, copper connecting strips, foundation channels, HRC fuses, fuse clips, etc. The cable entry shall be at the end of the cable box. The Capacitor bank shall comprise suitable number of single phase units in series parallel combination. However, the number of parallel units in each of the series racks shall be such that failure of one unit shall not create an over voltage on the units in parallel with it, which would result in the failure of the parallel units. The assembly of the banks in cubical shall be such that enclosure provided sufficient ventilation for each unit. Necessary louvers shall be provided.
374
The voltage rating shall be selected to form an economical and compact design. The selection of voltage rating shall take into account the increase of voltage at the capacitor terminals above the actual system voltage due to the presence of series reactors, if any. The permissible over voltage will be based on this increased voltage rating. Each capacitor unit/bank shall be fitted with directly connected continuously rated, low loss discharge device to discharge the capacitors to reduce the voltage to 50 volts within one minute. The discharge resistors shall be insulated to avoid terminal faults. For the sheet, steel and support structural members cleaning, degreasing, phosphating followed by two coats of Zinc Chromate primer and two coats of finish paint shall be done. The Capacitor units of bank shall be connected to each other by continuous running earth bus.
b. Individual capacitor unit : The ratings of Capacitors shall be as indicated in Data sheet A. A stainless steel or anodized name plate shall be provided on each capacitor unit. Bushings shall be of glass or porcelain and shall be joined to the case by solder / welding or other method which ensures an adequate and permanent seal. Each unit shall satisfactorily operated at 135% of rated KVAR including factors of over voltage, harmonic currents and manufacturing tolerance. The units shall be capable of continuously withstanding satisfactorily and any over voltage up to a maximum of 10% above the rated voltage, excluding transients.
c. Unit Protection Each Capacitor unit shall be individually protected by HRC fuses so that a faulty capacitor unit shall be disconnected by the fuse without causing the bank to be disconnected. The fuse clearing time shall coordinate with the pressure built up within the unit to avoid explosion. Mounting of the individual fuse shall be external to the capacitor case.
375
d. Test and Test Reports All routine test shall be conducted in accordance with the latest edition of IS:2934. Type test certificates for similar capacitor units shall be furnished. One capacitor unit shall be type tested for thermal stability test. The tested unit shall not form a part of supply to us.
2.11.17 VFD Units a. Construction Features VFDs are envisaged for fuel feeders, boiler ID & FD fans, boiler feed pumps and main cooling water circulation pumps. The Panels shall be dust , vermin corrosion proof construction sheet steel clad, totally enclosed compartmentalized cubicle design with front and rarer access. All the Panels shall be single busbar arrangement type with bottom cable entries. The VFD unit shall be suitable for the following operating system. Rated Voltage Rated Frequency Fault Level Enclosure : : 415 V + & - 10 % , 3 Ph, 4 Wire. : 50 Hz + & - 5 % DC
50 KA for 1 Sec for AC : IP 42
Individual feeder modules organized in metallic segregated compartment. Vertical busbar serving to feeder modules in the vertical Panel or running through insulated cables. Cable Termination compartment , suitable for terminating the cables specified in the drawings Perforated sheet steel / insulating material enclosed horizontal auxiliary bus way for control, interlock, indication and metering wiring running horizontally.
376
The front of the boards shall comprise of individually enclosed Drives, Starters, ACBs, MCCBs, and Switch disconnectors All auxiliary devices .for control, indication , measurement and protection such as control and selector switches, indicating lamps ammeters, voltmeters, energy meters, and protective relays shall be mounted on the front side of the respective compartment only. The design shall be such that unless required from maintenance/ inspection purpose all power on / off on start / stop and relay reset operations shall be performed without opening the panel board. b. Busbars :The Cross section of the busbars shall be uniform throughout . The main busbar shall be sized for minimum 120 % of the full load current of the respective secondary of transformer. In any case , the current density shall be not more than 0.8 A/Sq.mm.for continuous operation or suitable for 50KA rating for one (1) second, whichever higher, for other busbars. Marshaling Compartments . A common Marshalling Compartments / cabinets, as an extension, for the switchboards shall be provided, for connection of multicore cables from DCS racks. Marshalling compartments of adequate size shall be provided, 1 No. in each switchboard ( Common for all VFD feeder in a particular switchboard ) to house the interposing relays, multiplying relays . The terminal blocks shall be mounted in such way that FIELD terminal blocks/ termination and DCS terminal blocks / termination are accommodated on either side (Front and rear). However, submarshalling compartment may be considered and the interconnection between the sub-marshalling compartment and the main marshalling compartment through inter panel wiring shall be arranged by the Tenderer. All inter panel wiring between the individual modules, submarshalling compartment and the main marshalling compartment shall be with shielded cables through metallic troughs with cover.
377
Marshalling cabinets shall house terminal blocks and transducers for connection to VFD compartments/ DCS racks, as shown in the drawings. However, local push button stations and other field instrument cables shall be directly connected to the respective motor feeder compartments. All analog cabling / wiring shall be of shielded type. Control supply shall be with 230 V AC. The terminal block arrangement shall be arranged as below :All Digital Inputs (DIs) from different feeders to be terminated at a separate array of terminal blocks. All Digital Outputs (DOS) from different feeders to be terminate at a separate array of terminal blocks. All analog inputs (AIs) From different feeders to be terminated at a separate array of terminal blocks. All analog Outputs (AOS) from different feeders to be terminated at a separate array of terminal blocks. All terminal blocks shall be identified with the respective feeder names. The coloring of terminal blocks for the DIs, Dos, AIs, & AOs shall be unique for easy identification. The Communication port of all the Tri Vector Meters / KWH meters in the VFD Panel Board shall be connected in series through screened twisted pair cable of 0.5. Sq.mm. and a single point connectivity shall be provided in the marshalling compartment for hooking up these signals to the plant DCS . However, there shall be an independent terminal block individually for all the Tri-Vector Meter/ KWH Meter. . The continuous current rating VFD shall be at least 110 % of respective connected motor FLC. The Output Choke shall be provided for the drives , which is provided with cable length beyond stipulated / recommended length by the VFD manufacturer.
378
Each Out going feeder from VFD drive/ module shall be feeding to only one motor. Ammeter with selector switch and three (3) Nos. of CTs of Class 1 accuracy with selector switch shall be provided for all VFD The requirement of auxiliary contactor shall be provided to meet the control Philosophy as furnished. Each VFD shall be provided with suitable rating of semi-conductor fuses. Space heater supply for the motors more than 30 KW shall be extended from the respective VFD, When VFD is in OFF condition. All the control circuits shall be provided with MCB control for isolation purpose. Thermistor relay shall be provided in the circuit wherever applicable.
2.11.18 Cables : Following 11KV (UE), 3Cx 300 sq. mm. XLPE insulated, Al. conductor Cables, are envisaged for this project. Approx. Length meters. 5 Runs 550mtr. x
Cable from 11KV Switchboard 11KV Outdoor Kiosk in 132KV Switchyard 11KV Switchboard 11KV Switchboard
Cable to 11KV Outdoor Kiosk in 132KV Switchyard Generator Transformer
5 Runs x 20mtr. Cogen Aux. Transformer 1Run x 75mtr 2000KVA, T1 Cogen Aux. Transformer 1Run x 75mtr 2000KVA, T2
379
Cable trays : Pre fabricated G.I. cable trays shall be considered by the Tenderer. For size up to and including 150mm. the cable trays shall be perforated. The trays including and above 300mm size shall be ladder type. The fabrication of cable trays shall be done with 2mm thick sheet. Cable trays shall be hot dip galvanized having minimum galvanizing of 110gm/sq. m uniform. The quantities are estimated quantity Tenderer to estimate based on scope and plant layout. Unit rates shall be given for any addition or deletion of quantities. 2.11.19 Steel supports : Apart from the switchyard structures which are separately considered MS steel material shall be used for following, Below Panels on cable trench. Supporting cable trays at every 1.5M in built up cable trenches. The insert plates in cable trenches will be provided by other agency. The required quantity of 5 MT is to be considered for this purpose. 2.11.20 132 KV Metering and Relay Panels : a. Metering : Following meters shall be provided in metering panel for monitoring, indicating and integrating power export to BSEB and Aux. for Plant : - Ammeters - Voltmeter 0 150 KV - Frequency meter - Semaphore - Indication lamps - Selector switches for Voltmeter and Ammeter - Load Manager to read & store various electrical parameters of power export
380
b. Relays Microprocessor based numeric relays are to be used. - Diff. protection relay for MAIN Trafo. - Restricted Earth Fault Relay (64) - Instantaneous over current relay (50) - Non directional earth fault relay(51 N) - Directional Over current fault relay (67) - Buccholz trip - Oil temp. trip - OLTC oil surge trip - Master trip unit - Trip circuit supervision relay - Stand by E/F relay - IDMT O/C and E/F relay for Main and Dist. Trafo. - Instantaneous O/C relay - df /dT relay and vector surge relay - Annunciation 2.11.21 Earthing system : Earth mat as per IEEE 80 and IS 3043 requirements. Earthing Electrodes CI pipe type GI Earthing strip as per IS 3043. Earthing grid GI 75 x 10 mm Lightning conductor 8 SWG GI Earthing risers and pads - as required.
2.11.22 Details of Trivector meters in metering Panel a. b. c. d. e. f. g. Application - Measurement of Electrical parameters Installation - Indoor Rated Voltage - 110V, 50 Hz. Rated Current - 1 Amp Accuracy Class - 0.2 Ref. Amb. Temp - 50C. Make - BSEB Approved
381
2.11.23 Bus bar Trunking Following are the requirements of bus bar trunking sets, From 2000 KVA transformer to L.T. Panel (Cogen Auxiliaries) Rating 3200Amps Approx. Length 15 meter. 2 sets Sr. No. 1 1.1 1.2 1.3 1.4 Particulars General Location Indoor/Outdoor Reference Ambient Temperature Climatic Conditions Power System A) Voltage, Phase, Wire, Frequency B) Short Circuit Level C) Neutral Earthing Type Of Bus Duct Specific Data Outdoor / Indoor 50 C Tropical, hot humid & dusty 415V, 3PH, 4W, 50HZ 50KA SYM for 1 sec for 3200 Amps ratings Solidly earthed Non segregated phase rectangular
1.5
2 2.1
Bus Bars Material
Alumi. on Alumin alloy (ECE 91 E grade) 433V, as specified 50KA SYM for 1 sec for 3200 Amps ratings 100KApeak for 3200A 25 mm 25 mm 40 mm 35 C
2.2 2.3 2.4 2.5
Rated Voltage And Continuous Current Short Time Current & Duration Dynamic Current Rating Air Clearance A) Phase To Phase B) Phase To Earth Insulator Creepage Distance Temp. Rise Over Specified Ambient Temp. When Carrying Continuous Current at 50 Hz
2.6 2.7
382
Sr. No. 2.8
2.9 3 3.1
Particulars Withstand voltage a) 1 min, power frequency b) Impulse 1.2/50 micro sec. wave Size of Bus Bars Enclosure Degree of Protection Provided
Specific Data 3 KV for 1 min. -As required. IP:55 for outdoor / IP52 for indoor portion manuf. STD. Light gray (631 OF IS:5) Epoxy finish & Zn chromate primer CRCA sheet steel 2.0 mm thickness As given above As required 1 set per transformer as per rating MS Channels / angles Required Al. 50 x 10 MM FLAT Not required Not required To be considered IS:8084 and IS:5082 Inter linked
3.2
Color Interior Exterior Special Paint
3.3 3.4 3.5 3.6 4 5 6 7 8 9 10 11
Material And Thickness Length of Bus Duct No. of L Bend No. of CU flexible joints Bus duct support Wall frame assembly Material and size of earth bus Portable hot air blowing equipment Space heaters Phase transposition assembly Applicable Standard Configuration
Note : Short circuit calculations and temp. rise calculations for bus bar trunking shall be approved before manufacturing the trunking.
383
2.11.24 L.T. Panels : Following are the technical particulars of L.T. Panel 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7 Switchgear Cubicle & Bus bars Type of switchgear Metal Clad, Indoor, Draw out type Rated Voltage and Frequency 433V, 3Ph., 50 Hz. Max. System Voltage Class 457V, Indoor switchgear P.F. withstand Capacity for 2.5 KV 1min. Short Circuit Withstand 50 KA for 1 sec. Capacity at rated voltage Design Amb. Temp. 50C Cont. Current Rating of Bus 3200 Amp for main bus bar in bar Cogen Aux. Panel and with maximum current density of 0.75A / sq. mm. Max. Temp. at cont. Operating 85C Current Applicable Standard As per relevant IS Switchgear Construction Material of construction Thickness of Sheet steel Panel, Frame, Gland Plate, Doors, Removable covers, Partitions Degree of protection Color of Finish shade CRCA sheet steel 14 SWG 16 SWG IP 54 as per IS 2147 Light Gray Semi glossy finish as per Shade 631 of IS 5 for Exterior and Brilliant White finish for interior Electrolytic Aluminum with Heat Shrinkable Sleeves Aluminum Flat 50 x 6 mm 25 mm between phases 20 mm between phase and earth Bottom
1.8 1.9 2.0 2.1 2.2
2.3 2.4
2.5 2.6 2.7 2.8
Bus bar Material Earthing Bus bar Material Minimum Clearance in Air Cable Entry
384
3.0 3.1 3.2 3.3
Incoming Breaker Details Type Rated Current at amb. Temp. Accessories with ACB
3.4 3.5 3.6 3.7 4.0 4.1 4.2 4.3 4.5 5.0 5.1 5.2 5.3
Rated Breaking Capacity Type of operating mechanism Min. No. of auxiliary contacts Auxiliary Control Voltage Current Transformers Type Winding Material Accuracy Class Applicable Standard Wiring Details Material for wiring Voltage Grade Wiring size ( Minimum.)
Electrical Draw Out type Air Circuit Breaker As per SLD P based S/C, O/C and E/F release, U / V, shunt trip and Aux. Contact Block 60KA for 1 sec. Motor Operated spring assisted latch mechanism 4NO + 4 NC. 440V, A.C. for U / V coil Cast Resin bar primary Copper Class 1 for metering Class 5P10 for protection IS 2705 PVC insulated stranded Copper wire. 650 V a) For power circuits as per current Rating 2.5 sq. b) For CT secondary circuits 2.5 sq. c) For other circuits 1.5 sq. mm. As per SLD with SFU and ACB
6.0
Outgoing Feeder details
385
2.11.25 L. T. Capacitors Designation Quantity and Output In Kvar Rated Voltage Ref. Standard Upper Limit of Temperature Category as per IS:2834 Location of Capacitors Connection and Switching Device Size And Material Of Earth Bus Air Clearance for Live Parts Phase-Phase Phase-Earth Type of Dielectric Material : : : : : Shunt capacitors 50 KVAR each bank 440 V, 3 PH, 50 HZ IS 2834,IS 13925 85 C
: Indoor : Connected in LTPCC through FSU & Contactors : 50 x 6 MM GI : : 25 mm : 20 mm : APP
2.12
CABLING 2.12.1 General Construction The cables shall be brand new and in good condition. These shall be suitable for laying in laying in trays, trenches, ducts, conduits and underground buried installation with uncontrolled backfill and possibility of flooding by water. The Tenderer shall also include in his scope cable tray/packs, double compression 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. The Tenderer shall provide the details and necessary drawings of cable trenches with sectional views. Extra PVC/ Rubber and caps for each XLPE Cable size shall be supplied. The terminating and straight thro' joint kits for the cables shall be suitable for the type of cables offered and for storage without deterioration up to 50 deg C ambient temperature.
386
a)
PVC Cables All the power cables shall be of aluminium and all the control cables shall be of copper. All power / control cables for use on medium voltage systems shall be heavy duty type, 1100 V grade with aluminium / copper conductor, PVC insulated, inner sheathed, armoured and overall PVC sheathed. with FRLS PVC insulation . The construction of the conductors shall be 'stranded'. Conductors of nominal area less than 25 Sq. mm shall be circular only. Conductors of nominal area 25 Sq. mm and above may be circular or shaped. The core insulation shall be with PVC compound applied over the conductor by extrusion and shall conforms to the requirements or Type 'A' compound of IS : 5831. Control cables having 6 core and above shall be identified with prominent and indelible Arabic numerals on the outer surface with a spacing of maximum 500 mm between two consecutive numbers. The inner sheath shall be applied over the laid- UP cores by extrusion and shall be of PVC conforming to the requirements of Type STI PVC compound of IS : 3831. The extruded inner sheath shall be of uniform thickness of size not less than 0.5 mm up to 16 Sq. mm 0.8 mm from 25 Sq. mm up to 120 Sq. mm and 1.0 mm above 120 Sq. mm conductor size. For multi-core cables, the armouring shall be by single round galvanized steel wires where the calculated diameter below armouring does not exceed 13 mm an galvanized steel strips where this dimension is greater than 13 mm. The outer sheath for the cables shall be extrusion FRLS (Fire Retardant Low Smoke) PVC compound
387
b)
XLPE Cables Power cables for 11 KV system shall be with Aluminium Conductor, XPLE insulated, screened, sheathed, armoured and overall FRLS PVC sheathed. The construction of the conductors shall be stranded and compacted circular for all cables. The cables shall be provided with both conductor screening and insulation screening. The conductors shall be provided with nonmetallic extruded semi-conducting shielding. The core insulation shall be with cross-linked polyethylene unfilled insulating compound. It shall be free from void and shall withstand all mechanical and thermal stresses under steady state and transient operating conditions. The insulation shielding consist of non-metallic extruded semiconducting compound in combination with a non-magnetic metallic screening of copper. The insulation screen shall be strippable without application of heat. The copper screen shall be capable of carrying the single line to ground fault current for a duration of one (1) second. The screen XPLE insulation and insulation screen shall all be extruded in one operation by "Triple Extrusion" process to ensure perfect bonding between the layers. The core identification shall be coloured strips numerals. or by printed
388
The inner sheath shall be applied over the laid Up cores by extrusion and shall conform to the requirements of Type ST 2 compound of IS : 5831. The extruded inner sheath shall be of uniform thickness of size not less than 0.7 mm for all sizes of cables. For multi core cables, the armouring shall be by galvanized steel strips armouring for single core cables shall be with hard-down aluminium round wire of 2.5 mm diameter. The outer sheath for the cables shall be extrusion FRLS (Fire Retardant Low Smoke) PVC compound c) Cable Accessories The termination and straight through joint kits for use on high voltage systems shall be suitable for the type of cables offered as per this specification. The termination and joints shall be supplied in kit form. The kit shall include all insulating and sealing materials apart from conductor fitting and consumable items. An installation instruction shall also be included in each kit. i) Termination Kits The terminating kits shall be suitable for termination of the cable to an indoor switch gear or to a weather proof cable box of a outdoor mounted transformer / motor. the terminating kits shall preferably be one of the following types or equivalent : Heat-shrinkable sleeve type of M/s. Raychem. 'TAPEX' of M-SEAL make using non-linear resistance material for stress grading. 'PUSH-ON' type of CCI make using factory moulded silicone rubber insulators. Cold shrinkable type 3 M Birla For outdoor terminations, whether shields / sealing ends and any other accessories required shall also form part of the kit.
389
ii) Jointing Kits The straight thro' jointing kits shall be suitable for underground buried installation with uncontrolled backfill and possibility of flooding by water. The jointing kits shall be one of the following types : 'TAPEX' of M-SEAL make. 'TROPOLINK' type of CCI make. Heat shrinkable sleeve type of M/s Raychem. Cold shrinkable type 3 m Birla 2.12.2 Inspection & Testing The cables shall be tested and examine at the manufacturer's works. All the materials employed in the manufacture of the cable shall be subjected, both before and after manufacturer of the cable, to examination, testing and approval by Owner / Consultant. Manufacturer shall furnish all necessary information concerning the supply to Owners inspectors. The inspector shall have free access to the manufacturer's works for the purpose of inspecting the process of manufacture in all its stages and he will have the power to reject any wire or other material which appears to him to be of unsuitable description or of unsatisfactory quality. a) Cables i) After completion of manufacture of cables and prior to despatch, cables shall be subjected to type, routine, acceptance and special tests as detailed below. Consultant / Owner reserves the right to witness all tests with sufficient advance notice from Tenderer. The test reports for all cables shall be got approved from the Engineer before despatch of the cables.
390
ii) All routine tests, acceptances tests, type tests as well shall be carried out on PVC cables as listed in IS : 1554, Part-1. iii) The inner and outer sheath of XLPE cables shall be subjected to all the tests applicable for FRLS PVC cables. The test requirements for insulation and sheath of PVC cables. The test requirements for insulation and sheath of PVC cables shall be as per latest revision of IS : 5831. The following tests shall be carried out on XLPE cables as per IS : 7098 Part-II. iv) Type Tests The following shall constitute type tests : Tensile test Wrapping test Conductor resistance test Test for armour wires Test for thickness of insulation and sheath Physical tests for insulation Physical tests for PVC sheath, Fire resistance Cold-impact Bleeding and blooming Particle discharge test Bending test Heating cycle test High voltage tests v) Acceptance Tests : Tensile test (for aluminium) Wrapping test (for aluminium) Conductor resistance test Test for thickness of insulation and sheath Partial discharge test High voltage test
391
vi) Routine Tests : Conductor resistance test Partial discharge test High voltage test b) Cable Accessories Type tests shall have to be carried out to prove the genera qualities and design of a given type of termination / jointing system. The type test shall be conforming to the latest IEC 502-2, 466 specifications. The type test certificates shall be submitted along with the offer. 2.12.3 Packing and Marking Cable shall be despatched in wooden drum of suitable barrel diameter, securely battened, with the take-off end fully protected against mechanical damage. The wood used for construction of the drum shall be properly seasoned, sound and free from defects. Wood preservatives shall be applied to the entire drum. On the flange of the drum necessary information such as manufacturer's name, type size voltage grade of cable, length of cable in meters, drum No. cable code, ISI Certification mark, gross weight etc. shall be printed. An arrow shall be printed on the drum with suitable instruction to show the direction of rotation of the drum. 2.12.4 Information Required Catalogue and brochure giving technical and physical details of the cable like current rating, de-rating factors, etc. 'Type Test' certificates. Shelf life of cable accessories for the ambient temperature specified.
392
2.12.5
Other Cables: a) Signal Cable: Signal cable shall be tinned copper conductor, PVC insulated twisted, each pair shielded over all shielding inner sheath armoured PVC jacketed. Shielding shall be Aluminium Mylar with 25% overlap & 100% coverage with minimum shield thickness of 0.06 mm. Drain wire shall be provided for individual pair and overall shield, which shall be of 18 AWG, 7 stranded tinned copper conductor. Cable shall be PVC insulated and primary insulation shall be 90C PVC. The insulation grade shall be 600 V as minimum. The cable shall confirm to the relevant I.S. standards.
b) Control Cable: Control cable shall be stranded conductors of electrolytic grade copper. PVC insulated twisted, intermediate sheath extruded-overall armoured. Cable shall be PVC insulated and primary insulation shall be 90C PVC. The insulation grade shall be 600/1100 V as minimum. The cable shall confirm to the relevant I.S. standards. c) Compensating Cable: Compensating cable shall be P/K type. PVC insulated twisted, each pair shielded over all shielding. Inner sheath armoured-PVC jacketed as per ANSI 96.1. Shielding shall be Aluminium Mylar with 25% overlap & 100% coverage with minimum shield thickness of 0.006mm. Drain wire shall be provided for individual pair and overall shield, which shall be of 18 AWG, 7 stranded tinned copper conductor. Cable shall be PVC insulated and primary insulation shall be 90C PVC. The insulation grade shall be 600/1100V as minimum. The cable shall confirm to the relevant I.S. standards. d) Cable Gland: Cable gland shall be nickel plated brass and shall be double compression type weatherproof. Structural carbon steel rolled / channel / ISMC100 / ISA 50x50x6 / ISA 40x40x5 / IS 2062 Gr-A/0
393
e) Control Panel Wiring Wiring Material : Insulated tinned copper stranded conductor. In case any wiring is done on door mounted items it shall be with multi-strand wires with adequate loop length : Control, signal, etc. - 1.0 mm2 Power - 1.5 mm2 (min) : Colour code shall be 230 V AC : L = Brown 230 V AC : N = Blue Earth=green/yellow 24 V DC (power) : +ve = Red 24 V DC (power) : - = White 4-20 mA : 4-20 mA Black (+) White (-) Digital inputs / outputs: Grey
Wiring sizes Wire colour
f) Cable Dressing: Wiring carrying different voltages shall be grouped separately Wiring shall be arranged to ensure free access to all devices for maintenance services No wiring shall be routed across face or rear of any device, which will restrict opening of covers or obstruct access to leads, terminals, etc. Tapping or splicing between terminal points is not permissible. Groups of wires shall be bunched with cable straps at suitable distances. Common connections should be limited only to 2 wires per terminal. Ducting : suitably grouped wires shall be placed in PVC wiring trays with covers. Terminal lugs : crimpable, insulated sleeve, ring / pin / U type as per Tenderer standard for internal terminations.
394
Identification : Wire number of each termination shall be by means of sleeve ferrules. Cross ferruling shall not be used. Instrument tag number and terminal number shall be used on terminal end. Power supply individual 2 pole MCBs shall be used for each power consuming device mounted in the panel & in field. The main switch shall be non-fuse type breaker. g) Terminals: Terminal size shall be 1 size higher than wire size subjected to a minimum of 2.5 mm2. Terminals shall be segregated accordingly to voltage levels. 25% capacity shall be provided in the terminal blocks wherever supplied. Care shall be taken to separate signal and power supply cables providing separate ducts, terminal strips / blocks, etc. Generally no more than two wires shall be terminated on one side of a single terminal. Additional terminals shall be provided for looping if necessary. The use of shorting links for looping shall be avoided. Terminal housing shall be sized with due consideration to accessibility and maintenance. 50 mm minimum space shall be provided between terminal strips and sides of the box parallel to the strip for up to 50 terminals and an additional 25 mm for each additional 25 terminals. 100 mm minimum space to be provided between two terminal strips for up to 50 terminals and an additional 35 mm for each 25 additional terminals. 75 mm minimum space shall be provided between terminal strip and top or bottom of the box for up to 50 terminals and an additional 25 mm for each additional 25 terminals. The bottom of any terminal strips shall not be lower than 300 mm from the gland plate unit in any cabinet. All terminal strips shall be mounted on suitable anodised metallic or plastic stand off. Removable cover plate shall be provided for all terminals other than low voltage instrument signals. Identification: Wire number of each termination / wire shall be by means of number and letter ferrules. Direct ferruling of black letters on white sleeves is required.
395
2.12.6 Cable Termination & Testing All PVC cables shall be terminated at the equipments/ panel by means of single compression type glands and tinned copper lugs. Power cables shall be identified with red, yellow and blue PVC tapes. Where copper to aluminium connections are made necessary bimetallic washers. shall be used. In case of control cables, all cores shall be identified at both ends by their terminal numbers by means of grooved PVC ferrules. Wire numbers shall be as per inter-connection diagrams to be furnished by Tenderer. Tenderer shall drill holes for fixing glands wherever necessary at no extra cost. The cable shall be taken through adequate size gland inside the panel or any other electrical equipment. The individual cores shall then be dressed and taken along the cable ways Cable leads shall be terminated at the equipment terminals by means of crimped type solder less connectors. Crimping shall be done by hydraulic crimping tool and conducting jelly shall be applied on the conductor. Insulation of the leads should be removed immediately before the crimping After completion of the termination the waste material such as PVC insulation removed from cables, cable pieces & armour strips etc. Shall be immediately removed from the work place and shall be to appropriate place allotted for this purpose. Before energising the cables following tasks shall be carried out checking of identification Nos. Measurement of resistance. Insulation resistance. Pressure Testing in case of 11KV XLPE cable. Proper records shall be maintained for future reference.
396
2.12.7 H.T., L.T. Power and control Cables a. 11KV (UE) cables shall be with XLPE insulation Aluminium conductor armoured cables. All other cables shall be 1.1KV grade PVC / XLPE insulated armoured cables. All power cables up to 4 sq. mm. will be with stranded copper conductors. The cables above 6 sq. mm. will be with Aluminium conductors The cable sizing shall be confirmed by Tenderer as per the fault level of system. The necessary de-rating factors as recommended by manufacturers shall be considered while deciding the cable size. These shall be mainly comprising of, De-rating for temperature, De-rating for depth of laying, Grouping factor, Voltage drop as follows, (i) Steady state voltage drop shall be limited to 3% and (ii) voltage drop during starting of motors shall be limited to 10% Metering: Following meters shall be provided in metering panel for monitoring, indicating and integrating power export to BSEB and Aux. for Plant: Ammeters Voltmeter 0 200 KV Frequency meter Semaphore Indication lamps Selector switches for Voltmeter and Ammeter Load Manager to read & store various electrical parameters of power export
b. c.
2.12.8
397
2.13
DCS BASED INSTRUMENTATION & CONTROL This section gives the general philosophy of the Instrumentation and Control System proposed for the proposed cogeneration power plant. The cogeneration power plant will be complete with the basic instrumentation and control system, necessary for its safe and efficient operation. Comprehensive instrumentation and control equipment will be provided for each major areas i.e Boiler, Turbo-generator, Electrical system and Balance of Plant. The control system shall be based on the State-Of-The-Art Distributed Control System (DCS) technology, with Data Acquisition and control of the key operational parameters. The Centralized control / monitoring shall be from a Remote Central Control Room, where the DCS and its sub systems including the operator console, shall be located. The same will be located at turbine operating floor level. In addition to the same, a centralised monitoring terminal is required in the administrative block. This terminal is required for viewing the critical operation of the cogen plant alongwith sugar & ethanol plant. Control cabling from cogen DCS to administrative building in Tenderers scope The key instrumentation and control system shall be as follows: 2.13.1 Boiler and its auxiliaries The control of the boiler like operation / start up / shut down / trip, shall be realized directly from the DCS. All the signals required for controlling the boiler operation shall be processed by the DCS and necessary actuating signals for the various final control elements shall be driven from the DCS. The major control of the boiler includes the following, as a minimum: i. Drum level (3 element) control ii. Combustion control iii. De-aerator level control iv. De-aerator pressure control v. Furnace draft pressure control
398
vi. Superheated Steam Temperature Control (2 element) vii. Blow down tank level control viii. Soot blower control Signals from the following shall be taken to the DCS for monitoring / interlocking purpose. i. ii. iii. iv. v. Electro static precipitator Boiler feed pumps and transfer pumps De-aerator Chemical dosing Boiler safety and protection interlocks
2.13.2 Turbine & auxiliaries The following controls of each of the turbine shall be performed by the DCS, as a minimum: i. ii. iii. iv. v. vi. Lube oil Control oil Gland sealing steam Turbine protection and safety interlocks Turbine start up / stopping sequence Generator cooling system
The following functions of the turbine shall be realized by dedicated independent micro processor based systems and shall be interfaced with the DCS through serial communication for monitoring / interlocking purpose : i. Turbine vibration monitoring ii. Turbine governing The information of the following shall be monitored by the DCS for Data logging / Interlocking purpose : i. Power generation details ii. AOP / EOP / MOP / CEP status iii. Temperature of windings / Bearings of various pumps, generator etc.
399
The following details on the electrical signals shall be processed / monitored by the DCS for interlock / data acquisition purpose : i. Safety relay status ii. Breaker status iii. Generated voltage, current, kilowatt, KVAR, power factor, frequency iv. Lin voltage, current, kilowatt, KVAR, power factor, frequency v. Synchronization The instrument air compressor shall be controlled by their individual dedicated PLC system. This system shall be interfaced with the DCS through serial communication for monitoring and data acquisition purpose. Various electrical inputs from the transducers and the digital signals from MCC panels shall be processed in the DCS system for achieving the necessary interlocks / controls. The water treatment system monitoring shall be by DCS, data acquisition will be by serial communication mode. The PRDS functions, fuel and ash handling system, shall be directly processed by the DCS. The design of the total control system will be such that the following sub system functions will be handled by the respective equipment: i. Data acquisition, display and logging sub system for monitoring, display, logging and printing of process parameters like flow, temperature, pressure, level, power, current, voltage, analytical and status will be performed by the operator station. ii. Start / Stop Sequence & Interlock sub systems consisting of the safety interlocks, Sequence of starting and stopping of the power plant and alarm generation will be achieved through the DCS.
400
iii. Closed loop control sub system consisting of the continuous monitoring of the operational parameters like Level, Pressure, Flow etc. and controlling of the same using the PID functions will be achieved by DCS system. iv. Engineer / Operator Interface sub system consisting of setting / changing the operational parameters based on the experience of the operator and as a reaction to emergency situations will be achieved by the computers used as the operator station. v. Communication sub system for interconnecting all the above systems. vi. Data highway and network for connecting the control and data acquisition sub systems, operator interface sub systems to a duplexed data highway such that there will be information exchange among each one of them. vii. Auxiliary units such as system cabinets, printer consoles, marshaling cabinets and power supply distribution cabinets. The Distributed Control System is proposed for control and instrumentation system, keeping in view the safety, reliability and availability for comprehensive presentation of plant operation status, trends and essential operator interaction facility. The DCS based plant control will have the following inherent advantages: i. Integration of information from different individual controls provides centralized data on plant operation. ii. Increased reliability due to the use of Large Scale Integrated (LSI) components. iii. Increased flexibility for modification at any stage due to software configuration capability. iv. Modular design concept provides easy expandability for future in hardware and software. v. Higher maintainability due to improved self-diagnostic and display features.
401
The major design aspects of the system will be as follows: i. Control will be of the type which normally relieves the operator of continual regulating duties and will be backed up by interlocks and safety systems that will take pre-planned action in cases where unsafe trends and / or conditions develop faster than the operators ability to respond. Continuous self checking features shall be incorporated in system design with automatic transfer to healthy / redundant circuits to enhance the reliability of the complete system. All the closed loop analog signals shall be processed by the DCS. Redundancy will be provided in the Central Processing unit, power supply (both at the CPU & I/O), I/O modules and communication modules (both between the controller and the operator station and between the I/O modules and the controller). Redundancy will also be provided for the communication cables. Power supply used for interrogation with field devices shall also be redundant.
ii.
iii. iv.
v. vi.
vii. The DCS shall be provided with processor, power supply, communication and I/O redundancy for critical I/Os. viii. The Input / Output modules will be provided with noise filter and galvanic / upto isolation from external control source. ix. The Input / Outputs modules will also be provided with protection against reversal of polarity of supply voltage The inputs modules shall be suitable for processing the field signals. The outputs will be short circuit proof and protected by fuses. The memory will be non volatile or battery backed up as required.
x.
xi.
402
xii. The DCS programming language shall be based on logic statements / ladder logic. xiii. On line replacement of modules shall be possible without affecting the process. xiv. Auto boot up facility for the DCS shall be within 2 minutes. xv. Display response time shall be less than 2 sec. xvi. Data communication net work response time shall be less than 100 m Sec. xvii. Closed loop control task execution (control response time) shall be done within 250 m Sec. xviii. Sequence control / Interlocks scan time should be within 100 m sec. xix. Display update time shall be less than 1 sec. xx. The system shall be designed so that the failure of any monitoring device or control components or spurious intermediate grounding in the signal path shall not open the signal loop nor cause the loss or malfunction of signal to other devices using the same signal. xxi. All equipment / systems located in the field shall be suitable for continuous operation without loss of function, departure from the specific function or damage at the ambient temperature and humidity conditions. xxii. The control system software shall have all the essential capabilities to perform advanced control algorithms as a minimum. It shall be user friendly, easily programmable and have excellent data acquisition, graphic display and logging capabilities.
403
The field instruments that are primarily responsible for measuring the process parameters will be having the following major design features: i. All the field instruments / equipment that are used shall be of the same make for ensuring the smooth and optimal maintenance including efficient spare parts management. All field instruments used for sensing transmission and measuring shall be of electronic smart type with signal transmission in current mode of 4-20 mA. All control valves and control damper drives will be of pneumatic type because of their fast response and ease of maintenance. Appropriate de-rating of electronic components and parts. All the panels outside the DCS shall have communication facility through RS 485 interface. Important plant parameters, that are required to assess the plant efficiency, must be serially communicated to the operator station for the purpose of display / logging.
ii.
iii.
iv. v.
vi.
vii. All solid state systems / equipment shall be able to withstand the electrical noise and surge as encountered in actual service conditions and inherent in a power plant and shall meet the specification requirements of surge protection. viii. All solid state electronic system / equipment furnished shall meet the requirements of Burn-in and Elevated temperature test. ix. All the instrumentation cables shall be flame retardant low smoke type. The instrumentation cables and wires shall function without breakdown for surges experienced in the control system. Voltage class and insulation level shall be compatible with the signals they convey.
x.
404
The turbine shall be provided with an electro-hydraulic governing system. The system shall be designed such that the governing of the turbine shall be automatic and provides for safe operation. All the conventional recording and annunciation methods will be dispensed with and instead it will be taken care by the DCS operator station with the SCADA software. Apart from the above integrated control system, local gauges will be provided near the equipment / pipelines at essential parts of the plant for the purpose of operator guidance. 2.13.3 Scope Of Supply a. Design, system & software engineering, manufacture, supply of hardware & licensed software, testing, inspection, Factory Acceptance Test (FAT) packing, forwarding, transportation, Site Acceptance Test (SAT), erection & commissioning, post commissioning assistance till plant stabilisation. b. The integration of all the inputs / signals for continuous monitoring, operation, data logging, data analysis, alarms, safety interlocks, annunciations etc. will be achieved through the DCS. c. The DCS will include the DCS control station, related licensed software & hardware, instrument & control cabling from the marshalling cabinet receiving signals from junction boxes of all cogeneration equipment, all MCCs and software links with Turbo-visory panel, Woodward Governor and turbine temperature scanner. d. The scope includes training, documentation, establishing communication between operating station and DCS and any other item, which is necessary for smooth operation of the system. e. Tenderer to carry out engineering of system hardware and software to meet functional requirement outlined elsewhere. However, the system shall be freely expandable to reasonably high level, by adding hardware and related software without in any way, compromising the system capability with respect to system communication and memory to handle additional software.
405
f. The entire cogeneration plant will be smoothly started, normally operated, provided with necessary interlocks & emergency trips, monitored, controlled and smooth shut down from the DCS. The DCS to have required software or compatibility to internet.
2.13.4 General Specifications For DCS Distributed Control system shall be provided for the safe and efficient monitoring & operation of Co-generation plant (i.e. Boiler, Turbine, Generator and its auxiliaries, Balance of plant, electrical breakers etc) in all regimes of operation. The system shall be microprocessor based having functional distribution and data base distribution sub-system wise. Signals from thermocouples & RTDs will be converted to mA signal by converter cards in Tenderers marshalling cabinet. The marshalling cabinet to have MTL 3013 or equivalent P&F isolation amplifiers for signals received from proximity switches. a) Digital Inputs Digital inputs shall be potential free. The inputs to the DCS shall be contact closures, closed during process normal conditions. Contact interrogation voltage shall be 24 V DC. Loop current : to be informed by Tenderer Galvanic / optical isolation : required for input channels Max. number of inputs per card : 32 nos.
406
b)
Dynamic colour graphic displays All the process parameters, variables shall be displayed dynamically on graphic displays. Process data shall be visible on this screen with its equipments. Equipments shall be displayed in standard ISA symbols. Normal operation & control of the process shall be possible using numerical keypads and functional keys on the console by monitoring the same on the screens. The OS should perform all the normal plant operation, control & monitoring functions. It should be possible to select displays either through keyboard or mouse. Display should be updated at least once in one second. Hyperlinks (Navigation buttons) shall be configured for navigating from one page to the other for a particular service.
c)
Alarm: Alarms shall be software configurable and shall be divided under following two categories Process alarms : First out Process alarms : Normal Hardware & diagnostic alarms with error codes and description Alarms shall be displayed on the console screen at the time of its occurrence. The same shall appear in the first out sequence. Alarms shall occur on the screen with its tag / description / process data. Critical alarms should have time stamping in milliseconds. The same shall be also printed on the printer. Tenderer shall add alarm text. ISA sequence shall be followed for alarms.
407
d)
Push Buttons and Selector Switches : Shall be software configurable on the screen which includes following Momentary NO & NC push buttons Latched push buttons Two or three way position selector switches
e)
Bar Graphs: Bar graphs shall show the dynamic value of process parameters, which will correspond to numeric value in Engineering. Unit. This shall also be displayed in percentage value, engineering units. Bar graph for PID controller includes process variable, set point, remote SP, manipulated variable (MV) in different colours. Status of loop i.e. auto / manual / cascade shall be displayed alphabetically and with colour change.
f)
Controller faceplate / Switch face plate: Controller faceplate shall include numeric Engineering. Unit display and Bar graph for process variable, set point & manipulated value. Auto / manual / cascade operation shall be possible. Set point change & manual operation shall be possible from this faceplate. Manual to auto changeover & vice versa shall be bump less. Changeover from local set point also shall be bump less. PV / SP tracking in PID controller shall be possible. Switch face plate shall include ON / OFF switches including start / stop PBs. Operation of start / stop push buttons / selector switches shall be possible from this faceplate. Feedback of start / stop operation shall also be displayed on this faceplate.
g)
Tuning Display: This display shall be useful for tuning of PID controller. This shall include controller faceplate. P, I, D values shall be accessible from this screen and can be changed only by engineer with password facility. Trending display to be configured for tuning controllers.
408
h)
Totalliser: Totalliser shall display the numeric totalised values of flow parameters. Reset facility for totalliser shall be available from same display screen with password or engineer login. It should be possible to change the totalliser constant from the faceplate. (These features shall have password lock facility) All DOs shall be converted to plug in relays. Relay contacts shall be wired up to the terminals (1 fused terminal per output). 24 V power supply to digital input interrogation and analog transmitter power shall be provided. All phase supplies shall be of SMPS type of Phoenix / Mean well. The system shall be able to operate satisfactorily up to 50 Deg. and 10% to 90% non-condensing humidity. Modular system shall be adopted to facilitate easy system expansion. The type of modules shall be kept minimum possible in order to have inter-changeability and low inventory. On-line replacement of any module shall be possible in such way that removal and addition of module shall be possible without switching off the power supply. Furthermore, there should not be any interruption of the system while replacing a faulty module wherever redundant modules are provided. The system design shall ensure that no single failure in system results in any loss in system operation. The system shall provide safe operation under all plant disturbances. Galvanic / Optical isolation shall be provided for all field signals. Isolation shall also be provided between operator / engineering station and controller subsystem.
409
The system software shall be governed by the operation system running in a real time mode and shall be to meet all functional requirements specified elsewhere as a minimum. i) Software The configuration software for the DCS shall be in the functional flow diagram or ladder. Programs shall be protected from accidental changes by use of password. Development mode of MMI software to be provided for graphics modification. MMI Software to be loaded on a PC, i.e. operating station. There will be common PC operating cum engineering station. Engineering changes shall be password protected. Tenderer to provide configuration details of PC. Both run time and development software for intelligent devices like governor to be included. Necessary tags to permit future developments to be included in H.M.I. Only permanent license software to be provided There must be total integration of all intelligent devices including AVR, governor LGPG relays and the DCS system. Tenderer to note that all testing / checking / configuration of DCS will be carried out from a PC. The alarm registration time stamping shall be done at CPU level, Tenderer to inform the resolution time. The system shall be capable of adapting to program changes without affecting the hardware and plant operation. It shall be possible to make logic changes and MMI changes on line without affecting control operation. For the programming / configuration of DCS, the operating station itself shall be used. Necessary hardware & software to carry out configuration, testing, debugging, editing of both DCS & MMI Software shall be supplied and loaded in the OS.
410
Self-diagnostics should be in the form of error codes to indicate the type of error encountered by processor and other hardware. The various error messages with text shall be displayed on the operating station. The diagnostic features shall be programmed such that the error messages will appear on the operating station along with the text and can be acknowledged and cleared, whatever additional programming needs to be done for this shall be in Tenderers scope. The system shall have self-surveillance, monitoring and diagnostic facility so that failure / malfunction can be diagnosed automatically to the level of individual channels of module level. The system shall be internally protected against system errors and hardware damage resulting from Electrical transients on power wiring Electrical transients on signal wiring and connecting and disconnecting devices or removing and inserting PCBs in the system. The system shall be capable of accepting various signal inputs for its direct use while preventing noise errors due to electromagnetic interface or radio frequency. j) CPU The CPU shall be redundant and shall be provided with sufficient memory for the initial configuration plus 30% additional memory for future expansion. DCS should have adequate memory with EEPROM back-up and real time clock feature. CPU shall retain its memory in the event of a power failure, with provision of battery back up, EEPROM and RAM The DCS should be capable of freely mixing analog & sequence logic, executing user defined functions not included in standard functional blocks, storing control configuration in on-board nonvolatile memory and providing an alarm indication for back-up battery low voltage, on-line tuning of PID control loops and other parameters. System shall be provided with protection against overload current and line voltage spikes.
411
Scan rate for the close loop/open loop on full load shall be 250msec (max) The CPU shall be capable of executing the following control functions as a minimum Filtering Linearization including sq. root extraction for flow signal Alarms, limits, checking switches Integrating & totalisation Ratio / bias Mid value selection Transmitter failure detection Function curve systems PID loops, PID action and values shall be settable from OS Auto manual bump less transfer Output reversal block. Range suppression for analog inputs Set point ramp up / down function Manipulated variable ramp up / down function AND / OR / NOT and other logic gates / Time delays / Counters / Latches Diagnostics Feed forward control Mathematical functions Alarm / acknowledge / reset function Auto / manual stations Manual loader Drum level pressure compensation Bump-less switch over should take place from single element mode to three element mode and vice versa. An alarm output shall be generated to announce the failure of any critical component such as DCS, power supply, I/O module, communications, etc. on the operating terminal. k) The capacity of the DCS system should be such that even after considering the space for future expansion, the loading should be lesser than 70% to permit required response time during peak loading. Free memory to be minimum 30%
412
2.13.5 Other specifications for Distributed Control System (DCS): 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. Processor redundancy Communication redundancy between processor & HMI Power supply redundancy I/O redundancy Time for backup processor to take over Required Required
Required At card level Less than one scan cycle Memory utilisation of its capacity 60% max. Online configuration Required Galvanic isolation for power supply Required Optic isolation for Input / Output signals Required No. of points per analogue input module 12 No. of points per analogue output module 12 No. of inputs per digital input module 32 No. of outputs per digital output module 32 Installed spare I/Os 25% Spare module space in racks 25% Spare capacity for system memory & user 30% minimum memory Future expansion capability 25% All spare points in I/O modules wire up Required to the marshalling cabinet Commissioning spares and consumables Required
2.13.6 Spare Installed spare of 25% shall be provided for each type of the modules. The controller and data acquisition racks shall have 25% usable spare space for installing additional I/O modules in future. In addition internal wiring for the same shall be completed up to I/O Terminal.
413
2.13.7 Other details Location: Central control room (CCR) Monitoring of process parameters, equipments running status, motorised valves open / close positions Open loop controls viz. opening and closing of dampers, control valves, motorized valves, speed setting of variable speed drives in manual mode Closed loop controls i.e. automatic controls viz. drum level control, furnace control etc. Alarms: Process alarms viz. level high, pressure low etc. and overload / trip alarms of drives Operation: Start / stop drives, opening and closing of motorised valves. The operation from CCR shall be with safety interlocks, which shall be executed in respective panels or DCS from where the operation is carried. 2.13.8 Miscellaneous Items Some special precautions to be taken by panel manufacturer during panel manufacture are as follows: Terminal lugs shall be crimpable, insulated sleeve type for terminating external wires in the panel. Sockets for powering external instruments shall be supplied / mounted by Tenderer Shrouding shall be provided for all terminals other than low voltage level instrument wiring MCBs / Switches to have service and switch nos. punched on tags, duly installed on MCBs. Instrument wires (for termination at site, if any) shall be terminated on plastic strip for easy identification at site. 10% spare contactors and 25% spare terminals shall be given on each terminal strip Terminals and wires for power incoming and distribution will be suitably sized. Mounting arrangement to be provided for Back of panel instruments Door limit switch should be covered. Some field instruments shall be powered from control panel.
414
2.13.9 DCS shall have following features: Alpha numeric and bar graph display of process parameter values Running status indication of drives on graphics Safety interlocks Close loop controls Open loop controls Controller facia with indication of PV, SP, MV, A/M status, P, I, D values Setting of SP, manual loading, tuning of P, I, D constants Trend Alarm logging Shift reports
2.13.10 Controller And Data Acquisition Sub-System Controller and data acquisition subsystem is the main field interface subsystem and is capable of performing control and data acquisition functions either as one integrated subsystem or separate subsystem for each of these functions. 2.13.11 Controller sub-system The control function of the system shall be executed by microprocessor based Controllers consisting of power supply modules, communication modules and I/O modules and a set of algorithms which are easily fields configurable using user friendly software. The hardware capability of the controller shall primarily be exploited for regulatory control functions only. However, the sequencing and interlocking capability shall also be used. Controllers shall be able to scan close loop in less than 200 milliseconds Controllers shall be capable of accepting process signals from various field junction boxes, generator / turbine control panels and MCCs without any additional conditioning equipment.
415
The controller shall be capable of processing linear and non-linear analog inputs, providing square root extraction for flow signals, linearization and compensation for thermocouple. The controllers shall be able to generate 4-20 mA DC current signals for analog outputs and potential free contacts for the discrete outputs as minimum. Loop integrity shall be maintained in controller sub-system architecture by providing one to one controller backup. In case failure is detected in the active controller all the loops of the failed controller shall have automatic control transfer switching, which shall transfer the entire configuration and data base of failed controller to the back up controller. Design must ensure that data integrity is maintained during switch over and no portion of data to be transferred is corrupted before and during switch over to the backup controller . The indication of the failed controller shall be displayed at local as well as on the central level. Loop integrity shall be applicable to power supply modules and any other device associated with the controller subsystem. The controllers shall be able to operate in either manual, auto and cascade mode. In cascade loops, the primary controller shall be able to track the steeping of the secondary controller is not operating in cascade mode. All controllers shall have facility for slow and fast ramping of steeping and output. The controllers shall be provided with redundant power supply. 2.13.12 Data acquisition system. Data acquisition system shall interface and multiplex analog and discrete inputs from open loops. The inputs shall include 4-20mA DC thermocouple, resistance temperature detector and discrete contacts. The system shall be capable of processing linear and non-linear analog inputs linearization of RTD inputs, square root extraction for flow inputs.
416
a)
Analog input Modules shall accept 420 milliamps signal from the 2 wire field transmitters Max. number of inputs per card : 8 / or 16 nos. 24 V DC power required for 2 wire transmitter powering shall be supplied from a separate redundant power pack, which will be in Tenderer scope.
b)
Digital Output module The output from DCS module shall be 24 V DC, which shall be supplied from the module itself. All the outputs going to MCC / solenoid valves (about 40 nos.) / lamps or any other panel shall be though interposing relays. Type of Digital O/P Interposing relays : 24 V DC Potential output : Relay Board with Phoenix, miniature relays, coil voltage 24 V DC, with LED for ON / OFF indication on relay board, contact rating 5 Amps, 230 C AC Output status indication : Required Galvanic / optical isolation : Required for O/P channels Surge withstand capability : IEC 255-4 On DCS failure or card failure outputs should drop to ZERO State Max. no. of outputs per card 32 Nos. DCS Tenderer will require to provide power supply for the solenoid coils of boiler & turbine installation. About 40 solenoid coils each having 12 VA hold will need to be supplied. The scan time for critical loops will be less than 50 m sec and for analog the cycle time will be less than 200 m sec.
417
Data acquisition system shall be provided with redundant power supply. Each I/O shall be isolated from the external control circuit. Each I/O shall be protected from short circuit and reverse polarity of power voltage. Logic controller sub-system The control functions required to implement the logic scheme shall be executed by microprocessor based logic control system, which consisting of power supply module, CPU module, memory module, communication interface module and I/O modules. Memory shall be non-volatile. However in case volatile memory is provided, battery backup shall be provided with a minimum of 3 months lifetime to keep program storage intact. A battery drain indication shall be provided at least one week before the battery gets drained. Redundancy shall be provided in such a way that in case of failure of the main processor, the standby shall take over automatically. The changeover shall be bump-less and the system shall be fail proof. The indication of the failed device shall be displayed at operator station Each processor and each I/O rack shall have a separate independent power supply. Failure of one power supply shall not affect the system operation Each I/O shall be galvanically isolated from external control circuit. The minimum isolation level between I/O and logic circuit shall be 1000 volts DC Each I/O shall be protected against the reversal of polarity of the power voltage to I/O module. Each I/O module shall have a LED per channel to indicate the status of each I/O
418
Input / Output modules shall be mounted by the DCS Tenderer on suitable mounting rack in the panel. Replacement of I/O modules shall be possible without disconnecting field wires. It shall be possible to accommodate any type of I/O module in any sequence. All I/O modules shall have indicated LED on field side of I/O. Blank covers shall be provided for the spare I/O module slots on the I/O rack. All DCS hardware should be suitable for ambient temperature 60 C and humidity 85% Each input shall be provided with filters to filter out any noise in the input line and contact bouncing noise. All inputs shall be provided with only dry contacts. All the inputs shall preferably be double ended i.e. two wires per input and not with common return for all inputs. The interrogation voltage to the input contacts shall be powered form separate power supply. The output from the system shall be potential free dry contacts Each output shall be short circuit proof and protected by fuse. Visual indication of fuse blown must be provided for each module. 2.13.13 Controller and data acquisition system loading The system loading for controllers and data acquisition system shall not exceed 60% or maximum 70% after considering the provided and required future space. The loading as indicated is the worst case of high system activity referred to the use of memory. 2.13.14 Communication System The communication system shall be digital communication bus that provides a high speed data transfer rapidly and reliably between the operator station, process I/O devices and other devices connected to it.
419
Communication system shall be dual redundant, consisting of two separate communication buses and two separate communication system interfaces for each device. The overall system performance shall not be degraded whether Communication system is 10% loaded or 100% loaded. Communication speed on the communication bus shall be sufficient to update the operator station data base one in every second. In case of main bus failure or any communication device failure, the Transfer to the back-up device or bus shall be automatic without interrupting the system operation and without any operators intervention. Information about the failed device/bus shall be displayed on the operator station. It shall be possible to switch over the communication form main bus to the redundant bus manually without disturbing the system operation. It shall also be possible to connect or disconnect a device from the system without disturbing the operation. Web Enabling Software to view or transmit data through internet to be provided. 2.13.15 Operator / Engineering Interface Sub-System i. The operator interface sub-system shall provide the centralized information to the plant operator / Engineer in the following details. Indication of all analog and digital process variables of control loops, open loops and all loop related parameters. Manipulation of control loops including changing set point, mode, output, configuration, turning and computational constants. Graphic displays and status indication. Alarm displays and annunciation. Compilation of graphic displays. Self-diagnostic messages. Required interlocking schemes
420
b)
The Engineering interface sub-system shall be used for configuring, tuning and maintenance of the system. It shall be possible to perform the following system configuration functions. Data base configuration including overview, group, loop, multi-loop and Multi-variable control configuration. Configuration or re-configuration of alarms settings, their values, addition or deletion of any control block or component in loop Tuning of control loops like changing P.I.D., dead time values, etc. Compilation of graphic displays. Compilation of logs/report/historical trend points. To call detailed self-diagnostic displays for maintenance aid.
c)
The operator /engineering interface sub system shall consist of two operator stations, in which any one of the stations shall be used as a engineering station Each operator station shall consist of TFT monitor and keyboard, each driven by independent electronics. The operator stations shall be housed in the consoles. Each Station shall be of industrial type and size shall be 19. LCD data, display update rate shall be less than one second. All the operator station shall be interchangeable. However under normal operating Condition, each operator station shall be assigned a specific area. The system shall have global database available at each operator station. Further any change made in the database of one operator station shall automatically update the database of other operator station. One logging printer and one alarm & event printer shall be provided. Alternatively, each engineering / operator station will be provided with one printer for sequentially logging data and alarm & events.
d)
e) f) g) h)
i)
421
j)
Keyboard Keyboard shall be self explanatory, easy to operate and shall meet all the functions to configure, operate and maintain the system. A conversational user friendly software shall be used for operation configuration and maintenance of system. Keyboard shall preferably be touch sensitive QWERTY membrane type. Each keyboard entry shall be registered with an audio beep.
k)
Process displays (i) Overview display Each display shall incorporate a minimum of 120 analog or discrete inputs which can be monitored simultaneously on the LCD screen i.e. page. Each page shall be organized into a suitable number of groups. Each group shall further incorporate suitable number of inputs i.e. tags. Suitable identifications and description shall be shown for each group on the overview display to relate it to a loop display. All analog points in the overview shall be represented as variable lengths indicating deviation above or below the normal operating value or set point. . Alarms shall be displayed in change of colour against each variable. An input in alarm condition shall be identified by flashing Control loops operating in manual mode shall be indicated (ii) Group display Group display shall be limited to the group of inputs as displayed in the overview display. Each group shall preferable include eight number of inputs.
422
Each input in the group shall be identified by the tag number, unit of measurement and process description which shall be displayed on the LCD screen. Display, as a minimum, shall show following degree of details: Process variable in analog form shall show as a percentage of the transmitter span on a linear scale bar graph of 0-100% engineering units and in digital form as alphanumeric display in engineering units. Set point value in analog form as a percentage of the transmitter span on linear scale bar graph of 0-100% engineering units and in digital form alphanumeric display in engineering units. Output value in analog form as a percentage of the transmitter span on linear scale bar graph of 0-100% and digital form as percentage. Controller modes i.e. auto, manual & cascade. Process alarm on process variable, deviation or velocity Control valve failure position. The contact input/ output shall be represented by simulated graphic lamps and configurable alphanumeric status description. It shall be possible to control the process from group view. Following control actions shall be possible. Increase/decrease of set point value either slow or fast. Change of controller mode i.e Auto / manual transfer Changing output to the final control element For digital points start/stop or open/close command.
423
(iii)
Loop Display Loop display shall provide a separate detailed display for each of the process inputs. The graphic representation of analog and digital points shall similar to group display. However in addition following information shall also be presented in alphanumeric form as a minimum. Controller tuning constants. Process variable zero and span values. Alarm set point on various parameters. Limits on set point, output, velocity etc. Controller action (direct/ reverse). Failure position of final control element. Engineering units. It shall be possible to change the following through the keyboard of operator. Changing tuning constants (restricted by password) Changing scale, zero and span (restricted by password). Changing limits on set point, output, velocity etc. Changing configuration of any loop (restricted by password) Changing alarm set points. Changing control mode. Changing output to the final control element. To issue start/ stop or open/ close command for digital points. Loop display shall also contain a trend displaying process variable, set point and output with sample interval time of maximum 1 second and full scale time base of minimum 60 seconds for tuning the process control loops.
424
(iv)
Graphic display It shall be possible to display dynamic graphic of different sections of the plant on the engineering station. Graphic display shall be interactive type through which it shall be possible to control the process. It shall be possible to send motor start/ stop and shut down valve open/ close. It shall be possible to view the process variable and alarm points and view and change steeping value, manipulated variable, controller mode etc from the graphic display. The system shall have the capability of having and developing graphic symbol library as per ISA-5.1 and 5.3. Various colours used in the generation of graphics like colour of process lines, utility lines etc. The same shall be finalized during detailed engineering. It shall be possible to go from any graphic page to related graphic pages or any group view or alarm summary.
(v)
Trend display The system shall be capable of displaying the real time and historical trends for the parameters or variables like measured variable, set point, output, calculated variable etc. The system shall also have a multi-trend capability in such a way that it shall be able to display set point, measured variable and output on the same display. It shall be possible to display by scrolling or expanding the time base for all the time base for all the trends.
425
Historical data shall be stored on the non-volatile memory device like hard disc in such a way that such historical data can be utilized for archival storage and subsequent recall. Maximum possible period of storage shall be indicated by the Tenderer. Historical data trends shall be displayed for a minimum up to 25 hours for a data-sampling rate of 1 minute. 2.13.16 Alarm monitoring and display a) Alarm management It shall be possible to display process as well as system alarms on the operator station for operators attention and action. Alarm messages shall be displayed by flashing the page and group number of the input under alarm irrespective of type of display. All alarms shall be displayed as and when they occur or generated with change in the colour of display in the following sequence, activating an audio signal. The system shall not put off the audio alarm and visual flashing even after the condition returns to normal unless the operator acknowledges it. b) Alarm summary display It shall be possible to display summary of all alarms in the sequence of their occurrence and shall disappear from display only when they are acknowledged and cleared. The alarm display shall list the following for each alarm as a minimum. The date and time of occurrence. Tag number identification. Point description. Serial number of alarm in the sequence of its occurrence. The system shall be able to display an alarm summary
426
c)
Alarm history The history of alarm conditions shall be maintained in the database for alarm history display and printed on shift wise basis. The alarm display and print out shall list the following for each alarm as minimum. The data and time of occurrence. Tag number identification. Point description. Time of acknowledgement. Time of return to normal. The system shall be able to display and print out the alarm history of min of 300 alarms.
d)
System alarm Any abnormal condition in sub-system or any other functional device shall be displayed as system alarm messages on the operator station irrespective of the display selected.
e)
Configuration display Configuration display shall provide a separate detailed display for each loop indicating the configuration of that loop. When control requires more than one loop, all interrelated loops shall also be displayed. The following information is required in configuration display. Loop configuration giving designation of each block. Control block interconnection. Value of each block parameter time P.I.D, ratio, bias. deadtime etc.
427
2.13.17 Logging function All parameters required for logging shall be stored in memory in accordance with data base update rate. However it shall be possible to perform basic arithmetic calculations such as averaging, summing, efficiency calculations etc prior to logging. In general log format shall be user definable. However the same shall be given at the time of detailed engineering. 2.13.18 Self diagnostics The self diagnostic message for a sub system failure shall appear on the operator station irrespective of display selected. The system shall have an extensive set of self-diagnostic routines which shall locate and identify the system failure at least up to module level including redundant components. At local level, failure of a module in a sub system shall be identified by an individual display. Failure of a subsystem shall be annunciated with the change in colour. One display page shall be available for each subsystem on the communication subsystem. Data storage, archival and retrieval. Historical data shall be stored on a non-volatile memory device like hard disc which can be subsequently recalled by operator on any screen. It shall be possible to store and retrieve this data on removable mass storage media like compact disc.
428
2.13.19 Measurement The following parameters, in minimum, will be measured, monitored, logged, integrated, displayed and collated in the DCS. Power (kWh, kVA, kVARH and other available parameters) from generator metering, export metering, power to sugar complex, feeder wise for cogeneration PCC, DG set, etc. Steam generated, steam to turbine, bleed steam flow, controlled extraction steam flow, MP & LP steam exported to sugar factory. Water (flow and total) for raw water, DM water, softened water, CT make-up, etc. Calibrated feeder movement for bagasse All other measurements required for the control loops.
2.13.20 Instruments Details of field instruments have been provided in the specifications of respective equipments. The same is also summarised below: a) All instruments and equipments shall be suitable for use in a hot, humid and tropical industrial climate in which corrosive gases and / or chemicals may be present. As a minimum, all instruments and enclosures in field shall be dust proof, weather proof to NEMA 4 (IP:55) and secure against the ingress of flue, dampness and vermin. All external surface shall be suitably treated to provide anti-corrosion protection. The instruments like control valves, thermo wells, orifice flanges, level instruments etc. coming on pipes and vessels under IBR shall be certified by IBR.
b)
429
c)
Location of tap off connections shall be either from the side or from the top of the steam generator equipment but not from the bottom. This requirement is applicable to both pipes and vessels. The location of lower side connection shall be high enough to prevent plugging due to dirt or other suspended solids. In addition, the connections shall be short, vertical or horizontal and without any pockets. Materials of construction of instruments shall be consistent with temperature, pressure, corrosion conditions and other steam generator requirements. The design of control panels, if applicable, shall incorporate provision for expansion by installing spare capacity. Each panel shall be designed to accommodate 10% minimum additional equipment including 10% spare cable/ tube entry points. However centralised monitoring and control through DCS is preferred. Instrument power circuits shall employ an isolation transformer and individually protected from fault with the help of MCBs and fuses. Power supply to the individual instrument shall be disconnect able with the help of switch and protected with the help of fuse. Ranges for instruments shall be selected, in general, such that in normal process operation the indication on the indicator or chart is between 40% to 60% of span for linear and 60% to 90% of span for square root. The complete instrument system shall be designed for safe operation, by using normally closed contacts which open on fault conditions. Adequate alarms shall be provided to give audible and visual warning of malfunction . The Tenderer shall also provide alarm contacts for the operation of parallel alarms, common pre-alarm and shut down alarm by the Owner wherever indicated. All lamps shall be provided with lamp test facility.
d)
e)
f)
g)
h)
i)
430
j)
Gauge glasses shall be provided for all level measurements requiring automatic or manual control or monitoring. They shall have at least the same pressure and temperature rating as that of equipments on which they are to be installed. They shall have ball check auto shut off valves. Isolation and bypass valves shall be installed with all control valves. Hand wheels and air lock valves shall be considered for all control valves. Control valve sizing formula shall, in general, be as per ISA-75, 07. Control valves shall be sized for the available pressure drop at normal flow and shall permit up to 110% of the maximum flow. The Tenderer shall submit the sizing calculations for all control valves. DP shut off shall be 10% more than upstream pressure for actuator sizing. Orifice plate calculations shall in general, follow BS 1042. Orifice diameters shall be selected so that d/D ratio is between 0.2 to 0.7 for gases and steam and up to 0.75 for liquids. Tenderer shall submit the sizing calculations for orifice plates. Main steam generator stop valve & air vent valve will be motorized and shall be designed in accordance with ASME code for valves (ASME B 16.34) and Indian Boiler Regulations. All transmitters shall be provided with output meter/output gauge at the transmitters end. All transmitters will be smart type. The Tenderer shall ensure that the packing of instruments and associated equipment is adequate to prevent damage from such contingencies as rough handling, weather, condensation, dew, vermin and vibrations. All solenoid valves shall be universal type and continuous rated type.
k)
l)
m)
n)
o)
p)
q)
431
Analysis for PH, Conductivity, Silica and Oxygen (SWAS) shall be complete with sampling system and shall be supplied with complete calibration kit including zero and span samples or buffer solution and special tools required for the maintenance. SWAS analyser will conduct online monitoring of FW quality at FW control station, drum water and superheated steam. The SWAS panels will be located in the powerhouse. The annunciations and results of the SWAS to be communicated to DCS. r) Tenderer will adhere to the approved makes for all instruments as provided in this document. Tenderer will provide data sheets for all gauges, transmitters, thermo-wells, flow meters, energy meters, electrical meters, orifice, vortex meters, rota meters, impulse piping, etc. for approval of Owner / Consultant during engineering
2.13.21 Basic Controls Design Generator, gearbox, turbine bearing temperature monitoring shall be through the temperature scanner. Critical AI/AO/DI/DO signals will be redundant while non-critical & DAS points will be non-redundant. All controllers for critical controls will be redundant. The field inputs for critical inputs will be1/2 logics. 25% of the I/Os to be considered as critical. Sequence of event recorder will be provided Required Annunciation windows shall be included 25% spare I/Os to be considered. TG governing will be by Woodward 505E. However the critical parameters will be monitored by providing serial Modus Interface All I/Os will be potential free
432
2.13.22 Estimated Bill Of Material Sr. No I Description
DCS System As per I/O count to be derived by Tenderer and approved by Consultant / Owner II 2 Sets of redundant servers, three 19 colour monitors, and 2 colour Graphic printer. III Interconnecting cables between System Cabinets Marshalling cabinets Relay Cabinets IV Power Cable for system cabinets V. Erection Hardware 1. Erection Material 2. Cable Gland Wiring and cabling accessories VII. Software Runtime + Development Run time software Project application engineering Documentation Supervision of installation & commissioning VIII. Field calibration instrument Function: Smart transmitter calibration and hart communication Accessories: (a) case & manuals (b) battery pack with AA batteries (c) lead set IX. Software link RS485, mod bus protocol for temperature scanner, TSI monitor, temperature scanner, Woodward governor, etc. (all placed within a radius of 15m)
433
2.13.23 I/O counts The I/O Counts to be derived by the Tenderer based on the approved P & IDs. An indicative list of I/Os is provided below: I/O summary for steam generator & auxiliaries DI (potential free) DO (potential free) Analog outputs (4-20mA) Analog inputs Analog inputs (thermocouple, mV) : 450 : 300 : 60 : 175 : 30
I/O summary for turbine & auxiliaries: Digital inputs Digital outputs Analog inputs (4-20mA) Thermocouple RTD inputs Analog output : 400 : 200 : 75 : 25 : 15 : 15
I/O summary for ESP: Digital inputs Digital outputs Analog inputs Analog outputs I/O Summary for balance of plant: Digital inputs Digital outputs Analog inputs (4-20mA) Analog inputs (RTD) Analog outputs (4-20mA) Analog inputs (thermocouple) : 200 : 75 : 75 : 50 : 15 : 25 : 150 : 40 : 20 :4
434
List of minimum controls loop to be considered for Boiler Drum level control loop Steam temperature control Combustion control Furnace draft control Soot blower control De-aerator level control De-aerator pressure control PRDS steam pressure & water flow control MP PRDS steam pressure & water flow control LP CBD level control SWAS signal monitoring and annunciation pH, conductivity The following interlock schemes for steam generator & auxiliaries will be operated through DCS and will have status indication on DCS: Boiler feed pump 1 Boiler feed pump 2 Boiler feed pump 3 ID fans FD fans SA / PA fans Boiler interlocks Pocket feeder # 1 Pocket feeder # 2 Pocket feeder # 3 Pocket feeder # 4 Pocket feeder # 5 Pocket feeder # 6 Pocket feeder # 7 Pocket feeder # 8 Screw feeder # 1 Screw feeder # 2 Screw feeder # 3 Screw feeder # 4 HP dosing pump # 1 HP dosing pump # 2 LP dosing stirrer
435
LP dosing pump # 1 HP dosing pump # 2 HP dosing stirrer Main steam stop valve Main steam bypass stop valve Air vent valve Steam turbine generator & auxiliaries Lube oil system Turbine Protection Generator Protection HT Panel Protection Turbine Run-up system Bleed & Extraction system CEP control station level monitoring Temperature Scanner Generator Cooling System Turbo Supervisory signals monitoring Minimum close loop controls of steam turbine generator achieved through DCS: Turbine gland steam pressure control Auxiliary steam pressure control Spray water pressure control Auxiliary steam temperature control Uncontrolled extraction temperature control CEP operation based on hot well level ESP Transformer start, trip, current, voltage Micro-tapper panel feedback, fault Hopper heater feedback, trip Insulator feedback, trip RAV feedback, trip Hopper level high, temperature high, inlet temperature high All safety interlocks
436
DM water, Water treatment plant MCW / ACW pumps ON / OFF MCW pumps speed vs. pressure control MCW / ACW pressure with high / low MCW / ACW temperature with high / low Air compressors ON / OFF Compressed air pressure DM tank, FW tank level high, low, low-low SWAS panel indications and alarms Storage tank level Conductivity and pH meters DI / DO of all motors Electrical Switchyard Control and DAS HT relays controls LT relays controls Synchroniser, Relays & breaker status UPS status signals DC power status signals TVM meter and other energy meters - generation & export KW / amps / on-off status of all continuously operating motors Operation of OLTC Switchyard SCADA Balance of Plant Area Ladder logic of fuel & ash handling system Status of fire fighting system Status & pressure of forced air ventilation system Monitoring of control room temperature All required mimics of the power plant
437
2.14
UNINTERRUPTED POWER SUPPLY (UPS) 2.14.1 Scope Of Work General Information Rated voltage Rated frequency Rated power Configuration Codes / Standards 2.14.2 Specifications of UPS 2.14.2.1 Requirement The Tenderer shall supply 30 kVA or 25% higher than peak requirement, parallel redundant Un - interrupted Power Supply (UPS) in the scope. UPS with AC distribution board and accessories shall meet AC requirements of instruments, instrument panel, governor, relay, metering cum synchronizing panels and other Owners loads. 2.14.2.2 Standards The equipment covered by this specification shall be in line with the requirements of the following IS, unless otherwise specified. IS 1248 IS 3136 IS 3700 IS 3895 IS 4540 IS 5001 IS 5060 Direct acting electrical indicating instruments Polycrystalline semiconductor rectifier equipment Essential ratings and characteristics of semi conductor devices. Mono-crystalline semiconductor rectifier cells and stacks Mono-crystalline semiconductor rectifier assemblies Guide for preparation of drawings of semiconductor devices Code of practice for use of semiconductor junction devices
: : : : :
230 VAC 50 Hz 30 kVA Parallel redundant IS
438
2.14.3 System Operation The uninterrupted power supply system shall be complete with chargers, inverters, static switches, bypass transformer with Automatic voltage regulator and manual bypass switch. Normally the system will supply the load in UPS mode. In case of any trouble with one of the Inverter Sections, the load shall be catered by the redundant system if both the inverters fail, loads shall be transferred to the bypass transformer without any interruption. A manual by pass switch (make before break) shall be provided to isolate the inverters and static switches for maintenance. When it becomes necessary to boost charge the battery (i.e. when the battery has discharged during mains failure), the charger shall be set to the boost mode manually. The rectifier section shall now cater for boost charging the battery and at the same time supplying the inverter. After completion of boost charging, the charger shall be reset to float mode manually. It shall be possible to run the system at rated load for half an hour and at about 75% load continuously without any damage in case of failure of cooling fans. 2.14.4 Design The charger shall have necessary features to prevent damage to the battery. The output voltage (110 V AC, single phase and 230V AC single phase) shall be stabilised to within +/- 5% variation, for mains input (415 V AC, three phase) variation of +/- 20% in voltage and +/- 5% in frequency. The source fault level at the point of supply shall be 50 MVA. Charger shall have adjustable current limiting feature controlling the output current and the battery current in float and boost mode. Charger output to the battery shall be passed through a smoothing circuit so that the ripple content is limited to a value safe for the battery.
439
The charger shall be designed to boost charge the completely discharged, batteries in 10 hours. The changeover between boost charge mode and float charge mode shall be affected manually. Necessary alarms to indicate battery discharged and DC over voltage conditions shall be provided. Selector switch shall be provided for selecting the float charge or boost charge mode. The inverter unit shall be designed to operate from the charger output continuously without use of battery smoothing effect. With the battery connected to the UPS system, a filter shall be provided at the input of inverter unit to reduce-the AC feed back from the inverter to the battery to a maximum of 2%. Efficiency of the Inverter shall not be less than 80% at rated load and pf. The output waveform distortion shall not be greater than 3%. The inverters shall be suitable for synchronising with the mains having frequency variation of +/- 3%. The inverters shall be de-linked when the variation exceeds this and shall run on its own oscillator maintaining its output frequency to +/- 1 % of 50 Hz. Current limit protection shall be provided which will protect the inverter against overloads and short circuits at the output. The current limit shall be adjustable. Once the overload is removed, the inverter shall automatically resume normal operation. UPS shall be designed to withstand 125% overload for 15 minutes and 150% overload for 10 seconds. The inverter output shall have spike / surge suppression filters to protect the loads By-pass transformer shall be natural air-cooled type suitable for indoor location. Links shall be provided on 415 V windings to give offload tapings of +/- 2.5% & +/- 5% of normal voltage.
440
A manual Bypass switch, make before break type, shall be provided to take the system out for maintenance without interrupting power to the load. The switch shall be mounted in the inverter section. The enclosure to be of IP 3X or better. The Tenderer shall ensure that neutral of the all transformers are solidly connected to earth to ensure that the potential between earth and neutral is zero at all conditions 2.14.5 Cabinets The UPS shall be housed in a 2 mm thick sheet steel Cabinet with separated panels for housing the charger, inverter and Bypass transformer. The panels shall be freestanding, front aligned, dust and Vermin proof with suitable ventilation Louvers and cooling fan. Hinged doors shall be provided at the front and back, as required, with dust tight gaskets. Inter panel sheet steel barriers shall be used. The enclosure degree of protection shall be minimum IP 21. The cable entry shall be from the bottom. A removable bottom gland plate shall be provided fitted with double compression type cable glands for external cable connections. Elmex type clamp terminals shall be provided for wires up to 16 sq. mm. and terminals for, large size shall be bolted type complete with cable lugs. All switches shall be rotary type mounted on the front of the door. Fuses shall be HRC link type. Busbars shall be colour coded and live parts shall be properly shrouded to ensure complete safety to operating / maintenance personnel. All instruments shall be switchboard type, back connected, 96 mm square. Scale shall have red mark indicating maximum rating. An earth bus, suitably sized, shall be provided at the bottom of the panels with provision for earth connection at both ends to existing main earth grid. All non-current carrying metallic parts shall be earthed.
441
Anti condensation heaters, thermostatically controlled shall be provided in each vertical panel complete with switch fuse unit/MCB. Each panel shall be provided with one 5A receptacle and switch and panel lighting. Distribution board at the outlet of UPS system shall be provided with adequately sized incomer FSU (single phase) and outgoing FSU feeders as below, for continuous use. Incomer 250 Amps Outgoing 32 Amps Outgoing 16 Amps 2.14.6 Battery Set of indoor sealed maintenance-free battery of capacity to meet the UPS back -up requirement for half-an-hour with all necessary accessories and devices as required for satisfactory functioning of the system shall be included in scope. By pass Supply Voltage Stabilizer By pass supply shall be taken through servo stabilizer. Voltage stabilizer output regulation shall be + / - 1 % for 0-100% load variation and full range of input supply variation over the entire power factor range. 2.14.7 Static Switches Static switches shall be solid state with performance characteristics matching with the Inverters. Controls permitting manually actuated transfers to either source shall be provided. Actuating device of such controls shall be so located or guarded to prevent accidental operation. On the front of panel an indication shall be provided for each static switch to show its position. 1 No. 3 Nos. 6 Nos.
442
2.14.8 Metering, Indications and Alarms The following metering and indications shall be provided on each panel : a) Charger Panel b) Incomer AC supply voltage with selector switch Incomer AC line current with selector switch Output voltage charger Output current charger Battery charging/discharging current Indicating lamps for A. C .input supply 'ON, output supply 'ON. Indicating lamps for battery on float / Boost.
Inverter Panel D.C. Input current Bypass transformer secondary voltage UPS output voltage with selector switch UPS output current with selector switch Frequency meter Power factor meter Indicating lamp for Battery output 'ON'. Bypass supply 'ON' Load on Bypass Mains synchronized.
2.14.9 Audio Visual Alarm Audio Visual Alarm shall be provided for the following complete with ACCEPT, RESET and TEST facilities a) Charger Panel Mains Under Voltage, single phasing, in case of three phase input. Charger / Diode Failure Cooling fan tripped (Common for all fans)
443
Low battery voltage DC over-voltage Battery earth fault b) Inverter Panel DC input failure Inverter -1 output failure Inverter -II output failure Load-on by pass SCR fuse failure UPS output under voltage Potential free 'NO' contacts for annunciation for all the above (rated for 2 A, 230 V DC) mentioned alarms shall be provided, wired up to terminal strip and to be grouped separately for charger and inverter unit. 2.14.10 Inspection and Testing:The following tests shall be carried out on the system to ensure its successful operation as per the specification. The system shall run under rated load at rated power factor for a minimum continuous period of 10 hours. Output voltage, current, frequency and critical temperatures shall be recorded. Test shall also be done with the fans off and the system loaded as described in this specification. Output voltage and frequency regulations on various load combinations from 0-10 % load. Over load withstand test as per this specification shall be carried out immediately after continuous operation on rated full load and maximum operating temperature (hot condition) Waveform analysis with Oscilloscope under the following conditions shall be done. Full load conditions
444
Simulation of input AC-power failure to the rectifier. Simulation of battery charger failure and battery failure. Simulation of failure of inverters (causing the full load to be transferred to the By Pass supply) Manual return of full load at rated power factor from Bypass supply to the inverter. Short circuit the output bus to record the current limiting effect of the inverter. Reverse input polarity test. Test on all controls and Alarms for correct setting and operation. Test and calibrate the instruments.
2.15
ERECTION & COMMISSIONING 2.15.1 General Specifications Tenderers scope for erection and commissioning services includes: a. Receive / Handling b. Stock c. Security d. Issue e. Installation f. Erection g. Commissioning h. Supply of commissioning spares i. Handing over j. Drawings & Manuals and k. Training to Owners project and O & M teams
445
Unloading, handling and storage at site, pre-fabrication/assembly if any, civil works, erection, testing, commissioning, trial operation, final painting and guarantee performance testing. Providing warehousing, testing facilities, obtaining approvals from statutory authorities and providing required documentation, data etc. All Equipment and instruments required for erection, start-up, initial filling, commissioning and performance guarantee tests. The Tenderer shall deploy erection Tenderers who have carried out similar or larger jobs and will present their credentials for approval of Owner / Consultant. The Tenderer shall be required to erect all mechanical & electrical equipment, Steel work, chutes, hoppers, instruments and controls cables and conduits. etc complete in all respect. The Tenderer shall provide all skilled, semi skilled and unskilled workers, Supervisory staffs, tools and tackles, erection materials hosting testing of equipment and other related services required to complete the erection and commissioning all equipment with auxiliaries. The work shall include the following. a. b. c. d. e. f. g. h. i. j. Receipt of material at site Providing storage and safe custody of the equipment. Checking of the foundations. Alignment , levelling and grouting . Current / drilling / welding as required on the existing structure / buildings. Complete assembly and erection materials . Minor rectification work wherever required. Final painting . Initial lubrication and greasing. Trial run and commissioning.
446
2.15.2 Specification for Erection of Mechanical Equipment a) Checking of foundations The Tenderer shall as a first field activity, check the foundations for the correctness of the same as per relevant drawings & and certify the same for concreting and the same may be rechecked for its correctness after concreting, such as levels, location of bolt holes, sleeves, pockets, openings, fixture plates and other embedment in RCC works, etc. All the structural fixtures required shall be supplied by the Tenderer. Where required by manufacturers the concrete surfaces shall be chipped and finally dressed up true to obtain the required contact between sole plates and concrete surfaces. The fine dressing of the concrete shall be with Prussian blue match checks. Tenderer shall ensure that while lifting turbines/generator, piping and other auxiliaries for transporting, slings shall be put over the points indicated on the equipment. Slings over casing shall have gunny bags or soft wood packing to avoid the scratches and nicks on the equipment. Slings / D-Shackles of proper sizes shall be used for all lifting and rigging purposes. All care shall be taken to safeguard the equipment against any damage. Tenderer shall thoroughly clean all machine surfaces / slings, surfaces/keys, brackets sole plates etc. and apply anti-scuffing paste or other recommended equivalent before assembly of the said parts. The components whose surfaces are coated with protective coating are to be thoroughly cleaned. The Tenderer shall carry out all necessary checks such as accuracy of levels, centres lines, bolt positions, of installation of all equipment covered in the scope of work.
447
b)
Checking of Equipment after Grouting After the grout is set and cured, the Tenderer shall check and verify the alignment of equipments, alignment of shafts of rotating machinery, the slopes of all bearing pedestals, centring of rotors with respect to their seating bores, couplings etc. as applicable and the like items to ensure that no displacement had taken place during grouting. The values recorded prior to grouting shall be used during post grouting check-Up and verifications. Such pre and post grout records of alignment details shall be maintained by the Tenderer in a manner acceptable to the Owner.
c)
Shaft Alignment All the shafts of rotating equipment shall be properly aligned to those of the matching equipment to the required accuracy. The equipment shall be free from excessive vibration so as to avoid over-heating of bearing or other conditions which may tend to shorten the life of the equipment. All bearings shafts and other rotating parts shall be thoroughly cleaned and suitably lubricated before starting. The Tenderer shall maintain a record in the form acceptable to Owner / Consultant of all the operations carried out on each weld and maintain a record indicating the number of welds, the names of the welders who welded the same. All site joints shall be subject to acceptance of Owner / Consultant. Any joints declared rejected shall have to be redone at the Tenderer's cost. The Tenderer shall carry out the tightening of the bolts on the equipment and piping covered under this specification by using either the calibrated torque wrench method or the turn of nut method.
448
The methods used, the tools and the equipment deployed shall be subject to the approval of Owner / Consultant. The bolting work shall be carried out by competent technicians. The Tenderer shall install all necessary platforms, stairways and ladders required for the safe and convenient operation and maintenance of all the equipments, valves etc. covered in this specification at no extra cost. The Tenderer shall completely erect all the equipments for the complete E & M portion including hangers and supports, valves & accessories in accordance with the approved drawings. This includes all necessary bolting, welding, testing and cleaning. Systems shall be demonstrated in condition to operate continuously in a manner acceptable to Owner / Consultant. Welding shall be used throughout for joining pipes except where flanged screwed or other type joints are lines & elevation as indicated in the drawings. While erecting the field run pipes the Tenderer shall check the accessibility of valves, instrument tapping points and maintain minimum head room requirements and other necessary clearances for adjoining work areas. The Tenderer shall be responsible for correct orientation of all valves so that seats, stem and hand wheels will be in desired location. All supports & hangers for the pipes have to be fabricated and provided for approximately every three metre (3 Mtr.) of pipe. However in any case sufficient numbers shall be provided so that the deflection of pipe between hangers shall not exceed the limits indicated in the drawings.
449
The Tenderer shall make all necessary arrangements including making of temporary closures on piping / equipment for carrying out the hydrostatic testing on all piping / equipment with motor operated pump. All piping flanges are required to be blue matched using surface plate to obtain at least 80% contact area before installation. All welded joints of pipes shall be cleaned of welding slags, & burrs by hand file wire brushes and flexible grinders wherever required and using white cloth. No cotton waste shall be used while cleaning the equipment / piping All welding procedures adopted for performing welding work shall be qualified in accordance with the requirements of Section IX of ASME & IBR. These welding procedures shall clearly state the type of material, thickness, the joint details, the repeat temperature maintained, the post-weld heat treatment given, the welding current and voltage used during qualification of welding procedures. For all high pressure piping welding, the latest applicable requirements of the Indian Boiler Regulations must be complied with. All records of the welding procedures, the welders qualifications, tests and welders performance details for the work performed under these specifications shall be maintained by the Tenderer and be made available to the Owner on request.
450
Wherever applicable, the Tenderer will submit : All non-destructive examination procedures, stress relief and /repair procedure actually used during fabrication. Welder and welding procedure qualification certificates. Welder identification list, listing welder's and welding operator's qualification procedure and welding identification symbols. Material mill test reports on components as specified by the specification. The inspection plan with verification, inspection plan check points, verification sketches, if used, and method used to verify that the inspection and testing points, in the inspection plan were performed satisfactorily. Sketches and drawings used for indicating the method of trace ability of the radiographs to the location on the equipment. Non-destructive examination result report. Stress relief time temperature charts.
The Tenderer shall dismantle the valves & actuator for overhauling, servicing and lubricating wherever required as advised by Owner/ Consultant. The Tenderer shall also lap or grind the valve seat for ensuring the satisfactory performances of valves at no extra cost. All consumables such as gaskets, gland packing which form the permanent part of equipment shall be in the Tenderer's scope.
451
The hanger assemblies shall not be used for attachment of rigging to hoist the pipes into position. Other means shall be used to securely hold the pipe in position till pipe supports are completely assembled and attached to the pipe & building structure. All temporary rigging shall be removed in such a way that pipe supports are not subjected to any sudden load. During hydro static testing of pipes, all piping having variable spring type supports shall be secured in place by temporary pinned or blocked solid during the test. The Tenderer shall carry out the pre-commissioning activities such as chemical cleaning of piping system, water flushing, flushing of oil systems, flushing of control fluid system. The scope of pre-commissioning activities covers installation of all temporary piping, supports, valves, tanks, pumps & all other accessories & services to complete the process. The Tenderer shall carry out the edge preparation of weld joints at site in accordance with the details acceptable to Owner/ Consultant. Wherever possible machining or automatic flame cutting will be allowed only wherever edges preparation otherwise is impractical. All slag / burrs shall be removed from cuts and all the hand cuts shall be ground smooth to the satisfaction of Owner / Consultant. Tenderer shall carry out all the electrical pre commissioning tests on the generator, excitation system, as stipulated by the relevant specification and codes. The Tenderer shall hand over all parts/materials remaining extra over the normal requirement with proper identification tags, in a packed condition to the Owner / Consultant. The work to be carried out is of highly sophisticated nature requiring quality precision workmanship, engineering and construction management.
452
It should also ensure successful and timely commercial operation of equipment in stalled. The Tenderer must have adequate quantity of precision tools, construction aids in his possession. Tenderer must also have adequate trained, qualified and experienced supervisory staff and skilled personnel. All temporary scaffolding shall be removed before the start of the commissioning activities to prevent hazards.
2.15.3
Specification for Erection of Electrical Equipments a) Scope The specification covers the installation, testing and commissioning of all electrical equipments and accessories required for the power plant for efficient and trouble free operation. b) Standards The electrical installation work covered by this specification shall unless otherwise stated comply with the requirements of the latest edition of relevant Indian Standard, statutory regulations and codes of practices. Indian Electricity Rules. Tariff advisory committee. IS-10118 : Code of practice for selection, installation & maintenance of switchgear and control gear IS-6600 : Guide for loading of oil immersed transformers IS-3043 : Code for practice for earthing IS-2309 : Code of practice for protection of building and allied structures against lightning IS-2274 : Code of practice for electrical wiring installation IS-6665 : Code of practice for industrial lighting
453
c)
General Requirements The installation shall be carried out by an electrical Tenderer holding a valid license as required by the State Government. The Tenderer shall provide particulars of the license held by him or his sub-Tenderer to the Owner. The installation shall require approval of the Chief Electrical Inspector to the Government of Bihar and the Tenderer shall prepare all necessary drawings / documents in obtaining the approval. He shall also fully assist the Owner in obtaining approval from any other statutory authorities for the successful commissioning of the power plant and the Substation. Any modification in the equipment or installation that may be demanded by the inspector shall be carried out at no additional cost to the Owner. In accordance with the specific installation instructions or as directed by the Owner, the Tenderer shall unload, erect, assemble, install, wire, test and commission all electrical equipments included in this tender. Equipments shall be installed in a neat workmen like manner with highest regard for safety. Erection materials, tools, testing instruments or any other machinery of any nature shall not be supplied by the Owner. The Tenderer shall arrange for the same in a timely manner and he shall not be allowed to claim for any delay or extra cost of any nature. Consumable materials of any nature required for the job shall also have to be arranged by the Tenderer.
454
Clearing the site after completion of erection as well as regular clearance of unwanted materials from site, returning all packing material and excess material shall also be covered under the scope of work. All equipments and instruments of indoor and outdoor, shall be inscribed with number, nomenclature, danger boards and other instructions. The Tenderer shall touch up the surface for all equipments, which are scratched and / or damaged during transportation and erection. The paint used shall match exactly the surface being touched up. The Tenderer shall employ skilled and semiskilled labourers for erection, installation & testing as required. All electricians, cable jointers, wiremen, welder and others employed shall be suitably qualified possessing certificates / licenses recognised by the competent authorities. The Tenderer shall also furnish a list of Engineers /Supervisors and staff employed by him for erection and installation jobs, giving in brief, qualification and experience of such staff and indicating whether they hold such competency certificates / licenses to supervise the electrical installation jobs as required under Indian Electricity Rules & State electrical inspectorate Rules. The Tenderer shall set up his own workshop and other facilities at site to undertake fabrication jobs, pipe bending, threading etc. The Tenderer shall be responsible for recording of all readings and observations during erection, testing and commissioning, in registers or on prescribed performs. All such test data and records shall be duly signed by the Tenderer's Engineer / Owners representative and shall be submitted to Owner in triplicate.
455
The Tenderer shall carry out all tests at site for outdoor and indoor Electrical equipment and commission the installation in the presence of Owners representative . The Tenderer shall be responsible for final adjustment of relays, instruments, meters breakers etc . and also for submission of relay settings and calculations. All support insulators, Circuits breakers, Isolators, Power Transformers, Instrument Transformers, etc. shall be properly handled and erected as per the relevant codes of practice and manufactures drawings and instruction manuals. For power transformers, drying out oil filling as required, after checking and testing the dielectric strength shall be carried out by the Tenderer. If required oil filtration shall be carried out and the Tenderer shall arrange for the necessary equipment. Handling equipment, sling ropes etc. should be tested before erection and periodically for strength. Necessary Junction boxes for CTs and PT's shall be supplied and installed. d) Switchgear, Control & Relay Panel Switchgear, control and relay panel, etc. shall be installed in accordance with the latest edition of IS-1011B and manufacturer's instructions. The panels shall be installed on finished surfaces. The correct level shall be ascertained before final grouting. The Tenderer shall take utmost care in handling delicate equipments and mechanism like instruments, relays. Dragging shall be avoided as for as possible. Proper pipes shall be provided underneath when dragging for short distance. Wherever the instruments and relays are supplied separately, they shall be mounted only after the associated control panels have been erected and aligned.
456
Any damage to relays and instruments shall be immediately reported to the Owner. Tenderer shall also make all necessary adjustments as specified by the manufacturer for proper functioning of the equipment. Tenderer shall also carry out the following : e) Cleaning of internal parts like chambers, insulators etc. by vacuum cleaners. Prepare base for mounting the equipment including levelling. Drying of equipment in case of low insulation resistance.
Illumination system : Outdoor type street light fittings shall be mounted on GI pipe bracket with clamps welded to fabricated tubular pole. Power supply to street light fitting is to be provided by looping the PVC cables coming from Lighting Panel up to junction box. From junction box flexible copper cables shall be provided to fitting. All hardware items such as nuts, bolts, washers, anchor fasteners used for mounting lighting fixtures shall be zinc passivated The lamps / tubes shall be handled carefully and shall be fitted just before commissioning of illumination system. For installation and termination of PVC cables the details specifications are given elsewhere in this document with shall be followed. Before energizing the installation, insulations resistance test shall be carried out. Illumination level shall be measured with lug meter in indoor and outdoor areas. All the test results shall be handed over to client.
457
f)
Panels : All the switchgears shall be checked for dimensions as per manufacturers drawings. The locations of switchgears shall be checked as per the layout drawing. The base plates, channels to be embedded in the trenches well in advance of the actual erection of panel. Clearances required as per drawings shall be checked by the Tenderer. The switchgear shall be handled with care under guidance of a competent supervisor. Base channels shall be grouted, on levelled cement concrete. All foundations grouted bolts shall be cured for a minimum period of 48 hours. All the panel shall be assembled, aligned and levelled as per the instructions of the manufacturers given in respective drawings. It should be checked that panel to panel coupling bolts and bus bar links fit properly without any strain on any part. It should also be checked that lowering, lifting, racking in and out of breakers and all motions are free from any obstructions. The fixing bolts shall be grouted only after satisfying all the requirements. The hardware used for this purpose shall be zinc passivated. After completion of the panel erection, all the cubicles, switches, starters, CTS, bus bar chambers should be cleaned and checked for tightness. All wiring connections shall also be checked for their correctness as per drawings. Metering and protective CT as per the polarities and phase sequence. All starters, switches, contactor contacts should be cleaned with C.T.C. At Hinges of panel, doors should be lightly lubricated to give free and noiseless movement. All the control wiring, bus bars, other live parts of switchgear and incoming and outgoing cables should be meggered with 1000 V megger for L.T. panels.5KV megger shall be used for 11KV Breaker Panel.
458
The panels must be completely sealed to prevent entry of any dust, vermin & rodents. The gland plate shall be drilled for the no. of cables as per cable schedule, extra holes shall also be drilled and sealed with rubber grommets for any additional cables. Gas cutting shall be never be done. The panels must be cleaned with a vacuum cleaner. All loose material lying in the panel shall be removed. Before commissioning any switch gear panel, the following points must be checked and ensured for safe energisation of the board. (i) The erection of panel to be commissioned is complete in all respects including all mountings and earthing. (ii) That all the openings in floor inside and outside the panel have been sealed off. (iii) That all the metering instruments have been checked and calibrated. (iv) That all control fuses are of proper rating and showing continuity (v) That all the indicating lamps are healthy and in position. (vi) That the H.V. Test of breakers bus bars and outgoing and incoming cables has been conducted and is satisfactory. (vii) That IR value has been recorded for bus bars. Circuit breaker, incoming and outgoing cables. (viii) That all the surroundings and panels have been cleaned and temporary earth leads have been removed. (ix) That mechanical and electrical interlocks are OK. (x) Each panel before erection shall be checked for all above and shown to Owner at site. Joint inspection report shall be made. (xi) The record of tests carried out/changes made in wiring and locations of panels shall be made for future references. (xii) The specifications given in this section are also applicable to all panels in general. The guidelines provided in this section need to be followed in addition to the specific instructions provided by individual panel manufacturer.
459
g)
Cables: All the cables required for the work will be supplied by Tenderer. This shall include taking the delivery at site, shifting to locations, cut to lengths, laying, dressing, testing and commissioning with termination arrangements. The cables shall be laid in trenches, trays or conduits Cable routing given on the drawings shall be checked in the field to avoid interference with structures, piping ducting and minor adjustments shall be made to suit the field conditions. All cables shall be carefully measured and then only cut to the required length leaving sufficient length for final connections to the equipment on site. The Tenderer shall confirm the exact requirement of cable for particular feeder by measuring at site along the actually finalized route. He shall prepare cut length schedule of cables before taking up cable laying. Cables shall be laid in complete uncut length from one equipment to other. Cables shall be neatly arranged in the trenches/trays in such a manner, that crisscrossing is avoided and final take off to the motor/switch gear facilitated. Arrangement of cables within the trench/ tray shall be the responsibility of the Tenderer. All cables shall be identified close to their termination point by cable numbers as per schedule. Cable numbers will be punched on aluminium strips (2 mm thick) securely fastened to the cable and wrapped around it. Temporary ends of cables shall be protected against dust and moisture to prevent damage to the insulation. While laying the cable, ends of cables shall be taped with PVC tape
460
Cables shall be handled carefully during installation to prevent mechanical injury to the cables. Ends of cables leaving trenches shall be coiled and provided with protective cover until the final termination to the equipment is completed. Where cables rise from trenches to motor, control station, lighting panels etc. They shall be taken in GI pipes for mechanical protection up to a minimum of 1000 mm above ground level. The diameter of the GI pipe shall be at least 3 times the diameter of the cable. The upper end of pipe shall be sealed to prevent ingress of water. Cable ends shall be carefully pulled through conduits to prevent damage to the cable. Wherever cables are taken in conduits, the Tenderer shall ensure that the area of conduit filled in by cables shall be as under :1 Cable in pipe : 53 % 2 Cable in Pipe : 50 % 3 Cables in pipe : 43 % More than three cables : 40 % If more cables are passing, additional conduit shall be laid after the cables are installed and all testing is complete, conduit ends above grade shall be plugged with suitable weather proof plastic compound. Where cables pass through foundation wall or other underground structures the necessary ducts or openings will be provided in advance for the same. However, should it become necessary to cut holes in existing foundations, structures, the electrical Tenderer shall identify the same and obtain an approval before cutting the same. Cables installed above ground level shall be run in trays, exposed on walls ceilings / structures and shall be run parallel to or at right angles to beams walls or columns. The cables shall be so routed that they will not be subjected to heat.
461
Individual cables or small groups which run along structures will be clamped by means of 16 SWG GI saddles on 25 x 6 mm saddle bars at a spacing of 300 mm. The cost of such saddles shall be included in the cost of installation of cable. Cables shall be supported so as to prevent sagging. G.I. clamps required as per the diameter and number of cables shall be on cables at every 300 mm. Cable carrier system i.e. cable trays / supports and supporting steel shall be painted black before laying of cables. h) Cable Termination & Testing : All XLPE / PVC cables shall be terminated at the equipments/ panel by means of single compression type glands and tinned copper lugs. Power cables shall be identified with red, yellow and blue PVC tapes. Where copper to aluminium connections are made necessary bimetallic washers. shall be used. In case of control cables, all cores shall be identified at both ends by their terminal numbers by means of grooved PVC ferrules. Wire numbers shall be as per inter-connection diagrams to be furnished to the Tenderer. Tenderer shall drill holes for fixing glands wherever necessary at no extra cost. The cable shall be taken through adequate size gland inside the panel or any other electrical equipment. The individual cores shall then be dressed and taken along the cable ways . Cable leads shall be terminated at the equipment terminals means of crimped type solder less connectors. Crimping shall done by hydraulic crimping tool and conducting jelly shall applied on the conductor. Insulation of the leads should removed immediately before the crimping by be be be
462
After completion of the termination the waste material such as PVC insulation removed from cables, cable pieces & armour strips etc. Shall be immediately removed from the work place and shall be to appropriate place allotted for this purpose. Before energizing the cables following tasks shall be carried out - checking of identification Nos. - Measurement of resistance. - Insulation resistance. - Pressure Testing in case of 33KV and 11KV XLPE cable. Proper records shall be maintained for future reference.
i)
Cable trays & supporting system :Cable trays of sizes as per drawing shall run in concrete trenches or overhead supported from columns, slabs etc. Cables shall be clamped in both horizontal and vertical runs by suitable clamps. Cable trays and supporting system shall be adequately provided to provide mechanical support during operating as well as short circuit conditions. The cable trays and supports shall be applied with two coats of red oxide primer and two coats of epoxy paint. Cable trays shall be fabricated from MS angles and strips as per sizes given in respective drawing.
463
j)
Transformer : The transformers shall be installed as per following specifications. Through external examination shall be made for any damage during transport particularly to radiators, explosion vents & for oil leakages. Transformer shall be lifted by crane of adequate capacity or by applying jacks at jacking pads provided on tank. The transformer shall be placed on its foundation & locked by means of wedges or angles driven in foundation. Breather shall be mounted on extension pipe fitted to conservator. It shall be ensured that breathing hole of the seal is not blocked by foreign material. Colour of silica gel shall be blue when filled. Earthing to transformer neutral and body shall be completed before energizing. The insulation resistance between windings and between winding to earth shall be checked by 1000v megger / 5000V megger in case of EHV winding while testing no external lines shall be connected in circuit. Before testing all bushings in cable box and busbar chamber shall be thoroughly cleaned. Tap changing mechanism shall be checked for its proper functioning & locking arrangements. Check shall be made on proper line connection of cable and alignment of busbars. General checks on installation such as oil level in conservator, oil leakages, earthing, cable connections, possibility of movement during operation shall be made before energizing the transformer. On energizing the transformer shall be checked for unable noise & vibrations. After 4 to 6 hours of energization on no load the transformer shall be loaded gradually. The currents & voltages at steps of loading shall be recorded for future reference.
464
CHAPTER - 3
SPECIFICATIONS FOR CIVIL & STRUCTURAL CONSTRUCTIONS

3.1 MAJOR CIVIL WORKS a. b. c. d. e. f. g. Site clearance by removing and disposing any impediment for commencing construction. Contour survey, soil testing, tests for ascertaining the soil bearing capacity, water tables at site, wind direction etc. Back filling and levelling, if required Compound wall, chain link/barbed wire fencing, gates, entrance arches etc., for sugar plant, housing, and plant and non-plant buildings etc. Foundations for cooling systems for all plants Foundations for bagasse, fuel and ash handling equipments Workers rest rooms, panel rooms, workers rest room, first aid facility, fire fighting facilities including sheds for fire tenders, foundations for fire fighting equipments, pipe lines for fire fighting/fire hydrants etc. and other auxillary buildings Non plant buildings such as administrative offices, canteen, laboratories, toilet blocks. Foundations for large tanks, pumps, fuel conveyors, pipe racks, electrical equipment, pipe / cable racks, water treatment equipment Panel rooms, sheds for equipments, sheds for D.G. sets All internal roads to be of RCC and RCC approach roads to be provided for all building / structures including green areas, road side drains, culverts, pipelines and other provisions for street lighting, yard lighting, area lighting etc. within battery limits, as shown in plant layout. Drainage channels, storm water drains Underground cable & bus ducts, tunnel for fuel handling, trench for CW piping, etc. Covered bagasse storage Earthing pits and earthing mats Required plumbing and sanitary fittings & equipments. Rain water harvesting, compound wall, sewage treatment plant and green belt Pile foundation to be provided, if required, based on soil investigation
h. i. j. k.
l. m. n. o. p. q. r.
465
s.
All building and civil work commencement certificates, building completion certificates, stability certificates, any other certificates as per statutory requirements of the Bihar and the Central Government, NOC of the BPCB, NOC of Airport Authority etc., all necessary permissions from the statutory authorities.
3.2
DESIGN DATA: The following basic design criteria are used in the designs of various structures. Soil bearing capacity (to be verified by Tenderer, prior to civil design) Min grade of concrete for RCC works Grade of reinforcement steel Type of Cement All structural steel members Seismic zone of factory area Wind velocity & direction : 12 ton/m at 2 m from NGL : M20 : IS : 1786 : 43 grade Portland cement : As per IS 800 : As per IS 1893-2002 : Velocity : As per IS : 875 South-West (May- Sep), North East (Oct Apr)
3.3
SYSTEM DESCRIPTION AND SPECIFICATIONS 3.3.1 Site Grading and Levelling The site clearance and grading work has been considered only of the area for the plant. The grading work will be done by cutting-filling balance method and no earth will be transported from outside. All excavation and back filling shall be in Tenderers scope. The contour survey and all necessary surveys of the cogen area shall be carried out by the EPC Tenderer.
466
3.3.2
Plant Internal Roads And Culverts Internal roads within the plant boundary and roads for access to equipment and buildings will have to be provided. Layout of the roads will be based on Plot Plan. Adequate turning space for vehicles will have to be provided and bend radii will be set according to maximum vehicle speed of 20km/hour. Roads will be as short and straight as possible. All internal roads shall be well designed RCC roads. All roads shall be designed as per IEC 58. Wherever drains or other underground facilities cross the roads, concrete pipe culverts class NP2 or NP 3 as required or RCC box culverts shall be provided. Roads shall be provided with kerb stones and the same shall be painted as per specification. All plant roads will be constructed so as to permit transportation of all heavy equipment. Internal roads will be minimum 6.0m wide.
3.3.3
Soil Investigation Soil investigation will be done by EPC Tenderer for the determination of safe bearing capacities for the design of foundations for various structural elements. Earth resistivity will be determined.
3.4
DESIGN CRITERIA The design criteria for various structures and structural elements will be as follows: 3.4.1 Steel Framed Structures The design of steel framed structures will be done by linear elastic method as per the provision of IS: 800.
467
3.4.2 Reinforced Concrete Framed Structures All reinforced concrete structures will be moment resisting frames along both longitudinal & transverse directions. The suspended slab will be considered as continuous over secondary beam and will not form part of the framing system. However it will be considered to be transferring the shear to the framing system. RCC structures/members will be designed as per IS:-456 using limit state method. 3.5 FOUNDATIONS 3.5.1 Introduction All main plant structures i.e. all plant and non-plant buildings for the cogeneration project will be supported on RCC foundation- isolated, combined or raft. Machine foundations for Compressors, BFP and misc. pumps and equipment foundations will be supported on RCC foundations - Isolated or Block foundations. Pile foundations will be provided, if required, by the soil investigation report 3.5.2 Design The foundations will be designed for the most critical combination of forces and moments, resulting from all the possible combinations of the various loading from the structural system. The effect of water table will be considered and the foundation will be checked for overturning for minimum and maximum vertical loads. There should be no uplift under any portion of the foundation for any loading condition. The foundation sections will be sized and reinforced adequately for bending moments and shear stresses. A levelling course of plain cement concrete will be provided before casting the foundation.
468
3.6
MACHINE FOUNDATIONS 3.6.1 Introduction This section outlines the design philosophy & construction aspect for foundations for large equipment as follows: a) b) c) d) e) f) 3.6.2 Steam Turbine Generator foundation Powerhouse foundation Steam Generator & Auxiliaries foundation Electrical equipment, DG set, compressor foundations All bagasse handling foundations All Miscellaneous machine foundations
General A necessary requirement for all rotating machinery is that it should be properly supported. Thus the foundation becomes an important element of machine installation. It has to resist both static and dynamic forces exerted by the machine and transmit these to the ground. In doing so, it is responsible for smooth running of the machine by ensuring that amplitudes are limited to values that are permissible for the machine and for local environment, including structures and people. The foundation must have sufficient structural strength to withstand all applicable forces and most severe combination of individual load cases that result in the maximum foundation loading for any conceivable set of normal or abnormal circumstances. Spring supported foundation shall be provided for low frequency machines, wherever the same are required from technical consideration.
3.6.3
Design Parameters The data required for the analysis and design of machine foundations may be listed as under: a) Loading diagram showing static and dynamic loads on the foundations, points of application of loads, area over which these loads will be distributed etc. b) Operating speed of the machine. c) Capacity or rated output of machine.
469
d) e) f) g)
Critical speeds of the machine. Geometric limitation. Opening limitations, depressions, projections etc. Details including sizes and locations of anchor bolts, pipe sleeves, inserts, embedded parts etc. h) Layout and distribution of pipe lines, ducts etc. and their supporting details. i) Temperatures in various areas during operation. j) Mass moment of inertia. k) Allowable amplitudes at the machine bearing points, etc. l) Tolerance in bearing and clearances of various components.
3.6.4
Loads The loads to be considered for analysis and design are: a. Static loads of the stationary components of the entire assembly along with the static weight of rotating parts. b. Dynamic loads from start-up torque. c. Loads on foundation resulting from admissible forces and moments of pump nozzles. d. Loads on pedestal top due to installation and maintenance. e. Any other forces/loads which equipment EPC Tenderer considers applicable.
3.6.5
Analysis And Design The analysis and design of machine foundations will be carried out to ensure the following: a) Compliance with the manufacturers requirements. b) No resonance phenomenon of a disturbing nature to machine operation should exist at the normal running speed. c) Calculations to be performed for dynamic as well as static cases for reinforced concrete block type pedestal.
470
3.6.6
Foundation Sizing The outline plan dimensions of foundations will be given by the machine EPC Tenderer. The height of foundation will be selected after taking into consideration soil strata and operating level of the machine. The eccentricity of common CG of machine and foundation with respect to the centroid of base area/pile group should not exceed 3% of the corresponding base dimensions of the foundation. In order to reduce the horizontal amplitudes, the height of foundation should be selected as small as possible. A larger base dimension should be selected in the direction of rocking moment, if any, acting on the foundation.
3.6.7
Compressor Foundation The Compressor is a machine of reciprocating type. This is a low speed machine and produces unbalance forces during operation, causing vibration in the foundation. Excessive foundation vibrations may cause settlement or damage to the foundation-machine system and also a feeling of discomfort and uneasiness to the personnel. Compressor foundation shall be isolated from the close slab and other foundations Vibrations are also transmitted through the ground. Ground vibrations may be minimized by providing trenches all around the foundation up to a suitable depth.
3.6.8
Miscellaneous Machine Foundations For the large variety of other types of machines there are numerous foundation designs and the most suitable one will depend on the particular application. Foundations for pumps, etc. are usually in the form of solid block foundations, resting on the undisturbed strata.
471
At machine supports supported on the finished floors, floor may be thickened and extra reinforcements provided. Also, the machines, which are almost vibration free and are very light to moderately heavy, may be supported in the above manner. Rubber or neoprene pads may have to be used under some of these machines to reduce transmission of vibrations to the supporting floor. 3.7 GENERAL DESIGN CONSIDERATIONS The design of various civil and structural works will be done as per relevant Indian Standard and sound engineering practices to meet the system and functional requirements. Design Loads: Design loads for all structures will be determined according to the criteria described below. Dead Loads: - Dead loads will consist of the weights of the structure and all equipment of a permanent or semi-permanent nature including tanks, wall panels, partitions, roofing, piping, drains, electrical trays, bus-ducts. Dead loads will be determined using the weight from IS-875 (Part -1). Live Loads:- Live loads will consist of uniform live loads and equipment live loads. Uniform live loads are assumed unit loads which are sufficient to provide for movable and transitory loads, such as the weight of people, portable equipment and tools, equipment, or parts which may be moved over or placed on floors during maintenance operations. These uniform live loads will not be considered on floor areas which will be permanently covered with equipment. Equipment live loads are calculated loads based upon the actual weight and size of the equipment and parts to be placed on floors during dismantling and maintenance or to be temporarily placed on or moved over floors during installation. Floors and supporting members which are subject to heavy equipment live loads will be designed on the basis of the weight of the equipment in addition to a uniform load of 500 kg/m, or specifically defined live loads, whichever is greater. Each member in the floor which may carry these loads will be designed for the heaviest piece or pieces of equipment arranged in the most critical position. For loads caused by moving equipment over the floor for installation, consideration will be given to the shoring of beams and floor
472
from floors below. When moving equipment over floors for installations are considered, stress increases of 25 percent are permitted in beams and columns. Wind Speed: The design wind speed will be based on IS: 875 (Part - 3). This design wind speed will be used to determine wind loads for all structures. Seismic Zone: As per IS: 1893-2002 3.7.1 Design Loads a) Dead Loads Dead load will comprise of the following and will be computed as per IS: 875 (Part-1). Following will be considered for evaluation of dead loads: i) ii) iii) iv) v) vi) b) An uniform 150/200 mm thick RCC slab wherever concrete floors are provided An uniform floor finish of 50 mm laid over RCC slab Other area flooring will consist of removable grating/chequered plate or 50 IPS. Beams & columns as per actual size Wall/cladding loads Self weight of supporting structure/facilities
Imposed Loads Imposed loads will include minor equipment loads, cable trays, small pipe racks/hangers (not exceeding 250 Kg/m ) and also loads during erection, operation & maintenance. Actual plant loads coming on the floor area occupied by the equipment will be calculated and compared with the superimposed loads given above. Higher of the two will be adopted for analysis and design.
473
c)
Steam Piping Load As per static/dynamic analysis for steam piping, the loads superimposed on structure by piping hangers and at the restraint points will be considered. However, pipe dynamic forces at hanger location/restraint points will be considered not to act simultaneously with seismic forces in that plane.
d)
Crane Loads The frames will be analyzed for the maximum wheel loads when the lifted weight is nearest to A row in one case and B row in another load case. The impact factor for vertical load will be 25% for crane girder and 10% for columns/foundations as per provision of IS: 875 and lateral crane surge of 10% of lifted weight and trolley weight will be considered in the analysis of the frame. The longitudinal surge will be 5% of the static wheel load. Each of the crane girders will be analyzed for the moving loads and for half the total surge loads on each gantry girder.
e)
Wind Loads The basic wind pressure will be taken as IS: 875(Part-III) and combination of wind loads with other types of loading will be done according to provision of IS:875 (Part-V). The basic wind speed of 50m/sec. up to height of 10metres above ground level.
f)
Earthquake Load As per IS: 1893, the seismic zone and basic horizontal seismic coefficient for this plant location will be decided. The importance factor of not less than 1.50 will be used to calculate base shear coefficient. The coefficient of soil-foundation interaction will be not less than 1.0. Reduction in live loads is to be considered for analysis according to IS: 875. In view of the asymmetrical nature of main powerhouse, response spectrum method will be used for analysis.
474
g)
Temperature Loads The effect of temperature loads will be considered for design of the structural frames. For temperature loading calculation the total temperature variation will be considered as 2/3rd of the average annual variation in temperature. The structure will be designed to withstand stresses due to 50% of the total temperature variation. The structures will also be analyzed/checked for temperature effects in the areas where the temperature rise is expected to be high.
h)
Load Combinations The following load combinations will be considered for finding out the critical forces, moments and torsion on the structural elements. i) DL + LL ii) DL + LL + CLA + DLC CS iii) DL + LL + CLB + DLC CS iv) DL + LL + CLA + DLC CS TL v) DL + LL + CLB + DLC CS TL vi) DL + 0.5LL + K1(DLC) + K2(CLA) vii) DL + 0.5LL + K1(DLC) + K2(CLB) + EL TL vii) DL +LL + DLC + K3(CLA) K3(CS)+ WL1+TL viii) DL +LL + DLC + K3(CLB) K3 (CS)+WL1+TL ix) DL +LL + DLC + K3 (CLA) K3 (CS) WL2+TL x) DL +LL + DLC + K3(CLB) K3(CS) WL2 TL xi) DL +LL WL1 TL xii) DL + LL WL2 TL The following load combinations will be used for getting max. tension at column base which will be used for the design of holding down bolts i) 0.9DL EL ii) 0.9DL WL1 iii) 0.9DL WL2
475
i)
Nomenclature DL Dead load (comprising of only dead weight of structural members, side cladding etc.) LL Live load (including imposed load, plant loads & equipment loads) TL Temperature load DLC Dead load of crane bridge with impact CLA Crane trolley + lifted weight nearest to A row column with impact CLB Crane trolley + lifted weight nearest to B row column with impact. CS Crane surge EL Earthquake load WL1 Wind load with internal suction of 0.2p WL2 Wind load with internal pressure of 0.2p K1 (DLC) Dead load of crane bridge without impact K2 (CLA) Crane trolley without lifted weight with impact or (CLB) K3(CLA) Crane trolley + lifted weight with impact or (CLB) K3(CS) Crane surge for lifted weight.
3.7.2
Permissible Stresses The permissible stresses will be as per relevant IS Code. An increase of 33.3% in permissible stresses will be made wherever wind or earthquake load has been considered with dead load and appropriate amount of live load. For secondary effects without wind or earthquake load, permissible stress will be increased by not more than 25%.
476
3.8
DESIGN OF MISCELLANEOUS ITEMS 3.8.1 Cable Trenches The cable trenches and pre-cast removable RCC cover (with lifting arrangement) will be constructed using RCC/Masonry work. The cable trench walls will be designed for the following loads: 1. 2. 3. 4. Dead load of 155 Kg/m length of cable support and 75 Kg on one tier at the end. Triangular earth pressure + uniform surcharge pressure of 2T/m. Cable trench covers will be designed for self-weight of top slab and concentrated load of 200 Kg at center of span on each panel. Cable trench crossing the road/rails will be designed for class AA loading of IRC/relevant IS code and should be checked for transformer loading.
Suitable drainage arrangement will be provided to drain water from cable trenches. Cable trenches will not be used as storm water drains. The top of trenches will be kept at least 50mm above the finished ground level. Trench wall will not foul with the foundation. Suitable clear gap will be provided. A clear (vertical) space of at least 200-mm will be available for each tier in cable trench. From trench bed to lowest tier, a minimum clearance of 150 mm will be available. The trench bed will have a slope of 1/500 along the run and 1/250 perpendicular to the run. All the construction joints of cable trenches i.e. between base slab to base slab, the junction of vertical wall to base slab, from vertical wall to wall and all the expansion joints will be provided with approved quality PVC water stops of approx. 230 x 5 mm size for those sections where the ground water table is expected to rise above the junction of base slab and vertical wall of cable trenches. Cable trenches will be blocked at the ends if required with brick masonry in cement sand mortar 1:6 plaster with 12mm thick 1:5 cement sand mortar.
477
3.8.2
Drains Adequate surface drainage system will be provided within the plant area. Design will be done with obtained rainfall data and the storm water drainage system designed, (Culverts, ditches, drains etc.) to accommodate the most intense rainfall that is likely to occur over the catchments area in one hour period on an average of once per ten year. The surface of the site will be sloped to prevent the ponding of water. The maximum velocity for pipe drains and open drains will be limited to 2.4m/ sec and 1.8m/ sec respectively. However, minimum non-silting velocity of 0.6 m/sec will be ensured. Longitudinal bed slope will not be milder than 1 in 1000. Invert of the drainage system will be decided in such a way that the water can easily be discharged above the High Flood Level (HFL) outside substation boundary at suitable location and approved by Owner. Pumps for drainage of water (if required) will be provided.
3.9
ARCHITECTURAL CONCEPTS AND DESIGN An Architectural Design Basis Report will be submitted to the Owner including proposals for the following scheme components: shape, form, color, and basic materials for interior and exterior architecture along with an appropriate landscaping scheme. All schemes will be supported by architectural statement explaining the factors considered in the design. Exterior Architecture - General design criteria for the exterior architectural systems will be as follows: 3.9.1 Wall/Cladding System All external walls of the building shall be 230 mm thick brick walls and internal walls 230/115 mm thick brick walls as per requirement in CM 1:5. Internal plastering shall be 12 mm thick using CM 1:4 and external wall with CM 1:4., 20/25 mm thick and/or sand faced plaster or any other special finish if required, 115 wall shall be plastered with CM 1:3, 12 mm thick. Ceiling plastering shall be 6 mm thick with CM 1:3. Damp proof course 40 mm thick in PCC 1:2:4 using 6 mm down stone shall be provided in the external brick walls at grade level.
478
In order to quickly erect / complete the plant buildings, wall cladding with Galvalume sheets may be examined above 5.0 m from ground level and up to 5.0 m brick work can be adopted. Where ever advised, self supported galvalume roofing could also be provided for the main plant buildings and other non-plant buildings. 3.9.2 Roof As per details given in relevant chapters. 3.9.3 Flooring & Floor Finish The floor slabs will be designed as cast-in-situ RCC slabs with removable shuttering unless mentioned otherwise. The nominal thickness of RCC slabs will be 150/200 mm. Floor finish of 50mm thickness will be provided over the RCC Slab as per finish schedule wherever applicable. Type of floor finish will be as per the functional requirements of different areas and facilities. 3.9.4 Roof Water Proofing Treatment Above RCC Roofs Over the cast-in-situ roof slab, 50mm thick screed concrete (blended with water-proofing admixture) will be laid. The final treatment will be heavyduty type with bitumen felts. For the provision of handling of equipment on the roof and movement of personnel, tiles will be provided in place of pea gravel. Roof slope of 1 in 75 will be provided in one direction in A-B bay and sloping towards A-row. For other bays, roof slope of 1 in 100 will be provided in two directions. For rainwater down comers, heavy duty UPVC pipes will be used. Number and sizing will be as per the relevant Indian Standard.
479
3.9.5
Windows, Ventilators Window and Ventilator frames will be made of extruded aluminium, steel, or other tried and proven material as per the schedule given earlier. Frames will have a minimum depth of 38 mm and a minimum thickness of 3 mm. Ventilation sections will be compatible with the frames providing a weather tight seal. All aluminium windows shall be provided with MS grills of approved design and all glazed windows to be provided with sun control film. All steel windows to be provided with 12mm sq MS safety bars @ 100 mm c/c All windows will be fully flushed and sealed for weather tightness.
3.9.6
Doors: Pressed steel doors/ Aluminium doors will be provided as per the schedule given earlier. Steel doors will be the hollow metal type, flush, 46 mm thick, insulated, with formed hollow metal frames. The doors will be constructed from 1.3 mm steel with an internally reinforced, insulated core. Frames will be constructed of 1.6-mm steel, welded, and ground smooth. Both doors and frames will be factory galvanized or field painted. Doors will have a glazed vision panel when required by door function. Glazing will consist of tempered safety glass or wired glass. Fire barrier doors, if any, shall be specifically designed steel doors with required fire rating. The door, frame, and hardware will bear a certification label for the class of opening and rating. Doors for fire exits will be secured with panic bars. Solid core flush doors with both side veneer finish to be provided for housing and other non-plant buildings as advised and specified.
480
3.9.7
Equipment Access Doors:Large access exterior doors will be vertical lift rolling shutter type, with weather seals and windsocks. Components will be formed from galvanized steel, factory primed, and field painted. Doors at high traffic areas will be motor-operated. Doors will be manually operated where access is infrequent. Interior Architecture - Interior architectural systems will conform to the following general design criteria. Fire rated architectural system will be provided when required by building or fire codes. All normal occupied areas will be finished areas.
3.9.8
Painting: Inside masonry walls and ceilings of all buildings will be provided with white wash, color wash, oil bound distemper, acrylic emulsion paint as per schedule given earlier. Steel structures, doors, windows, steel rolling shutters, gangways, stairways railing, grating rain water pipes etc. will be painted with synthetic enamel paint.
3.9.9
Sanitary Facilities: Toilet and shower facilities will be provided for personnel in finished areas of all major buildings and in other areas as determined by project requirements. Sanitary facilities fixture types will be so selected to provide a balance of local and Western fixtures. Towel and waste receptacles will be recessed to the extent possible. Janitor closets and cleaning material storage areas will be provided in finished areas of all major buildings. The sewage from various locations will be collected in septic tank. The capacity of the sewerage system, septic tank, required gutters, air vents, PVC piping, etc. will be calculated based on manpower deployment of 500 personnel per shift.
481
All Architectural, Structural and RCC drawings and design calculations, shall be supplied in triplicate to the Client and their Consultants, minimum 15 days prior to construction of works at site, for approval purposes and only after approval, the works shall be taken up at site. A soft copy of all such drawings and designs, either by E-mail or by CD/DVD, shall also be provided along with the hard copies of the same. 3.10 CONSTRUCTION 3.10.1 Concrete: Reinforced concrete structures will be designed in accordance with the latest version of IS: 456 Code of Practice for Plain and Reinforced Concrete. Water retaining RCC Structures will be designed in accordance to IS:3370: Code of practice for concrete structures for the storage of liquids. The grade of concrete for various structures will be as follows: PCC below Foundations/Plinth Beams 1:4:8 PCC in base slabs for drains, water retaining structure etc. 1:3:6 PCC/RCC in grade slabs, pavements, plinth protection, etc M20 RCC in foundations and super structures M20 RCC for liquid retaining structures M25 RCC for T. G. Foundation M20 Minimum cement content shall be as follows: M15 : 324 kg/m M20 : 360 kg/m M25 : 400 kg/m 1:3:6 : 216 kg/m 1:4:8 : 216 kg/m 1:5:10 : 130 kg/m a) Grouting : Non-shrink flowable grout shall be used for grouting below base plate of columns. For grouting of base of machine foundation high flowable strength ready mixed non shrink grout shall be sued.
482
Type and grade of grouting for structural columns and equipment base shall be as indicated. Crushing strength of the grout shall generally be one grade higher than the base concrete. Minimum grade of grout shall be M30. Nominal thickness of grouting shall be at least 50 mm for building columns and pedestals of major equipments. For secondary posts, stair & ladder base, etc, grouting shall not be less than 25 mm thick b) Reinforcing Steel:Reinforcing steel will be High, Yield Strength Deformed bars conforming to IS-1786 (Grade Fe 415). Cement:- Cement used in all concrete mixes will be Ordinary Portland cement/ Portland Slag cement 43-Grade unless design requires a different type. Aggregates: Fine aggregates will be clean natural sand. Coarse aggregates will be crushed gravel or stone. All aggregates will meet the requirements of IS:383 - 1970. c) Admixtures: Plasticizers and retarders will be used to control setting time and to obtain optimum workability, if required. Water: Clean water of potable quality will be used in all concrete mixes. Mixes: A table will be supplied with the Design Intent Memorandum, which classifies the proposed mixes into a general range of classes. The minimum cement provided in concrete mixes will be as per the stipulations laid down in IS: 456. Secondary reinforcement : Polyester fibres will be used in cement mortar, PCC, RCC, etc. to enhance / improve the performance of mortar / PCC / RCC
483
d)
Design Mix Tests: Two sets of compression test samples, three samples per set, will be made from each proposed concrete mix. One set of three samples will be tested at an age of 7 days, and the other set will be tested at an age of 28 days. Tests will be in conformity with IS:4031-1968. Grade Slab: The existing earth fill will be thoroughly compacted, and provided with 150 mm of boulder soling or brick aggregates, interstices filled with small stones and sand. Floor paving will be of 100/150 mm thick in M-20 grade laid over the prepared surface.
e)
Finishing Formed Surfaces: Fins and other surface projections will be removed from all formed surfaces except exterior surfaces that will be covered with earth back fill. Exterior surfaces that will be exposed above grade and all interior surfaces, except those not usually exposed to view, will be cleaned and rubbed. Rubbing will produce a smooth, uniform surface free of marks, voids, surface glaze, and discoloration. Rubbing will be done by hand with a carborandum stone using only the mortar produced by the rubbing action and the application of water. Projecting ends of all form ties will be removed. The resulting recesses will be cleaned, wetted, and filled with patching mortar. Patches on rubbed surfaces will match the texture of the adjacent concrete. Plinth Protection: All buildings will be provided with 1000 mm wide and 100 mm thick plain cement concrete paving all around on the outside. The plinth protection will be laid over prepared subgrade and base formed with broken bricks or rubble laid to a thickness of 75 mm.
484
f)
Structural Elements : Minimum thickness of structural element to be as follows: Suspended flow slab / roof slab / walkways / canopy slabs, etc Ground floor slab (non-suspended) Water retaining slab / walls Cable / Pipe Trenches / Under ground pit / Launder walls and base slab All footing (including raft foundation) Tapered footing : 100 mm : 150 mm : 150 mm : 100 mm
: 250 mm : 150 mm (Min. at edges) Parapets / Chajjas : 75 mm Pre-cast louvers / fins : 50 mm Pre-cast trench cover slabs / floor slabs / : 75 mm louvers Paving : 150 mm Basement walls and base slab : 150 mm
g)
Curing: Concrete will be protected from loss of moisture for not less than 7 days after the concrete is placed. Trowelled surfaces, except those that receive a separate finish or coating, will be cured with a membrane curing compound. Float finished surfaces, except those that receive a separate finish, may be cured with either a membrane-curing compound or with water. Only water curing will be used if the surface receives a separate finish. Water Curing: Water saturation of concrete surfaces will begin as quickly as possible after initial set of the concrete. Water curing will begin within 12 hours in dry weather and within 24 hours in damp weather. The rate of water application will be regulated to provide complete surface coverage with a minimum of runoff The application of water may be interrupted for surface rubbing. The concrete surface will not be permitted to dry.
485
Damp proofing: Damp proof course in a thickness of 40mm and consisting of cement concrete 1:2:4 with admixture of approved water proofing compound, will be provided at plinth level for masonry walls in super structure. Waterproofing: A waterproofing seal will be provided for structures where applicable. Water-proofing will be carried out by a system duly approved by the Owner/Consultant. 3.10.2 Steel a) Structural Steel:Steel framed structures will be designed in accordance with IS:-800Code of Practice for Construction in steel adopting allowable stress design and plastic design. In addition steel framed structures will be designed in accordance with the criteria discussed in the following subsections. b) Materials: Structural steel shapes, plates, and appurtenances for general use will conform to Indian Standards IS:800 with a minimum yield strength of 250 MPa. Connection bolts will conform to IS:-1367. Connections will conform to the latest version of the Specification for Structural Joints. Welding electrodes will be as specified by the AWS. c) Tests: Mill test reports or reports of tests made by the fabricator will be required certifying that all material is in conformance with the applicable standards and specifications. In addition, the fabricator will provide an affidavit stating that all steel specified has been provided at yield stresses in accordance with the drawings and the specification.
486
d)
Minimum Heights for pedestals of Steel Columns : Top of RCC foundation (pedestals) shall normally be kept at a height of 300 mm above the floor level. Other Pedestals and Foundations : 200 mm above the finished floor level Equipment in open area : As required (300 mm min.) Equipment in covered area : As required (150 mm min.) Structures / Equipment : As per Tenderers data subject supplied to minimum as specified above In case the top of pedestal is kept at a lower level so that the column base plates together with gussets and stiffener remains below finished floor level (FFL), the column base as well as column section shall be encashed in concrete above FFL as below: Open area Covered : 300 mm above FPL / FGL, whichever is higher : 150 mm above the FFL Stairs and ladder pedestal
3.10.3 Miscellaneous Metal Items a) Steel Grating: Steel gratings will be pressure locked grating manufactured with 40mmx 5mm MS strips as longitudinal bearing strips (spanning the supports) and 25mm x 3mm strips in transverse direction. The grating will be provided with a 40mm x 5mm band all-round. The grating will be designed for 500kg/m2 loading and spans up to 1500mm. Stair treads will also be made of steel grating with nosing.
487
b)
Guard rail /Handrail: Guard rail will be a two-rail system with the top rail 1000 mm above the walkway surface and the intermediate rail 500 mm below the top rail. Guard rail post spacing will be proportioned to the length of the protected horizontal opening, but will not exceed 1200mm centre-to-centre of posts. Guard rail will be shop fabricated for specific locations and field welded or bolted to the erected structural steel. Steel pipe will conform to IS-1151, Medium grade.
c)
Anchor Bolts and Embedded Shapes: Anchor bolts will conform to IS:-5624. Embedded shapes and plates will be galvanized where required. Anchor bolt assemblies will be galvanized where required. Steel, which is not galvanized and will remain exposed, will be primed with a primer paint.
488
CHAPTER - 4
APPROVED LIST OF VENDORS, LIST OF SPARES AND LIST OF DRAWINGS, DOCUMENTS

4.1 APPROVED LIST OF VENDORS 4.1.1 Major Equipment Suppliers Steam turbine AC generator Steam generator Diesel Engine DCS BHEL / Siemens / Shin Nippon / TDPS Francotosi / Skoda / GEC BHEL / Siemens / TDPS / Jeumont / WEG / Cummins BHEL / Thermax / IJT / WIL Foster Wheeler / CVL Cummins / Greaves Cotton / MAN / Kirloskar / Wartsila / Powerica Emerson / Yokogawa / Honeywell / ABB / Siemens
4.1.2
Mechanical Air Conditioning System Blue-Star / Voltas / Carrier / Daiken / LG Condenser GEI Godavari / Siemens / BHEL / L&T Bearings SKF /FAG / ZKL Bellows Flexicon / Lone Star / Metallic Bellows / Instrumentation Ltd. / Cori Rubber Belt Weigh Scale PBL / IPA / Avery Blow down valve Levcon/BHEL/Hopkinson / Keystone Boiler Feed Pumps KSB / Kirloskar Ebarra / Sulzer Butterfly valves KSB / Audco / BDK / Instrumentation CBD & IBD Valves BHEL / Hopkinson / Fainger Laiser / Forbes Marshall Chains /Sprockets Diamond / Rolcon / Swajit Condensate Extraction Sulzer / Mather and Platt / KSB / Sigma Pumps Lutin Conveyor Belt Dunlop / Andrew Yule / Ravasco / MRF
489
Couplings (Tyre Type) De-aerator
Fenner / Unique Thermax / BDT / GEA / BHPV / BHEL / L&T / Tri-power Dust Extraction System Rajdeep / Ecomak / Duvent Ejector Mazda / New Field / BHEL ESP Thermax / BHEL / ETS-Elex / Alstom / VT Corp / CVL / Rieco / Him-Enviro Fire Hydrants / Fire Fireflex / Minimax / Minimak / Alert / Extinguishers Kafex / Safex Fire Protection systems New Fire / Vijay / Agni Heavy Ind/ (CO2) Mather & Platt Gate, Globe & Check Audco / BHEL / KSB / Fouress Valve CI 600 and above Gate, Globe & Check BDK / Audco / BHEL / KSB / Valtech valves Turbine Gear Box Lufkins / Flender / Skoda / Mitsubishi / Maag / Osaka / Hitachi Gear Box Radicon / Elecon / Shanti Governor Woodward 505 E GVC Eskay / Patel Air Temp / Mazda / TEMA HP & LP Dosing system Metapow India / Asia LMI / Enpro / PSI Engineering HP heater BHEL / L&T / GEI Godavari / TEMA / Patel Engg ID, FD and SA Fans AYL / ABB / BHEL / Batliboi / Reitz Turbovent / Flakt Insulation Lloyds / Minwool / Orient LRSB Soot blowers BHEL / Hopkinson / RR Lube oil purifier Alfa Laval / Pennwalt Magnetic Separator Electromag / Sterling / MCI Misc. valves & Fouress / Audco / KSB / Crescent / specialties Non IBR valves BDK / L&T / KSB NRV BHEL / Hopkinson / KSB Oil coolers Eskay / Reynolds / Southern Lubricants Oil filters Industrial Enterprises / Southern Lubricants / Enpro Oil Pumps Delta / Sigma Lutin / Prakash Pumps KSB/Khimline / Sulzer / Beacon Weir
490
Refractory Relief valves Rotary Soot Blowers Rupture disc Safety Switches Safety valves SJAE Spring hangers Welding Electrodes
Parshuram / ACC / KFS / Furnace Fabrica BHEL / L&T / JNM RR Tech / Hopkinson / BHEL / Sitson FMC Sanmar / Eagle / Burgmann AG / Jayshree / AE BHEL / L&T / TYCO Sanmar BHEL / Newfield / Thermal Systems BHEL / L&T / Sarathi / Myricks Advani Oerlikon / Esab / Hannover / Lincoln
4.1.3
Electrical Air Circuit Breakers Analog Meters Annunciators Auto Excitation Regulation System (Digital) Auto Synchroniser Battery Battery Charger Busduct Capacitor Banks Comprehensive Transformer Protection Relays Control panel CTs & PTs DC Distribution Board & EOP starter ABB / GE Power / L&T/ Siemens / Schneider AE / IMP / Rishab IEC / Minilec / Procon / Alen / Sun Auto Basler / BHEL / Elin / GE / Siemens / ABB Alstom / AVK-SEG / L&T / Siemens / Woodward Amara Raja / Exide / Universal (BUI) / Panasonic Amara Raja / BCH / Tritech / Chhabil / Sab Nif / Universal / Masstech C&S / Elpro / Power gear / General / Stardrive / Suman Control / BHEL Ductail / L&T / Malde / Siemens / CGL ABB / Alstom / Easun Reyrolle / GE / Multilin / Siemens / Alstom Auto Con, Logix, Future Electronics ABB / AE / CGL / Prayog / Pragati / KAPPA Alstom / GE Power Controls / L&T / Siemens / ICA / BCH / BHEL
491
DC Motors df/dt Relay Digital Meters Distance Protection Relays EHV XLPE Cables FD, TPN SFUS Feeder Protection (11kV Relays) Fuse Bases and HRC Fuses Generator Protection Relays HT Breaker Panels Illumination System Indicating Lamps Instrument Transformers 11kV & 415V) Insulators Isolators
IEC / KEC / Crompton Greaves Alstom / L&T / AVK-SEG AE / Enercon / L&T / Siemens ABB / Alstom / Easun Reyrolle / GE / Multilin / Siemens Nicco / RPG / KEI L & T /Schneider /Siemens/ABB ABB / Alstom / Easun Reyrolle / GE / Multilin / AVK-SEG L & T /Siemens/ABB ABB / Alstom / Beckwith / GE Multilin / Siemens ABB / BHEL / Siemens / Alstom/CGL Bajaj / CGL / Philips / Wipro Technic/Siemens/ L & T /Vaishno AE / Intrans / Kappa / Pragati / Prayog / Silkans IEC / Jayashree / Modern / WS Bimco / Elfab / GR Power / Kausik / PEI / SMC / S&S / Versatek / ABB / Universal / Pactil / Kiran C&S / Elpro / Enpro / Power Gear / Rajarajan / Suman Controls Bajaj/Crompton Greaves/Wipro IGE / Elpro / Lamco / Oblum / WS ABB / CGL / Siemens / KEC / NGEF ABB / Alstom / GE Power Controls / L&T / Siemens / CPRI approved ABB / GE Power / L&T / Siemens ABB / Alstom / Easun Reyrolle MDS Legrand /Indokopp/Groupe Schneider L&T / MDS / Siemens / Datar / CPRI approved Siemens/ABB/ L & T Alstom / Siemens/ Schneider
LAVT & Terminal Cubicles Lighting fixtures Lightning Arrestors LT Motors LT Panels LT Switchgear Components Master Trip & Auxiliary Relays MCB ELCB MCB Distribution Boards MCCB Microprocessor Based
492
Motor Overload Relays NGR Panel Outdoor Circuit Breaker Power & Control Cables Power Quality Meters Pressure Gauges Protection, Metering, Synchronising & Control Cubicle Protective Relays Push Buttons Relays Rotor Earth Fault & Sensitive Directional Earth Fault Relays (Microprocessor / Numerical Version) RELAYS Selector Switches Semiconductor Fuses SF6 Breakers Surge capacitor Temperature Scanner
Ampcontrols / Narkhede / Essen / National switch gear ABB/Crompton Greaves/ Areva / Kirloskar CCI / FGIL / Incab / Nicco / RPG / RR / Torrent / Universal / Finolex GE Multilin / L&T / Enercon / Conserv Bells / GIC / H. Guru / Waree ABB / Alstom / Easun Reyrolle / Elpro / Enpro Areva / Siemens / L & T /SEGC/ABB L & T /Siemens/Technic/Vaishno Siemens/ Group Schneider/ABB/L &T/ Alstom / AVK-SEG ABB / Alstom / AVK-SEGC
Kaycee/Salzar / AE Feroz / GE Power / Siemens ABB / Alstom / BHEL / CGL / Siemens Madhav / Narkhade / Vee Vee ABB / Massibus / Yokogawa Bluestar / Sun Transducers ABB / AE / Siemens Transformers Kirloskar / Crompton / Emco / Voltamp / Areva / Indo Tech / Siemens / Bharat Bijlee / PETE Trivector Meters ABB / L&T / Allen Solly / Sun Variable Frequency Drives ABB / GEC / Siemens / TB Wood / L&T XLPE Cable Termination 3M Birla / CCI / M-Seal / Raychem Kits
493
4.1.4
Instrumentation Air filter regulators Analysers Control valves Desuperheaters Draft Gauges Flow nozzles / Orifice Shavo-Norgon / Placka ABB / Rosemount / Yokogawa / Emerson MIL / ARCA / Fouress / IL / ABB / Dresser / Fisher ABB Introl / Chemtrol Forbs Marshal / Key Stone / Fisher Switzer / Bells / Levcon Micro precision / Hydro pneumatics / Fairflow / IL / General instruments / Gurunanak / Placa Bells / Rosemount / JNM / ABB / MIL / Moore / MTL Alfa Laval / Pennwalt Bells control / IL / Chemtrols H. Guru / GIC / Bells / Waree Switzer / Danfoss / Infoss / Verma Spirax Marshall / Pennant / Greaves Cotton Spirax Marshall / Triveni / Bhatia / Strainwell ABB / JNM / Foxboro / Rosemount H. Guru / GIC / Bells / Wica / Waree General Instruments / Pyroelectric / Altop / Toshniwal Rosemount / Honeywell / Yokogawa / Bells / Moore / E&H APC / DB / Emerson ABB / C-Doctor / Crompton / GEC / Voltas Bently Nevada / Shinkawa / Provibtech (USA) / B & K Holland
IP converters Oil Centrifuge Power cylinders Pressure gauges Pressure switches Steam traps Strainers SWAS Temperature Gauges Thermocouples Transmitters UPS Ventilation system Vibration system
Note: If the eligible EPC Tenderer is a manufacturer of any sub-components, the same will be acceptable. The Tenderer may request for additional approvals during the technical pre-bid meeting.
494
4.2 LIST OF SPARES 4.2.1 List of Spares for steam generator Sr. No. A. Item Pressure Parts a) Gaskets for drum manhole b) Pressure part bends Non Pressure Parts Spares for drum safety valve a) Valve disc b) Adjusting rings c) Spindle Super-heater safety valve a) Valve disc b) Adjusting rings c) Spindle Isolating valve for main steam a) Gland packing for main steam b) Gasket c) Packing Feed water isolating valve a) Glands packing for isolating valve for feed water b) Gasket Packing ring isolating valve for Attemperator a) Gland packing for isolating valve of attemperator b) Gasket c) Packing ring Feed water control valve a) Gland packing b) Seal ring c) Body bonnet gasket Unit Quantity
No. No.
2 10
B. 1.
No. No. No. No. No. No. Set Set Set Set Set
1 2 1 1 1 1 1 1 1 1 1
2.
3.
4.
5.
Set Set Set Set Set No
1 1 1 1 1 2
6.
495
Sr. No. 7.
Item SH Spray Control Valve a) Gland packing b) Seal ring c) Body bonnet gasket Fans a) ID fan bearing b) ID fan rotor c) SA fan bearing d) FD fan bearing Rotary Feeder Feeder valves Steam generator feed pump spares (like seals, gaskets, etc.) Valves (high pressure) a) 25 NB b) 50 NB c) 100 NB d) 200 NB e) Push buttons & indicating f) Fuses g) Gaskets
Unit
Quantity
Set Set Nos. No. No. Set Set Nos. Set
1 1 2 2 1 1 1 2 1
8.
9.
10.
2 2 2 2 3 nos. of each 2 nos. of each type 2 nos. for each high pressure flange 2 2 2 5 5 5 2 2 1
11.
Description a) Thermocouples b) Temperature monitors c) Feeder rotor d) Annunciator lamps e) Fuses f) Relays g) Pressure gauges shatter proof glass h) Temp. gauges shatter proof glass i) Level gauge toughened glass
496
Sr. No.
Item j) Slight glasses k) Alarm annunciator card l) Pressure gauges
Unit 1spare each 1 4
Quantity
12.
Tubes : 5% (to nearest figure) of all profiles for furnace, water walls, Eco, APH & SH
4.2.2
List of Spares for steam turbine generator Sr. No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. Description Set of radial and thrust bearing pads Front bearing supporting plates Rods for grid valve actuator Oil retaining rings Fuses Oil ring RTDs Gear box bearings, both high & low side Oil filter element for control and lube oil Spare vibration probes Spring for over-speed trip device Gaskets for governor valve and emergency stop valve Sheet packing for Condensers Tube for Condensers Sheet packing for Air Ejector Tubes for Air Ejector Gland Packing for CEP Bearing for CEP Cooling tubes for air cooler Sheet packing for air cooler Oil seal for main oil pump Oil seal for Aux. Oil pump Oil seal for emergency oil pump Quantity 1 set 1set 2 nos. 1 set of each type 1 of each type 2 of each type 1 of each type 1 set 2 sets of each 2 sets 1 no. 1 set each 1 set of each 20 pcs. 1 set of each 4% of total tubes 1 set of each 1 set of each 8% of total tubes 1 set of each 2 sets of each 2 sets of each 1 set of each
497
Sr. No. 24. 25. 26. 27.
Description Elements for Control Air Filter Packing for control filter 1 set of rotating diodes Bearing for AC Generator
Quantity 4 sets of each 4 sets of each 1 set 1 set of each
4.2.3
List of Spares for cooling tower Sr. no. 1. 2. 3. 4. 5. 6. 7. Description Motor bearings DE / NDE Set of oil seal Bolt, nut and rubber bush Sprayers / nozzles End flush valves Bearing for gear box Nozzles Unit Set Nos. Set Set Set Set Nos. Quantity 1 2 2 50 5 1 20
4.2.4
List of spares for WTP Sr. No. 1 Description Degassed Water Pumps Set of bearings (drive end) Set of bearings (non drive end) Set of gaskets Set of oil seals Effluent Disposal Pumps Bearing set , both ends Lobe Type / Roots Blowers Air Scouring Blowers Bearings, both ends Degasser Blower Complete rotor assembly including impeller, wheel, hub, nuts bolts and shaft Unit Quantity
Nos. Nos. Nos. Nos. Nos.
1 1 1 1 1
2 3
Nos.
Set
498
Sr. No. 5
Description Strong Acid Cat-ion Exchanger Resin Strainers Resin trap element Strong Base Anion Exchanger Resin Strainers Resin trap element Mixed Bed Unit Resin Strainers Resin Trap Element Activated Carbon Filter Activated Carbon Filter bed material Strainer PP Ball Valves 15 NB 25 NB 40 NB Rubber Lined Diaphragms Valves 20 NB 25 NB 40 NB 50 NB 80 NB
Unit
Quantity
LTR Dozen Nos.
50 5 1
LTR Dozen Nos.
50 5 1
LTR Dozen Nos.
10 5 1
KG KG Nos.
50 50 10
Nos. Nos. Nos. Nos. Nos. Nos. Nos. Nos.
2 2 2 2 2 2 2 2
10
499
4.2.5
List of Spares for Electrical Evacuation Item No. 1 1.1 1.2 1.3 1.4 1.5 1.6 1.7 2 2.1 2.2 2.3 2.4 2.5 3 3.1 3.2 3.3 3.4 3.5 3.6 4 4.1 4.2 4.3 4.4 4.5 Description Battery charger & DCDB AC fuses of each rating DC fuses of each rating Bridge protection fuses of each rating Control fuses of each rating DCDB fuses of each rating SCR bridges of each rating Indicating lamps HT Switchgear Breaker closing coils Breaker tripping coils Indicating lamps HT fuse for PT LT fuses HT Bus Duct Neoprene rubber gaskets Seal off bushings TPN set of Cu flexible for SWGR end TPN set of Cu flexible for TRAFO end AL expansion joint TPN Control fuse for space heater LT Bus Duct Seal off bushings TPN set of Cu flexible for SWGR end TPN set of Cu flexible for TRAFO end AL expansion joint TPN Control fuse for space heater Unit Quantity
Nos. Nos. Nos. Nos. Nos. Set Nos. Nos. Nos. Nos. Nos. Nos. M Set Set Set Set Nos. Set Set Set Set Nos.
2 2 2 2 2 1 2 2 2 2 2 2 10 1 1 1 1 2 1 1 1 1 3
500
4.2.6
List of Spares for DCS Item No. 1 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 Description DCS Analog control I/O module card Digital input module card Temperature (T/C) input module card Temperature (RTD) input module card Terminal boards Input signal conditioning card Output signal conditioning card Signal distributor Unit Quantity
Nos. Nos. Nos. Nos. Nos. Nos. Nos. Nos.
1 1 1 1 1 1 1 1
4.2.7
List Of Spares For Balance Of Plant Equipments Sr. no. 1 1.1 1.2 1.3 1.4 1.5 1.6 1.7 2 2.1 2.2 2.3 2.4 Description EOT Crane Brake linings with necessary rivets / screws / fixtures for EHT Brake Overload relay for each motor Coil for limit switch delay relay Limit switch HRC fuse links for all motors and for control circuit Seals for each thruster brake Indicating lamp of each type Plant Air Compressors O ring Sight flow glass Oil Filters Gasket bearing. Housing Drive side Unit Quantity
Set Set Nos. Set Set Set Set No. No. No. No.
1 1 2 1 1 1 1 1 1 1 1
501
4.2.8
List Of Spares for Fuel & Ash Handling Plants Item Description No. Fuel Handling Plant 1 Belt Conveyors 1.1 Idler Rollers for each belt width 1.1.1 Carrying 1.1.2 Impact 1.1.3 Return 1.2 Skirt Rubber 2. 2.1 2.1.1 2.1.2 2.1.3 3 3.1 Ash Handling System Belt Conveyors Idler rollers for each belt width Carrying Impact Return Screw Conveyor Hanger bearing bush Unit Quantity
Nos. Nos. Nos. M
10 10 10 10
Nos. Nos. Nos.
3 3 1
Nos.
502
4.3 4.3.1
LIST OF DRAWINGS & DOCUMENTS General All I.B.R. test certificates required to be submitted to the Boiler directorate/chief inspector of Bihar and all approvals to be obtained by the Tenderer. It shall be the responsibility of the Tenderer to provide all necessary information / documentation / follow up and arrange inspection of the Boiler Inspector. The responsibility of the steam generator Tenderer regarding IBR shall be only to be completed after handing over of P.O. and steam (Safety Valve) test certificate from the Boiler Inspector, along with required documents & drawings. Single line drawing to be provided by Tenderer will inter-alia include: 3 element drum level control, de-aerator level and pressure control, furnace draft control, steam temperature control etc. Tenderer will provide P & I drawings for feedwater system, de-aerator cum storage tank, blow-down tank, combustion control, LP & HP dosing, sample coolers arrangement, steam line, air line, fuel feeding, GA, plot plan, etc. Detailed list of drawings for information / approval to be freeze during kick-off meeting. All the drawings shall be approved and vetted by the Owner /their Consultants. All drawings which are to be approved and finally approved drawings, instruction and maintenance manuals of all equipments and other details will be handed over as under before commissioning. (a) 6 sets for the Owner including soft copy on CD. (b) 2 sets for the consultants to the Owner including soft copy on CD. The Tenderer shall submit all major drawings for approval, as well as a drawing list from which the Owner/Consultant will select those drawings which they consider necessary for completion of drawing approval. Before starting manufacturing of the equipment, the Tenderer shall have to take approval of the design drawings from the Owner/Consultant. Any manufacturing done prior to approval of the drawings shall be rectified in accordance with approved drawings by the Tenderer at his own cost, if any discrepancy arises and the equipment shall be supplied within stipulated period.
503
General Arrangement drawing shall be submitted for approval to the Owner/Consultant prior to the commencement of detailed engineering by the Tenderer. These drawings shall show to scale, location and size of building facility and all major equipment including electrical. Equipment and building outlines and overall dimensions as well as tie-in dimensions and clearances shall be clearly indicated. The Tenderer will be required to furnish all the necessary drawings data, etc. of the plant/equipment with appropriate status stamp in adequate number of copies as indicated below. Sr. No 1. 2. 3. Status of the drawing/ document etc. Reference/informati on For approval Final & certified duly signed No. of copies for No. of copies for Owner Consultant 2 prints 2 prints 3 prints 2 prints
6 7
Operation maintenance manual Performance & 2 copies acceptance test procedure All other documents 3 copies As built drawings 3 copies for the entire project
2 prints 4 prints & 1 reproducible tracing/ sepia & soft copy in CD & 3 copies + CD
1 CD 2 copies
2 copies 1 copy
Within a period of ten (10) days after the receipt of those drawings/document, the Owner/Consultant shall signify his approval or otherwise. The Tenderer shall submit copies of all drawings which are required to be approved by the Owner/Consultant. The drawings which are approved by the Owner/Consultant shall not be deviated from.
504
The drawings submitted by the Tenderer for approval shall contain all information regarding the manner in which equipment is going to be located and all the loading data for the Owner/Consultant to design suitable civil foundation. The drawing should show details of piping and electrical connections to be made by the Owner/Consultant for connecting the Tenderers equipment in the system. The operating & maintenance instruction and the erection procedures together with drawings of the equipment as completed shall be in sufficient detail to enable to Owner to properly erect/install the equipment, to maintain, dismantle, reassemble and adjust all parts of the equipment. The manuals shall give stop-to-step procedures for all operations likely to be carried out during the life of the plant/equipment including during erection, commissioning, testing, operation & maintenance, dismantling and repair. The manuals shall also contain copies of approved drawings as well as the performance/rating curves and copies of test certificates, if applicable. The maintenance instructions shall include the lubrication procedures, periodicity of lubrication as well as the brands of Indian lubricants to be used to ensure trouble free operation. Indicative list of drawings to be submitted are given below. The final list including classification for information / approval will be freezed during the kick-off meeting. Apart from the below list, overall plant GA, overall electrical SLD, fire fighting scheme, integrated plant piping, chimney height & diameter calculations, P & IDs for raw water, treated water, compressed air & cooling water, design basis of all civil structures, design of main boiler steel columns, etc. will be submitted for approval.
505
4.3.2
Tentative list of Drawings / documents to be submitted for steam generator Sr. No. 1) 2) 3) 4) 5) 6) 7) 8) 9) 10) 11) 12) 13) 14) 15) 16) 17) 18) 19) 20) 21) 22) 23) 24) 25) 26) 27) 28) 29) 30) 31) Item P & I Diagram Steam and water system P & I Diagram Plant steam system P & I Diagram De-aerator, FWPS & Dosing System P & I Diagram Air & Flue gas system P & I Diagram for HP Heater Boiler performance data sheet Sizing Calculation for Boiler feed pump (for both capacity & head) Sizing Calculation for Boiler feed water transfer pump Main steam line pressure drop calculation Piping line list Thermal insulation schedule (for piping & boiler) Valve Schedule Technical specifications for FD Fan Technical specifications for SA Fan Technical specifications for ID Fan Technical specifications for Boiler feed pump Technical specifications for Boiler feed water transfer pump Technical specifications for ESP Technical specifications for Soot Blowers Technical specifications for CBD valve Technical specifications for IBD valve Technical specifications for Boiler safety valve ( Drum & SH) HP dosing system LP dosing system Control valve Data Sheet Gate, Globe, Check valves Drum level gauge GA Plan (Combined with elevation) Main foundation Drawing Auxiliary foundation Drawing Terminal point drawing
506
Sr. No. 32) 33) 34) 35)
36) 37) 38) 39) 40) 41) 42) 43) 44) 45) 46) 47) 48) 49) 50) 51) 52) 53) 54)
Item Design basis for boiler structural De-aerator Assembly General Arrangement Drawing of Piping EQUIPMENT GA DRAWING a) ESP with loading data b) FD Fan c) SA Fan d) ID Fan e) LRSB f) Rotary Feeders g) Boiler feed pump h) Feed water transfer pump i) De-aerator j) Feed water tank k) CBD tank l) IBD tank ELECTRICAL & INSTRUMENTATION Single line diagram of boiler Single line diagram of ESP feeders Power & Control wiring for different types of feeders Cable tray & trench layout for the boiler Cable tray & trench layout for the ESP system Earthing layout drawing for the complete equipment in scope MCC Panel Specification GA, schematic and wiring diagrams of VFD panels Logic diagrams for drives Control schematics Hook up drawings Logic diagrams for soot blower system Instrument cable tray routing drawing Electrical load list Cable schedule Instrument schedule (List only) DCS I/O list Alarm set point list
507
Sr. No. 55) 56) 57) 58) 59) 60) 61) 62) 63) 64) 65) 66) 67)
Item Write up for control schematics JB schedule Sizing calculations for flow elements Motorized Valve Data Sheet. Actuator specs Instrument erection hardware details Flow elements Contract co-ordination procedure L2 Schedule Milestone activities Utility Requirement data Specification for Motorized valves Electrical Motor Selection
4.3.3
Tentative list of drawings / documents to be submitted for Steam turbine generator. Sr. No. 1) 2) 3) 4) 5) 6) 7) 8) 9) 10) 11) 12) 13) 14) 15) 16) 17) Item Specification For Control Valves Specification For Safety & Thermal Relief Valves BOM For Lube Oil System P&I Diagram For Lube Oil System GA With Foundation Plan For Lube Oil System GA Drawing For Duplex Lube Oil Cooler GA Drawing For OHT No-Load Mechanical Running Procedure Technical Specification For Steam Turbine Rust Prevention And Painting Procedure Test & Inspection Procedure Instrument List Of TG Auxiliaries Specification For CEP Allowable Nozzle Force And Moment P&I Diagram For Steam Line P&I Diagram For Oil Line Layout
508
Sr. No. 18) 19) 20) 21) 22) 23) 24) 4.3.4
Item P&ID For Vibration And Temperature Monitoring Generator Data Sheet Steam Flow V/S. Power Curves Specifications, GA & SLD Of AVR Panel And Breaker Cum Relay & Metering Panel Specifications, GA & SLD Of Battery Charger Cum DCDB Overall GA Powerhouse Plans
Tentative Drawings / documents to be submitted for Fuel & ash handling Sr. No. 1) 2) 3) 4) 5) 6) 7) 8) 9) 10) Item Material of construction for all components Make, type and details for bought out items Overall assembly drawings for the equipment Layout for the handling system Equipment Size / Power / Belt Selection Calculation Overall assembly drawing showing the drive arrangement, etc. for each equipment Calculations for the select structure Copy of material certificates/ inspection reports Logic diagram / wiring diagram Layout drawings for the total fuel & ash handling system and for the equipment supplied
509
4.3.5
Drawings and documentations for Electrical evacuation The drawings and documents to be furnished by the select vender shall include but not limited to the following Sr. No. I 1. Item General Detailed bar chart for the design, manufacture, delivery, erection, testing and commissioning period with critical milestone activities Duly filled technical data sheets Single line diagram for the complete system, including 110 V, DC power distribution system Proposed hook-up arrangement drawings for plant, with layout plan and sections Physical installation layout of the complete plant, to show all electrical equipment in scope Earthing layout for the Cogen plant Earthing connection details Earthing sizing calculations Lightning protection calculations, for the buildings and structures Cable schedule and inter connection chart for complete cabling in scope Cable tray / trench layout drawings, duly marking all the cables with identification details Cable tray and support arrangement drawings Relay co-ordination chart and calculations for the complete equipment and systems in scope GA drawings, catalogues and wiring diagrams, as applicable, for the items like capacitor banks, lighting fittings, lighting poles, junction boxes, receptacles, lighting and small power distribution boards, safety appliances, etc. Any other drawings / details, as required for CEIG and other statutory authorities Quality Assurance Plan List of manufacturers and specifications of all standard equipment Approval of Category Approval
2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.
Approval Approval Approval Information Approval Approval Approval Approval Approval Approval Information Approval Information
15. 16. 17.
Information Approval Approval
510
Sr. No. 18. 19.
Item Test certificates and inspection reports of all equipment Erection manuals and installation procedures for all equipment Operation and maintenance manuals for all equipment and systems As-Built drawings Switchyard Equipment Layout, with plan and sections for switchyards at plant end and sub-station end Dimensional General Arrangement Drawings, wiring diagrams, name plate details, terminal details, cable box / bushing details and drawings, for all equipment in switchyard Design calculations for the following - Equipment supports and structures - CT, PT burden calculation - Earth mat design calculations - Lighting calculation, for switchyard illumination - Bus bar sizing calculation - Support structure design calculations - Bus support insulator cantilever strength calculation - Switchyard lightning protection calculations Construction drawings to include - Equipment supports / load data - Switchyard foundation arrangements - Transformer foundation arrangement drawings - Cable trench and tray drawings - Oil soak pit drawings - Oil drain arrangement drawings - Details of equipment earthing - Structure drawings Junction box / marshaling box details Transformers General out line drawing, showing front side elevations and plan views of the transformer and all accessories and external features with detailed dimensions, weights, crane lift for untanking and for erection / removal of bushings, size of lifting lugs and pulling eyes, HV and LV terminal clearances
Approval of Category Information Information Information Information Approval Approval
20. II 1. 2.
3.
Approval
4.
Information
5. III 1.
Information Approval
511
Sr. No.
Item , live terminal to ground clearance, quantity of insulating oil, dimensional details for foundation Assembly drawings of HV, LV and Neutral groundings Schematic control and wiring drawings and drawings showing temperature indicator circuits and control system for cooling equipment Drawing showing construction and mounting details of marshalling box Drawing, giving details of name plate, terminal marking and connection diagram Drawing on tap changer gear assembly Remote tap changer control panel Remote tap changer control circuit The magnetization characteristic curves of the bushing current transformers, indicating the knee point voltage excitation current and secondary resistance Drawing on terminal clamps Core saturation curves Final drawings shall be supplied for the transformer, sufficiently before the actual dispatch of the equipment All bulletins, complete instruction manuals for the erection, operation and maintenance of the transformer are to be supplied before they are dispatched 11KV and LT switchgear panels and VFDs Design calculations for bus bars for short circuit and and temp rise Connection diagram for all units (like incomer, outgoing feeders, breaker wiring diagrams, starter wiring diagrams, etc.) Schematic diagram for the complete switch board Terminal connection diagram of the main terminal boards Sketches of the overall dimensions of the board / bus duct Plan, elevation and section views clearly showing the bus size Typical internal arrangement drawings for all types of feeders, showing clearly the dimensions of components / devices and clearances
Approval of Category
2. 3.
Information Information
4. 5. 6. 7. 8. 9.
Information Approval Information Information Information Information
10. 11. 12. 13.
Information Information Information Information
IV 1. 2.
Approval Information
3. 4. 5.
Approval Information Approval
6.
Information
512
Sr. No. 7.
Item Brand names of all components incorporated like, circuit breakers, relays, contactors, pilot device, pilot lamps, current transformers, HRC fuse fittings / links, terminal blocks, wirings, cable sockets, meters, selector switches for instruments, instrument fuse fittings / links etc. Guaranteed technical particulars for the critical components Certificates of tests giving the results of tests conducted as per the appropriate standards on similar switchboard and interior components Bus ducts General arrangement and routing drawings to show the support arrangements Cross section of the bus duct, to show bus bar support details, space heaters, breathers, flexible, joints, bends, bellows, seal off bushings, etc. Calculations for sizing and temp rise Type test certificates Protection, Metering and Control Panels General arrangement drawings showing front, rear and side views, inter connection and wiring diagram as well as other drawings which may be deemed necessary by the Owner. Approval of the GA drawing is required before the fabrication of panel starts. Approval of wiring and inter connection drawings is required before the manufacturer proceeds with the panel wiring The following drawings, dimensioned and drawn to scale : - Layouts of front and rear cubicles complete with identification markings for all mounted devices and complete list - General construction showing section views, details and framing - The above drawings shall incorporate the following details : - Power and control systems run ways - Outline including shipping dimensions - Mounting holes - Foundation details - Sufficient details to demonstrate accessibility of equipment for operation and maintenance
Approval of Category Information
8. 9.
Information Information
V 1. 2.
Approval Approval
3. 4. VI 1.
Information
Approval
2.
Information
513
Sr. No.
Item - Details of emblems, escutcheon and name plates (with exact lettering) - Panel cutouts - Total weight of each panel section - Size and location of ground bus - Location and size of internal lights, heaters, etc. maximum load (kW) Bill of material shall correlate components to outline drawings and diagrams. Components may be identified by the manufacturer and his catalogue numbers Each device designation correlated to outline and wiring diagrams. Contact development diagrams of control, selector, etc., switches push buttons Following schematic & wiring diagrams shall be furnished: - Each type of device internal wiring diagram Control power supply circuit voltage and source requirement for un-interruptible or interruptible. Each control circuit breaker size and trip rating. Control supply one line diagrams (AC, DC and un-interruptible AC) Cubicle internal connection wiring diagrams shall show identification of devices, terminals and connecting wires Interconnection schedule, to show clearly any connections to be made in field (because of shipping sectionalizing) DC System GA and wiring diagrams of Battery Charger Battery sizing calculations Dimensional details of battery banks Illumination System Lighting layout to show main lighting distribution board, lighting transformers, sub distribution boards, MCB distribution boards and lighting fittings with identification numbers Single line diagram with identification details for all lighting fittings Lighting calculations for the complete system Typical drawings for poles, towers and other mounting arrangements
Approval of Category
3.
Approval
4.
Information
5. 6.
Approval Approval
7. 8. VII 1. 2. 3. VIII 1.
Approval Information
Approval Approval Approval Approval
2. 3. 4.
Information Approval Approval
514
CHAPTER - 5
DATA SHEETS
(To be submitted in soft & hard copies. Soft copies to be sent to rln@hpcl.co.in with copy to mitcondadar@vsnl.net) 5.1 STEAM GENERATOR & AUXILIARIES Sr. no. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. Parameters M.C.R with 100% bagasse (TPH) Capacity with biomass(TPH) Pressure at turbine inlet valve kg/cm2 Temperature at turbine inlet valve Pr. at boiler MSSV Temp. at boiler MSSV Feed water temperature at deaerator inlet 0C (minimum) (required minimum of 45C) Feed water temperature at deaerator outlet 0C Feed water temperature at eco inlet / HP heater no.2 outlet 0C Excess air % theoretical air (maximum) Temperature of flue gases at the boiler outlet with 100% MCR on bagasse Steam generator thermal efficiency on bagasse & biomass Bagasse consumption at MCR condition, kgs/kg Auxiliary power consumption, KW at 100% MCR with bagasse Steam Drum Material Specification ID mm Plate thickness mm Length mm Holding capacity m3 Furnace Water Wall tubes Tube OD mm Thickness mm Pitch mm Value
515
Sr. no. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. 45. 46. 47. 48. 49. 50. 51. 52. 53. 54. 55. 56. 57. 58. 59. 60. 61.
Parameters Material specification Heat transfer area m2 Boiler Bank Tubes Arrangement Tube OD mm Material Heating surface m2 Boiler headers Diameter OD mm Thickness mm Material specifications Superheaters Type of superheater arrangement Location of superheater Superheater elements OD Superheater elements thickness Material Heat transfer area Type of attemperation No. of stages Turndown ratio Furnace (effective) Length of furnaces Width of furnaces Furnace area Heat release rate Material of grate bars Economiser OD of coil tube Thickness of coil tube Heating surface Precautions for erosion Air Preheater Air preheater tube dia Air preheater tube thickness Tube material specification Total heating surface
Value
516
Sr. no. 62. 63. 64. 65. 66. 67. 68. 69. 70. 71. 72. 73. 74. 75. 76. 77. 78. 79. 80. 81. 82. 83. 84. 85. 86. 87. 88. 89. 90. 91. 92. 93. 94. 95. 96. 97. 98.
Parameters Precautions for erosion Provision of Corten Steel Total HTA (m2) Pressure parts (effective) HRU Fans technical parameters Nos. of fans per steam generator nos. Capacity of the fan cu.m/sec(each) At MCR kW(each motor) Recommended drive motor kW Electrical driven FWP Nos. of pumps Capacity Head Drive power kW Deaerator Flow rate(m3/hr) Deaerator storage tank (m3 ) ESP Inlet dust concentration Gas flow Outlet dust concentration No. of fields VFD for fans VFD for fuel feeders Gas Velocity - Furnace - Boiler bank - Superheater - Economiser - Airpreheater - ESP No. & type of soot blowers Pressure & temperature of steam to soot blowers Capacity of bagasse silo Inclusion of SWAS Hot / cold ducting thickness Hot air / flue / cold air velocity, m/sec
Value
ID
FD
SA
517
Sr. no. 99. 100. 101. 102. 103. 104.
Parameters Inclusion of blow down flash recovery Aluminium cladding thickness Inclusion of steam flow meter Inclusion of cinder re-injection Make of travelling grate Inclusion of performance test as per ASME PTC 4.1, indirect method
Value
5.2
STEAM TURBINE GENERATOR & AUXILIARIES Sr. No. 1. 2. 3. Parameters Capacity, KW Inlet steam parameters, kg/cm2 , Deg C Steam flow to condenser in season to generate 20 MW at given steam flows to process in this tender HBD, TPH Specific steam flow in off-season to generate 20 MW, kg/kW No. Of Bleeds (Uncontrolled extraction) No. Of Pass out (internally controlled extraction.) Electronic over-speed trip. No. of nozzle control valves Make and model of governor. Pneumatically operated quick acting Non-return valve for a) Bleed lines b) Controlled extraction line Gland sealing system. No. of steam vent fans in gland condenser. Flash vessel for drain. Lagging and cladding. Temperature monitoring system. a) All bearings (Turbine, Gear box, and Generator) Nos. b) Turbine casing Nos. Make & model of vibration monitoring system. Value
4. 5. 6. 7. 8. 9. 10.
11. 12. 13. 14. 15.
16.
518
17. 18.
19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35.
36. 37. 38. 39. 40. 41. 42.
Non-contact type vibration transducers for each bearing. Displacement transducer - Turbine thrust bearing (Dual Type) - Turbine casing expansion. High speed coupling type. Provision of coupling guard. Type of gear box and service factor Gear Box input /output speed Gear ratio. Type of main oil pump. Barring arrangement. Motor rating. Type of coupling. Auto engagement and disengagement provision. Facility for manual barring. Low speed coupling type. Provision of coupling guard. Inclusion of MOP Inclusion of AOP Inclusion of EOP Oil cooler - Nos. - MOC Oil reservoir capacity as holding time Oil centrifuge system as % of total lube + control oil Capacity of OH oil tank in terms of coasting down time Provision of Duplex oil filter (Lubricating) Provision of Duplex oil cooler (Control) Differential oil pressure switch / Alarm across filter for lube / control). No. of oil vapour extractor.
519
43.
44. 45. 46. 47. 48. 49. 50. 51. 52. 53. 54. 55. 56. 57.
58. 59. 60. 61. 62. 63. 64. 65. 66. 67.
Alternator Rating, KW Voltage, KV Speed, RPM Class of insulation Cooling Efficiency at 100%, 80%, 60% capacity rating Rated frequency Power Factor. Overload Capacity Applicable Standard. No. of bearings. Insulation Class for Rotor, Stator and Exciter F Temperature rise class B Excitation system (Brush less with PMG) Short circuit ratio. Location of water cooler Capacity of cooler (2 x 100%) Provision of water leakage detector. Provision of Rotor earth fault detector. No. of RTDs. - In stator (2 per phase min.) - In cold air circuit (min 2) - In warm air circuit (min 1) - In each bearing (min 2 nos.) Provision of modes in AVR. No. of Auto modes (min 2) No. of Manual mode (min 1) Provision of rotating diode failure detector. Metering Panel including amps, voltage, kw, kvar, kva, kwh Provision of TVM with output signal to monitor & record all electrical parameters NGR to restrict fault current to 100 A for 30 Sec. LA and VT panel Rating of station class lightening arrestor (10 kA, 12 kV) Rating of station class surge capacitor (0.25 micro farad, 11 kV)
520
68. 69. 70. 71. 72.
73.
74. 5.3
Synchronization panel Auto synchronizer Details of temperature scanner Make of auto synchronizer Inclusion of external PRV, mating flange, pressure & temperature gauge, flow transmitters, safety valve, DSH and QCNRV for bleeds Inclusion of QCNRV mating flange, pressure & temperature gauge, flow transmitters and safety valve for controlled extraction No. of turbine stages
WATER TREATMENT PLANT & AUXILIARIES Sr. No. 1. 2. 3. 4. 5. 6. 7. Parameters Piping from raw water reservoir Clarifier / Clarifloculator / tube settler Inlet well, flash mixer, floculator etc., Dosing System Dosing Tanks Dosing Pumps Plant Instrumentation a) Pressure gauges b) Measuring / metering devices c) Flow meters d) Water meters with totalliser e) Any other miscellaneous instruments Clarified water pumps, capacity & head Settled water tanks in 2 parts (Clarified water storage tanks RCC) Basket strainers for clarifier water pumps All valves, fittings, piping etc., Pressure Filters Value
8. 9. 10. 11. 12.
521
Sr. No. 13.
14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42.
Parameters 2 nos. multi-grade vertical pressure filters, as per design, dished ends, air valve, pressure gauges, media mounted on RCC saddles, piping, headers, washing devices, delivery end, flange and sluice valves for working pressure as required by UFROMB unit and softener unit (minimum 40 M head) and all piping (Epoxy / MS) Activated carbon filters for UF RO + MB Unit UFRO Unit 1 stream - capacity Basket Filter MOC MSRL / SS RO feed pumps MOC SS 304 Mixed Bed Unit Degasser Tower All internals exposed to vapour / gas should be MSRL Blower for degasser Nos. Degasser Tank / Sump Degasser Water Transfer Pump No. of pumps Acid Measuring Tank Caustic Measuring Tank MOC No. of Blowers Instrumentation Conductivity meters Flow meter Pressure Gauges Hydraulic ejectors Morpholine / Hydrazine dosing tank Metering pump Softener Plant Activated Carbon Filters (Softener) MOC Thickness of shell plate Softeners Flow rate m3 / hr
Value
522
Sr. No. 43. 44. 45. 46. 47. 48. 49. 50. 51. 52. 53. 54. 55. 56. 57. 58. 59. 60.
Parameters Average MOC Brine Preparation Tank MOC Brine Measuring Tank Filtered Water (Service Water) scheme Specification of chemical storage & water storage tanks Hydrochloric Acid one tank Level Indicator MOC Caustic Lye Tank Cylindrical vertical tank with flat bottom and top end covers to hold 15 m3 of 50% caustic lye Level Indicator MOC Storage Tank for DM water MOC Level Indicator To provide float and scale device to increase the quantity of water in the tank and level transmitter with output to DCS Storage Tank for Soft water Level Indicator MOC Filtered water (service water) Tank MOC Level Indicator Potable Water Storage Tank including chlorination Specification of pumps General Pumps for Hydrochloric acid, as per design Pumps for raw water Fire Hydrant Pumps (As per relevant standards) Header and other details as per relevant standards. Clarified Water Transfer Pumps DM water transfer pumps
Value
61. 62. 63. 64. 65. 66. 67. 68. 69. 70. 71. 72. 73. 74.
523
Sr. No. 75. 76. 77.
Parameters Service water (filtered water transfer pumps) Potable Water Pumps Hydrochloric Acid & Caustic Lye
Value
5.4
COOLING TOWER 1. Design & Operating Conditions : Total tower capacity, m3/hr : No. of cooling towers, Nos : Cells per tower, Nos : Cells operating, Nos : Flow per cell, m3/hr : Type of tower 0 : Hot/re-cooled water temp., C Design inlet wet bulb temp : (without recirculation allowance), 0C : Tower operation : Type of water handled Constructional features : : Fan blade construction : Type of fill : Basin type Cold water (outlet) temp. : indicator Duty conditions Total design capacity Flow per cell Hot water inlet temperature Re-cooled water temperature Design inlet wet bulb temperature Design approach Total no. of cells/tower Number of cells operating
2.
3. 2. 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8
m3/hr M3/hr Deg. C Deg. C Deg. C Deg. C
524
5.5 5.5.1
FUEL & ASH HANDLING Belt Conveyor (To be filled up for all conveyors) S No 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Description Conveyor No Conveyor Type Profile Centers Material handled Bulk density Capacity Volumetric capacity Belt Speed C-C distance Lift Belt Width Material Construction/Grade Cover Grade Factor of Safety Gear Box Type Reduction Ratio Service Factor Coupling Type Head Pulley Head Pulley D X L X T Shaft Diameter Rubber Lagging Tail Pulley D X L X T Take Up Pulley D X L X T Idlers Idler Classification Carrying Idler Unit Value
TPH Cu. m /sec m/sec m m mm
12.
13. 14.
mm mm mm mm mm
15.
525
S No
Description Type Pipe Dia / Length Spacing Idler Housing Shaft diameter Impact Idler /Transition Idlers Type Pipe Dia / Length Spacing Idler Housing Shaft diameter Rubber Rings Dia /Material Return Idler Type Pipe Dia / Length Spacing Idler Housing Shaft diameter Take Up Type Bearing Type / make Belt Cleaners Internal External Hold Backs / Brakes Coasting Time Skirt Board Type / Location Material Thickness Rubber Skirt Skirt Length Deck Plate Location Material Thickness Hood Type Hood plate thickness Guide rollers Spacing
Unit mm mm mm
Value
mm mm mm mm
mm mm mm
16. 17. 18.
19. 20. 21.
Sec
22.
23.
24.
526
S No 25. 26. 27. 28. 29. 30.
Description Conveyor Frame type Short Support Discharge chute Plate Thickness Drive Base Frame Gallery Walk-way Safety Switches Zero speed/ Pull Cord /Belt Sway Contact Protection
Unit
Value
5.5.2
Chain Conveyor S No 1 2 3 4 5 6 7 8 9 10 11 Description Conveyor No Conveyor Type Profile Centers Material handled Bulk density Capacity Volumetric capacity Chain Speed C-C distance Lift Chain Pitch Material Roller Diameter Pin Material & Diameter Factor of Safety Make Gear Box Make Type Unit Value
TPH Cu. m /sec m/sec m m mm mm mm
12
527
S No
13 14
15
Description Reduction Ratio Service Factor Coupling Type Drive Sprocket Diameter No of teeth Shaft Diameter Non driven Sprocket Diameter No of teeth Slats Width Thickness Pitch Take Up Type Bearing Type / make Hold Backs / Brakes Coasting Time Skirt Board Type / Location Material Thickness Rubber Skirt Skirt Length Deck Plate Location Material Thickness Hood Type Hood plate thickness Conveyor Frame type Short Support Discharge chute Plate Thickness Drive Base Frame Gallery Walk-way
Unit
Value
mm mm mm mm mm mm mm mm mm
16 17 18 19 20
Sec
mm mm
21
mm
22
mm
23 24 25 26 27
mm
528
S No 28
Description Safety Switches Zero speed
Unit
Value
5.5.3
SUBMERGED BELT CONVEYOR S No 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Description Conveyor No Conveyor Type Profile Centers Material handled Bulk density Capacity Volumetric capacity Belt Speed C-C distance Lift Belt Width Material Construction/Grade Cover Grade Factor of Safety Make Gear Box Make Type Reduction Ratio Service Factor Coupling Type Head Pulley Head Pulley D X L X T Shaft Diameter Rubber Lagging Tail Pulley D X L X T Shaft Diameter Unit Value
TPH Cu. m /sec m/sec mtrs mtrs mm
12.
13. 14.
mm mm mm mm mm
529
S No
Description Snub / Bend Pulley D X L X T Shaft Diameter Take Up Pulley D X L X T Idlers Idler Classification Carrying Idler Type Pipe Dia / Length Spacing Idler Housing Shaft dia Impact Idler /Transition Idlers Type Pipe Dia / Length Spacing Idler Housing Shaft diameter Rubber Rings Dia /Material Return Idler Type Pipe Dia / Length Spacing Idler Housing Shaft diameter Take Up Type Bearing Type / make Belt Cleaners Internal External Hold Backs / Brakes Coasting Time Skirt Board Type / Location Material Thickness Rubber Skirt Skirt Length Deck Plate
Unit mm mm mm mm
Value
15.
mm mm mm
mm mm mm
mm mm mm
16. 17. 18.
19. 20. 21.
Sec
mm mm
22.
530
S No
Description Location Material Thickness Trough Type Size width X Length X Height Guide rollers Spacing Conveyor Frame type Short Support Discharge chute Plate Thickness Drive Base Frame Gallery Walk-way Safety Switches Zero speed/ Pull Cord /Belt Sway Contact Protection
Unit mm
Value
23.
mmxmm xmm mm
24. 25. 26. 27. 28. 29. 30.
mm
5.5.4
Screw Conveyor (To be filled up for all the screw conveyors) S No 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Description Conveyor No Conveyor Type Profile Centers Material handled Bulk density Capacity Volumetric capacity Tip Speed C-C distance Lift Screw Diameter Unit Value
TPH Cu. m /sec m/sec mtrs mtrs mm
531
S No
12.
13.
Description Pitch Material of Construction Gear Box Make Type Reduction Ratio Service Factor Coupling Type
Unit mm
Value
5.5.5
Structural Steel Work (CONVEYOR GALLERIES) Sr No 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Description Conveyor Galleries ( Conveyor wise) Overall Dimensions Type of Gantry Maximum slope on walkway No of approaches per conveyor Width of walkways / staircase Head room Provision of anti slip strips Live load for platforms and walkways Dynamic load factor considered for design Cladding material Handrails type Toe plate size / thickness Walk-way / platform grating type Unit Value
mmxmm
mm
532
5.6
EOT CRANE In Door (TG Building)
Location Power Supply Control Voltage Duty class / Spec. Mechanism Capacity (t) Speed (m/min) - Main/Micro (VVVF) No. of Falls Diameter (mm) Wire Construction/Factor of safety Rope Type Make Bkg. Strength (T) Qty. Type Frame size Motor Frame kW Duty No. of poles Make Brake Qty. Type
MAIN HOST
AUX. HOST
CROSS TRAVEL LONG TRAVEL
533
Make Brake Size Qty. Size Gear Box Make Ratio Qty. Total / Driving Thread Dia. (mm) Rail Size Wheel Girder dimensions & Construction Max. Load (t) Limit Switch (WMI) Trolley Height (t) Crane Weight (t) Lubrication
534
5.7
ELECTRICAL EVACUATION 5.7.1 a. b c. d. e. f. g. Distribution Transformer Rating (KVA) Voltage ratio Vector Group Quantity Type of cooling Temp. rise over an ambient of 50 C in oil by thermometer Tapping on HV winding : : : : : : : 2000 KVA 11 KV / 433 V Dyn11 2Nos. 2000 KVA ONAN 45 C 7.5 % through off circuit tap changer in steps of 2.5 % IS 2026 part I to IV Dyn11
h. i. j.
Ref. Standard Winding connection
: :
k. l.
Transformer losses (max. value without positive tolerance) No load at Rated Voltage and : Frequency Load Losses at 75C and Rated : Current at 0.8 p.f. : Impedance
2.5 KW 20 KW >6.25 %
The various fittings for the transformer will be as below : - Rating and diagram plate along with labels. wherever necessary - Earthing terminals - Lifting lugs for complete transformer - Air release plug on tank cover Dehydrating breather 0 1 No silica gel type with oil seal and connecting pipe. 150 mm dial Magnetic type oil level indicator with one set of contacts, for low oil level alarm - 1 No for the transformer conservator 150 mm dial oil temperature indicator with maximum reading pointer and electrically separate contacts for trip and alarm.
150 mm dial winding temperature indicator with maximum reading point and electrically separate contacts for trip and alarm Oil filling hope with cap, on conservator Oil conservator with drain valve and plug Drain valve with plug Filter valve with plug Sampling valves Explosion vent with double diaphragm and pressure equalizer pipe connection Thermometer pocket Double float type Buccholz Relay with two sets of contacts and one shutoff valve on either side of the Buccholz Relay Jacking lugs and hauling holes Marshalling box with wiring according to our standard practice Disconnection Chamber for H.V. Cable Neutral CT for REF
5.7.2 a. b. c. d. e. f. g. h.
Main Unit Transformer for cogeneration plant : 1 No. Rating Primary voltage Secondary Voltage Vector Group Impedance Frequency Type of cooling Application : : : : : : : : 20/25MVA 11 KV 132 KV YNd1 10% on basis of 20MVA 50 Hz ONAN / ONAF Generator transformer used for power export to grid at 132KV system 100 % continuous OLTC with RTCC and AVR Panel with tap range of + 10% to 10% in steps of 1.25 % Suitability for Bi-directional power flow required. Bushing Cable box suitable for XLPE cables
i. j.
Duty Tapping
: :
k.
Terminal arrangement HV Terminal LV Terminal
: :
536
l.
: Ref. Standard and Basic Insulation level to be considered Transformer losses at 25 MVA ONAF rating (max. value without positive tolerance) No load at Rated Voltage : and Frequency Load Losses at 75C and : Rated Current at 0.8 p.f. : Aux. Losses in ONAF
IS 2026 part I to IV BIL 650 KVp
j.
20KW 110KW 3KW
m.
The various fittings for the transformer will be as below : - Rating and diagram plate along with labels. wherever necessary - Earthing terminals - Lifting lugs for complete transformer - Air release plug on tank cover Dehydrating breather 0 1 No silica gel type with oil seal and connecting pipe. 150 mm dial Magnetic type oil level indicator with one set of contacts, for low oil level alarm - 1 No for the transformer conservator 150 mm dial oil temperature indicator with maximum reading pointer and electrically separate contacts for trip and alarm. 150 mm dial winding temperature indicator with maximum reading point and electrically separate contacts for trip and alarm - Oil filling hope with cap, on conservator - Oil conservator with drain valve and plug - Drain valve with plug - Filter valve with plug - Sampling valves - Explosion vent with double diaphragm and pressure equalizer pipe connection - Thermometer pocket - Double float type Buccholz Relay with two sets of contacts and one shutoff valve on either side of the Buccholz Relay - Jacking lugs and hauling holes - Marshalling box with wiring according to our standard practice
537
Disconnection Chamber for L.V. Cable 2 Core Neutral CT for Stand by Earth Fault and REF protection
5.7.3
132 KV Switchyard equipments : a) 132 KV Isolators a. Type : Motorised, Horizontal Centre Rotated, Double Break, Out Door type 1 No. with Earth Switch 2 Nos. without Earth Switch 132 KV 145 KV 40KA for 3sec. 1250 A 3 Copper tinned / 6 No + 6 NC 110V DC To be furnished On fabricated outdoor Structure 31 mm/KV
b. Quantity
c. d. e. f. g. h.
Rated Voltage Highest system voltage Fault level Continuous Rating No. of Poles Material of Moving silver plated Contact i. Auxiliary Contacts j. Control Supply k. Type test certificate: l. Type of Mounting m. Creepage Distance
: : : : : : : : : : :
538
b)
132 KV Lightning Arrestor a. Type b. c. d. e. f. g. h. i. Quantity Rated Voltage Nominal discharge current Fault level of system Discharge Class Surge Counter Type test certificate Creepage Distance : : : : : : : : : Station Type, Out door 2 sets 120 KV 10 KA 40 KA for 1sec. 3 Required Required. 31 mm/KV
c)
145 KV SF 6 Circuit Breakers 1.0 1.1 Functional requirements : Reference Standards a. IS 2516 Specifications of Outdoor Circuit Breakers b. IEC 56 Specifications of Outdoor Circuit Breakers
1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 1.11 1.12
SF 6 Gas insulated Outdoor 132 KV (rms), 3 Ph., 50 Hz. 145 KV (rms) 650 KVp 1250 Amps. Neutral solidly earthed Three single poles gang Operated. Rated Operating Duty 0 - 0.3 sec - CO - 3 min. - CO cycle as per IEC 56 Maximum Closing time 150 m sec Maximum Breaking time at rated breaking capacity 60 m sec.
Type Installation Nominal system Voltage Highest system Voltage Basic Insulation Level Cont. Current Rating System Earthing Type of operation
539
1.13 1.14 1.15 1.16 1.17 1.18
One min. Power Frequency withstand Voltage 1.2/50 micro sec Impulse Test Voltage Short Circuit Current for 3 secs. Maximum permissible temperature Minimum Clearances in air Mounting
275 KV 650KVp 40 KA.
90C As per Manufacturers design On GI structure supplied by CB manufacturer.
2.0 2.1 2.2
2.3
2.4
2.5
2.6 2.7 2.8
2.9
Motor Charged spring Operating mechanism Mechanism housing Weather proof enclosure with IP 55 construction as per IS 2147 Porcelain Housing Single piece, vitreous, homogeneous porcelain material having creepage distance of 31mm/KV. Termination Incoming and outgoing terminal pads shall have max current density of 1.6 A/sq. mm Control voltages 110 V D.C. for breaker closing, opening and spring charging motor. Voltage Tolerances for 85% to 110% of rated closing coil control voltage Voltage Tolerances for 70% to 110% of rated Tripping coil control voltage Aux. Contacts Min. 10 NO + 10 NC aux. Contacts with contact rating of 10Amp. Control / indications a. Local Remote Selector required Switch b. Manually Operated
Other Particulars : Mechanism
540
c. d. e. f. 3.0 d) Quantity
Emergency Trip Push Button Anti Pumping device Mechanical indication of Breaker ON Mechanical indication of Breaker OFF Operation Counter 1 No.
132 KV Current Transformers 1.0 1.1 Functional requirements : Reference Standards
1.2
Type
1.3 1.4 1.5 1.6
1.7 1.8 1.9 1.10 1.11
Installation Nominal Voltage Highest system Voltage Basic Insulation Level for 3 sec. System Earthing Core applications Core Details C.T. Ratio Rated cont. Terminal current
IS 2705 Specifications of Current Transformers b. IS 2099 Specifications of Bushings for voltages above 10 KV c. IS 3347 Specifications for porcelain transformer bushings Single phase, Dead Tank, Oil filled and Hermetically sealed Outdoor system 132 KV (rms), 3 Ph., 50 Hz. 145 KV (rms) 650 KVp
a.
Solidly Earthed system. As given in SLD As given in SLD As given in SLD 400 Amps on primary and 10 Amp on secondary side.
541
1.12
1.13 1.14
1.15 1.16 1.17 1.18
One min. Power Frequency withstand Voltage 1.2/50 micro sec Impulse Test Voltage Short Circuit Current for 1 sec. Maximum permissible temperature Creep age distance Mounting Quantity
275 KV rms
650KVp 40 KA.
90C 31mm /KV On GI structural support. 3 Nos. - 5 core in 20/25MVA Trafo. bay 3 Nos. - 1 core in Switchyard Incoming bay for check Metering 3 Nos. - 1 core in Switchyard Incoming bay for tariff metering
e)
132 KV Potential Transformer 1.0 1.1 Functional requirements : Reference Standards
1.2 1.3 1.4 1.5
Type
Installation Nominal Voltage Highest system Voltage
a. IS 3156 Specifications of Potential Transformers b. IS 2099 Specifications of Bushings for voltages above 10 KV c. IS 3347 Specifications for porcelain transformer bushings Single phase, Oil filled and Hermetically sealed Outdoor system 132 KV (rms), 3 Ph., 50 Hz. 145KV (rms)
542
1.6
1.7 1.8 1.9 1.10 1.11 1.12
1.13 1.14
1.15 1.16 1.17 1.18
Basic Insulation Level for 3 sec. System Earthing Core applications Core Details P.T. Ratio Rated Voltage Factor One min. Power Frequency withstand Voltage 1.2/50 micro sec Impulse Test Voltage Short Circuit Current for 1 sec. Maximum permissible temperature Cree page distance Mounting Sec. Terminal Box Details Primary connection
650 KVp
Solidly Earthed system. As given in SLD As given in SLD 132KV/V3/110V / V3 1.9 for 30 sec. 275 KV rms for primary winding 2 KV for secondary side. 650KVp 40 KA.
90C 31 mm per kV On GI structural support. Weather proof terminal box with H.R.C. Fuses and removable glad cover. Neutral end of primary winding shall be connected to earth through removable link. 3 Nos. 3 core in 20/25MVA Trafo. bay 3 Nos. - 1 core in Switchyard Incoming bay for check metering 3 Nos. - 1 core in Switchyard Incoming bay for Tariff metering
1.19
1.20
Quantity
543
5.7.4
Busbar Trunking Sr. No. 1 1.1 1.2 1.3 1.4 Particulars General Location Indoor/Outdoor Reference Ambient Temperature Climatic Conditions Power System A) Voltage, Phase, Wire, Frequency B) Short Circuit Level C) Neutral Earthing Type of Bus Duct Bus Bars Material Rated Voltage and Continuous Current Short Time Current & Duration Dynamic Current Rating Air Clearance A) Phase To Phase B) Phase To Earth Insulator Creep age Distance Enclosure Degree Of Protection Provided Specific Data
: : : : : : : : : : : : : : : : :
1.5 2 2.1 2.2 2.3 2.4 2.5
2.6 3 3.1
5.7.5
L.T. Panels: 1.0 1.1 1.2 1.3 1.4 1.5 Switchgear Cubicle & Busbars Type of switchgear Rated Voltage and Frequency Max. System Voltage Class P.F. withstand Capacity for 1min. Short Circuit Withstand Capacity at rated voltage
: : : : :
544
1.6 1.7 1.8 1.9 2.0 2.1 2.2 2.3 2.4 2.5
Design Ambient. Temp. Cont. Current Rating of Busbar Max. Temp. at cont. Operating Current Applicable Standard Switchgear Construction Material of construction Thickness of Sheet steel Panel, Frame, Gland Plate, Doors, Removable covers, Partitions Degree of protection
: : : : : : : : :
5.7.6 L. T. Capacitors a. b. c. d. e. f. g. h. i. j. k. Designation Quantity and Output In KVAR Rated Voltage Ref. Standard Upper Limit of Temperature Category as per IS:2834 Location of Capacitors Connection and Switching Device through FSU and Contactors Size And Material Of Earth Bus Air Clearances for Live Parts Phase-Phase Phase-Earth Type Of Dielectric Material : : : : : : : : : : :
545
5.7.7
Switchgear Cubicle & Bus bars 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 2.0 2.1 2.2 Switchgear Cubicle & Bus bars Type of switchgear Metal Clad, Indoor, Draw out type Rated Voltage and 11KV, 3Ph., 50 Hz. Frequency Max. System Voltage Class 12 KV, Indoor switchgear P.F. withstand Capacity for 28KV (r.m.s.) for 11KV, 1min. 2.5 KV for 415 Volts Impulse Withstand Voltage 75 KV peak Short Circuit Withstand Capacity at rated voltage 40 KA for 3 sec. Design Amb. Temp. 50 C Cont. Current Rating of 2000 Amp. Busbar Max. Temp. at cont. Operating Current As per IEC 694 Applicable Standard As per IS 13118 Switchgear Construction Material of construction CRCA sheet steel Thickness of Sheet steel Panel, Frame, Gland Plate, 10 SWG Doors, Removable covers, 14 SWG Partitions Degree of protection IP 4X as per IS 2147 Color of Finish shade Light Gray Semi glossy finish as per Shade 631 of IS 5 for Exterior and Brilliant White finish for interior Bus bar Material Electrolytic Aluminum with Heat Shrinkable Sleeves Earthing Bus bar Material Copper Flat 50 x 6 mm min or Equiv. Al. Minimum Clearance in Air 150 mm between phases 80 mm between phase and earth Cable Entry Bottom
2.3 2.4
2.5 2.6 2.7
2.8
546
3.0 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8
Circuit Breaker Details Type Rated Operating Duty Rated Current at amb. Temp. Rated Breaking Capacity Rated Making Capacity Total Opening Time Total Closing Time Type of operating mechanism
3.9 3.10
Min. No. of contacts Auxiliary Control Voltage
Vacuum Circuit Breaker 0-3min.- CO - 3min - CO As per feeder details given 40KA for 3 sec. 100KAp 2.5 to 3 cycles 3 to 3.5 cycles a. Motorized spring charging mechanism with mechanical trip facility b. Trip free and anti pumping mechanism Required. auxiliary 4No + 4 NC for Owners use. 110V, D.C. for Closing tripping, protection and indication circuit 230 V, A.C. for Spring Charging motor and space heater circuits. Cast Resin Class 'E' or better Copper Class 0.5 for metering Class 5P10 for protection and Class PS for diff. Protection IS 2705 Single phase , Cast Resin 11000 V / V3 for Primary and 110 V / V3 for secondary Star / Star As per SLD Class 1 1.2 Cont. / 1.9 for 30 Sec
4.0 4.1 4.2 4.3 4.4
Current Transformers Type Class of insulation Winding Material Accuracy Class
4.5 5.0 5.1 5.2
Applicable Standard Voltage Transformers Type Rated Voltage
5.3 5.4 5.5 5.6
Connection Burden Accuracy Class Rated Voltage Factor
547
5.7 5.6 6.0
Class of insulation Applicable Standard Feeder Details Switchboard
Class 'E' or better IS 3156 in As per SLD
5.7.8
Data Sheet for Air Circuit Breaker 1) 2) 3) 4) 5) 6) 7) 8) Type Make Rated Voltage Rated frequency One second short time current rating Momentary current rating Maximum temperature rise over ambient temperature Type of Tripping mechanism : : : : : : : :
5.7.9
Data Sheet for Indicating Instruments VOLTMETER Make Type Standard applicable Accuracy Class Voltage coil burden AMMETER Make Type Applicable standard Accuracy Class Current coil burden WATTMETERS Make Type Applicable standard Current coil burden
1) 2) 3) 4) 5)
: : : : :
1) 2) 3) 4) 5)
: : : : :
1) 2) 3) 4)
: : : :
548
1) 2) 3)
POWER FACTOR METER Make Type Applicable standard PROTECTIVE RELAYS Make Type Applicable standard Burden CONTACTORS Type Make No. of poles Aux Contacts Coil Voltage Class of insulation of coil OVERLOAD RELAYS Type Make Setting range Voltage rating Burden PUSH BUTTONS Make Type Number of Contacts Contact rating INDICATING LAMP Make Type Voltage
: : :
1) 2) 3) 4) 1) 2) 3) 4) 5) 6)
: : : : : : : : : :
1) 2) 3) 4) 5) 1) 2) 3) 4) 1) 2) 3)
: : : : : : : : : : : :
549
5.7.10
Battery / Battery Charger 1) 2) 3) 4) 5) 6) 7) 8) 9) 10) Type Make Applicable Standard DC system voltage Rated Voltage Capacity Rated Current Expected life Floating charge voltage Floating charge current : : : : : : : : : :
5.7.11
Lighting Fixtures 1) 2) 3) 4) 5) 6) 7) 8) Type Make Applicable Standard Rating Type of Reflector Type of Filament Type of Control Gear Accessories : : : : : : : :
5.7.12 Lighting Poles 1) 2) 3) 4) 5) Type Make Dimension Height Diameter Size of base plate Applicable Standard Accessories : : : : :
550
5.8
DCS
Sr. No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.
Particulars Scan time for critical loops Scan time for non-critical loops Future expandability Communication from CPU to OS Communication from CPU to Cards Engineering Workstation Operator Workstation Online UPS parallel, redundant configuration with 30 min back-up Printers LAN & Accessories Controller subsystem System Cabinet SOE System Type of network Training
Details
551
5.9
BUILDING DIMENSIONS Sr. No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Particulars Powerhouse width Powerhouse length Area for steam generator & auxiliaries Water treatment plant building width Water treatment plant building length Water treatment plant building height Cooling tower width Cooling tower length Cooling tower height Covered bagasse shed width Covered bagasse shed length Covered bagasse shed height Value in m
5.10
PERFORMANCE GUARANTEE Sr. No. 1. 2. Parameters Time period from notice to proceed up to commissioning trials Guaranteed power generation in sugar season for the required process steam flows, as per enclosed HBD Guaranteed power generation in sugar off-season for the required process steam flows, as per enclosed HBD Guaranteed auxiliary power consumption in sugar season with process steam flows, as per enclosed HBD Guaranteed auxiliary power consumption in sugar off-season with process steam flows, as per enclosed HBD Cogeneration plant steam rate (kgs/kW) at given process steam conditions for season, as per enclosed HBD Value
3.
4.
5.
6.
552
Sr. No. 7.
Parameters Cogeneration plant steam rate (kgs/kW) at given process steam conditions for offseason, as per enclosed HBD Performance test code for steam generator & auxiliaries Performance test code for steam turbine generator & auxiliaries Performance test code for cooling tower & auxiliaries Performance guarantee will need to be provided for total water consumption for design season & off-season basis.(makeup to reservoir) Performance guarantee for boiler feed water treatment
Value
8. 9. 10. 11.
+ 5% of guaranteed figures to be measured for 8 hours during the PG test.
12.
13.
14.
The boiler feed water samples will be analysed by the Tenderer at an approved laboratory of CPCB / BPCB / MoEF for all relevant parameters and they will necessarily confirm or better the requirements. Performance test code for all other As per relevant IS codes for equipments, including air compressor, specified capacity, material handling, fire fighting, water turndown, guaranteed treatment, DG sets, etc. auxiliary consumption, noise levels and specified output qualities Average annual availability, where (1- (B+D+P)) x 100% B = MW hours lost due to full breakdown (DNC x PH) D = MW hours lost due to de-rating excluding evacuation restrictions P = MW hours lost due to planned maintenance DNC = Declared Net Capability or the full load MW output of the unit PH = Period in Hours (8760 / year)
553
Sr. No.
Parameters Design margins, redundancy and buffer storage shall be incorporated as necessary to achieve the assured availability Duration of performance test (to be carried out by the Tenderer with calibrated instruments within 3 months of commissioning)
Value
15.
16.
Individual equipment will undergo performance test as per relevant standard and in the minimum to document the continuous Tenderer to submit HBD for normal availability of rated output season and off-season conditions. and efficiency. The cogeneration power plant as a complete system will undergo performance test for a period of 7 continuous days to prove reliability and capacity of all sub-systems. Within this period, individual PG tests of main power island will be carried for a minimum period of 8 hours, as per relevant code. PG test will also demonstrate the plant heat rate and auxiliary power consumption. Station heat rate (GCV of Fuel x Hourly fuel Consumption -Energy Supplied to process) / kWh
5.11
LIST OF TECHNICAL DEVIATIONS Clause no. & Page Details as per no, tender Deviation required by Tenderer Reply on sought deviations by Consultant to all tenderers
554

Technical Specifications For Sugauli Cogen

Enviado por

Dados do documento

Título original

Direitos autorais

Formatos disponíveis

Compartilhar este documento

Compartilhar ou incorporar documento

Opções de compartilhamento

Você considera este documento útil?

Este conteúdo é inapropriado?

Direitos autorais:

Formatos disponíveis

Technical Specifications For Sugauli Cogen

Enviado por

Direitos autorais:

Formatos disponíveis

Doc No. Date Assign No.

GDP/EPC-BID/09-10/025, R1 June 8, 2009 GPD/SDE/HPCL/08-09/045 September 12, 2008

ENGINEERING, PROCUREMENT & CONSTRUCTION (EPC) BID DOCUMENT

20 MW Cogeneration Power Plant Village Sugauli, District East Champaran, Bihar

Technical Basis And Specifications

Hindustan Petroleum Corporation Ltd. (HPCL)

MITCON Consultancy Services Ltd. (MITCON)

Doc No. Date Assign No. Date

GDP/EPC-BID/09-10/025, R1 June 8, 2009 GPD/SDE/HPCL/08-09/045 September 12, 2008

EPC BID DOCUMENT

TABLE OF CONTENTS (contd..)

TABLE OF CONTENTS (contd..) LIST OF APPENDICES

DESIGN BASIS, SCOPE OF WORK, TERMINAL POINTS AND PERFORMANCE GUARANTEE

Average Steam Ratio, kg / kW Season Off-Season

Power : 5.08 : 3.80

Seismic Coefficient Seismic Zone

23.5% 3.25% 21.75% 50% 1.5% 2270 Kcal/Kg

1.00 7.00 20.00 8.00 (0.56) 27.44 32.08 4.60

13.4 13.5 14. 15.

16. 17. 18. 19. 20. 20.1 20.2

20.4 20.5 21. 22.

: No corrosive, hazardous, toxic Or flammable material : 100% Oil Free

Bus bar Control Logic

Provision of Spare feeders

02) BATTARY CHARGER 03) DCDB :

All I/Os will be potential free

Sampling Compaction Rapid Hardening Cement Admixtures ii Materials :Cement

I.S. 1199 I.S. 2505 I.S. 8041 I.S. 9103

I.S. 2506 I.S. 2645

100 95-100 55-85 35-70 10-30 0-5

100 90-100 20-55 0-10 0-5

2 inches (50mm) 2 inches (50mm) 1 inches (38mm)

Structural Slabs :Bottom 1 inch (25mm) Tops 1 inch (25mm) ------------------------------------------------------------------------------

Fixing of Reinforcement ii Materials :-

Type of Structure Buried concrete in foundations, Culverts, retaining wall

+15 -8 +/-15 +/-15 -

Exposed concrete in columns, piers, retaining walls, abutments

+15 -8 +/-8 +/-15

+15 -8 +/-4 +/-8

+/-8 +/-4 +/-8 +/-4

774 I.S. 775

Level -40,+25 -30,+25 N.A. +/-15 +/-25 +/-25

Utility Power supply to sugar plant

Maximum Continuous Rating (kg/hr) Peak Generation

air Not exceeding 35% at MCR

Temperature of flue gas at the outlet 150C at MCR of air pre-heater

Steam generator efficiency

70 % (minimum) on bagasse having 50 % moisture with GCV of 2270 Kcal / kg.

Turn down ratio

Pressure : i. Boiler outlet steam ii. Drum iii. De-aerator

Draft : i. ii. iii. iv. v. vi.

Drum De-aerator IBD CBD HP heater level

%O2 in flue gas

Speed : i. ii. iii. iv.

ID fans FD fans Rotary drum feeders Bagasse screw feeder

Steam Pressure indicator

Steam Pressure indicator

Steam Temp. indicator

Steam Flow indicator

Feed water indicator Feed Water indicator

Feed water indicator

Flue Gas temp. indicator at

Air Temp. indicator at