Technical Specification for RO Plant

TECHNICAL SPECIFICATION FOR RO PLANT
Technical Specification of RO Plant RIPL/TMT MILL/18-19/05/WTP/01-REV-0
TABLE OF CONTENTS
1. INTRODUCTION 4
2. WATER REQUIREMENT 4
3. WATER SUPPLY SYSTEM 4
4. SCHEMES & CAPACITIES 4
4.1. DM PLANT WITH CLARIFIER 4

5. SCOPE OF SUPPLY 7
5.1. THE DETAILED SCOPE OF EQUIPMENT FOR CLARIFIER & DM PLANT STREAM IS AS 7
FOLLOWS
5.2. OTHER ITEMS INCLUDE 8
5.3. OTHER ACCESSORIES 8
6. SCOPE OF SERVICES 9
7. EXCLUSIONS 9
8. BATTERY 9
9. GENERAL TECHNICAL REQUIREMENTS 10
9.1. MECHANICAL 10
10. MATERIAL OF CONSTRUCTION 16
10.1. GENERAL 17
11. ELECTRICAL 18
12. INSTRUMENTATION AND CONTROL 18
12.1. TYPE OF INSTRUMENTATION AND CONTROL 18

12.2. DESIGN PHILOSOPHY 18
12.3. CONTROL PANEL 18
12.4. CABLING AND ACCESSORIES 18
12.5. ERECTION, CALIBRATION, TESTING AND COMMISSIONING 18

12.6. DESIGN REQUIREMENTS 19
12.7. GENERAL SPECIFICATIONS OF INSTRUMENTS 19
12.8. ERECTION MATERIAL SUPPLY 22
12.9. INSTALLATION 24
12.10. TESTING AND CALIBRATION 24
12.11. COMMISSIONING 25
12.12. SPARES PHILOSOPHY 25
12.13. CONTROL & INSTRUMENTATION AND CONTROL FOR RO/DM PLANT 25
Real Ispat & Power Pvt. Ltd., Bojhara,Raipur Page 2 of 28

12.14. INSTRUMENTATION LIST 25

13. DRAWINGS / DOCUMENTS TO BE SUBMITTED ALONG WITH THE BID 26
14. DRAWINGS & DOCUMENTS TO BE SUBMITTED AFTER AWARD OF 26
CONTRACT (ALL IN FIVE SETS)
15. VENDOR LIST - INSTRUMENTS 27
14. SUB - VENDOR LIST 28
ANNEXURES
Annexure I RAW WATER ANALYSIS REPORT

Annexure II TREATED WATER QUALITY (to be filled by vendor)
Annexure III TECHNICAL DETAILS Data sheet (to be filled by vendor)
Annexure IV AUXILIARIES CONSUMPTION (to be filled by vendor)
Annexure V Electrical (to be filled by vendor)
Annexure VI Instrumentation (to be filled by vendor)

1. INTRODUCTION
The main sources of water are from the River Water. From the bore well, the water is transferred to
main reservoir located in the power plant premises. The analysis of this raw water is as given in
Annexure.
One of raw water reservoir is envisaged for storing raw water. The RO treatment system draws raw
water from this reservoir or Clarified Storage tank(**) and supplies RO water as needed to the Rolling
mill & SMS div.
**If clarifier is used, the water from the River is directly feed in to clarifier. The clarified water will be
stored in the raw water tank.
2. WATER REQUIREMENT
Water is used as a cooling medium in the heat exchanger equipment in power plant such as oil coolers,
generator air coolers etc. of turbo-generator, make up water for the boiler to compensate the blow down
and other losses, dust suppression system in fuel storage area, dust conditioning in dry ash handling
system and fire fighting system. A small quantity of water will be required for drinking and sanitation for
plant personnel.
3. WATER SUPPLY SYSTEM
The following facilities are envisaged to meet the power plant water requirements as
One (1) no of Clarifier of 150 m³/h capacity (net output)
One (1) stream of MGF and ACF of 18 m³/h capacity
One (1) no of UF of 18 m³/h capacity with min.90% recovery
One (1) no. of RO of 16 m3/hr capacity with min.75% recovery
One (1) stream of DM plant of 12 m³/h capacity (net output from mixed bed outlet)
4. SCHEMES & CAPACITIES
The design of water treatment facilities needs to be done based on given raw water quality as per
Annexure. Consider 20% margin for designing the system and design value shall be furnished.
4.1. DM PLANT WITH CLARIFIER
4.1.1. Scheme for the Clarifier, DM plant with UF/RO
The Pretreatment of raw water shall consist of one Clarifier to remove the turbidity along with the dosing
system such as chlorine, polymer & coagulant. The clarified water is stored in the raw water tank. The
raw water from River will be pumped to clarifier by 2 x150 m³/hr (1W+1S) RWP. The sludge from
clarifier is dried in sludge drying beds.
The DM plant consist of one Multi grade filter (MGF), one Activated filter (ACF),one UF, One RO, one
degasser unit (DG), One strong acid cation (SAC) unit, One strong base anion (SBA) and One mixed
bed unit (MB). The raw water will be pumped from the raw water storage tank to a Multi grade filter by
18 ³/hr (1W+1S) Raw water transfer pumps. The outlet of the MGF via ACF is feed in to the UF which
has 90% recovery. The outlet of UF will be transferred to UF permeate tank. From this, the water is fed
in to RO which has 75% recovery (max80% recovery) and then to degasser unit where the CO2 is
removed using air blower. The degassed water is stored and fed to SAC & SBA. The water from the

SBA is polished in a mixed bed filter. The water from the mixed bed is stored in a DM storage tank. Raw
water shall be used for the back wash of MGF, UF permeate for UF back wash, Degassed water shall
be used for the back wash of RO and DM water shall be used for the regeneration of SAC, SBA and
MB.
Sodium hypo chlorite dosing systems shall be provided in the raw water tank. Auto pH correction dosing
shall be provided in the MB outlet line. The pressure of the water at the outlet of MB shall not be less
than 2 Kg/cm² (g).
4.1.2. Pretreatment Scheme
Clarifier --- Storage tank
The capacity of Clarifier is 150 m3/hr.
MGF --ACF---- UF membrane ---- RO Plant For MGF/ACF/UF stream : 16 m³/hr
4.1.3. Proposed scheme for the treatment for boiler water treatment
Option 1 :RO ---- Degasser ---SAC ---SBA --- Mixed Bed The throughput of RO shall be 12
m³/hr. The throughput of each stream of DM shall be 12 m³/hr.
Option 2 :RO ---- Degasser --- Mixed Bed(1W+1S) The throughput of RO shall be 12 m³/hr. The
throughput of each stream of DM shall be 12 m³/hr.
4.1.4. Plant capacity
The design basis of the DM Plant stream shall be as follows:
SAC/SBA : 240 m³ for each stream

Output between regeneration for DM plant
MB : 1680 m³ for each stream
Service cycle 20 hrs service + 4 hrs regeneration per day
4.1.5. Water Quality required at the outlet of UF, RO and degasser:
(i) R.O Permeate

Colloidal silica, ppm Nil
RO recovery 75% Min
TDS, ppm <30 ( for 4.1.3. option 1)
<15 ( for 4.1.3. option 2)
(ii) Degasser Tower

CO2 as CaCO3 at outlet < 5 ppm max.
(iii) Ion exchange water quality

Outlet water from anion exchanger shall be guaranteed as follows within the specified capacity range
throughout the period between the regenerations
Total reactive silica not to exceed mgl as SIO2 0.1

Total dissolved solids mgl as CaCO3 2.0
Conductivity @ 20° C not more than micro-mho/cm 10
Total hardness Nil
Total iron mgl < 0.02

(iv) Guarantee Water Quality at DM Plant Outlet
The guaranteed quality of DM water at mixed bed outlet will be as follows:

Conductivity, us/cm 0.2 max.
Total dissolved solids, PPM 0.1 max.
Silica as SiO2, PPM 0.02 (Max.) (Reactive & non reactive)
PH at mixed bed outlet 6.8 to 7.2
Iron, PPM NIL
Copper, PPM NIL
Total CO2, PPM NIL
Free chlorine, PPM NIL
Oil & Grease, PPM NIL
Total suspended solids, PPM NIL
Sodium leakage through cation exchanger shall not exceed 1 mg/l as CaCO3.
Chemical consumption for effluent neutralization as indicated by Bidder shall be guaranteed.
Bidder shall also guarantee the total power consumption of the equipment indicated by him.

5. SCOPE OF SUPPLY
Design, engineering, manufacture, supply, transport, unloading, storage, erection & commissioning and
performance testing of complete pretreatment plant consisting of pretreatment, Reverse Osmosis/ion exchange
system as per the scope of work given below:
5.1. THE DETAILED SCOPE OF EQUIPMENT FOR CLARIFIER & DM PLANT STREAM IS AS FOLLOWS:
 One (1) no. of Clarifier (High rate solid contact or Lamella or tube settler)
 One (1) no. of chlorine, polymer & coagulant dosing system
 One (1) no. of Sodium Hypochlorite dosing tank with 2 nos. of pumps in raw water tank. (if it is dosed in
clarifier, then separate dosing system is not required)
 Two (2) Nos. micron cartridges filter feed pump with complete electric motors and accessories
 One (1) nos. of multi grade Filters complete with filter media & accessories for the DM stream.
 One (1) nos. of Activated Carbon Filters.
 One (1) no. of Ultra filtration unit
 One (1) of UF permeate tank of capacity 30 min storage.
 One (1) No. Antiscalant dosing system with dosing tank, agitator, two (1W+1S) metering pumps,
necessary valves piping and accessories.
 One (1) No. Acid dosing system with dosing tank, necessary valves piping and accessories.
 One (1) No. micron cartridge filter housing with required number of cartridges of 5µ size.
 Two (2) Nos. high pressure pump with complete electric motors and accessories.
 One (1) No. module of R.O complete set, mounted on R.O skid with necessary number of pressure
vessels and elements, with adequate piping & valves to withstand the necessary pressure developed by
high pressure pump with all necessary accessories & instruments with necessary control / power wiring
for the instruments and other motors / electrics to the control panel mounted on the skid.
 One (1) No. module of chemical cleaning in process (CIP) circuit with necessary chemical CIP tank,
cleaning pump, cartridge filter, Heating Element & agitator with necessary piping and accessories for
both UF and RO separately
 One (1) nos. of of Degasser Tower
 One (1) nos. of Degassed Water Storage Tank of 30 min storage
 Two (2) nos. of (1W+1S) Degasser Blower
 Two (2) nos. of (1W+1S) Degassed Water Pump
 Two (2) nos. of Strong acid cation exchangers
 Two (2) nos. of Strong base anion exchangers
 Two (2) nos. of Mixed bed exchangers
 Two (2) nos. of (1W+1S) Air scouring blowers. The same blower shall be used for Neutralization pit air
agitation.
 Two (2) nos. of Acid measuring tank for cation bed & MB
 Two (2) nos of Caustic dilution tank for anion bed & MB
 One (1) no. of Caustic dilution tank for neutralization pit
 One (1) no. of Morpholine solution tank
 Two (2) nos. of (1W+1S) Morpholine dosing pumps with necessary valves, piping and accessories
 One (1) no of bulk acid storage tank of capacity 50KL (if req)
 One (1) no of bulk alkali storage tank of capacity 50KL (if req)
 Two (2) nos of unloading pump for HCl/Alakali of each capacity 10m3/hr
 Associated pipes, valves, gaskets, fasteners, etc
 Air grid for the neutralization pit.
 2x100% effluent transfer pumps (if req)
 Piping between the tank/pump and the acid measuring tanks.
 Agitators for all dosing tanks.

 Interconnecting pipe work complete with valves fittings, supports and accessories including air agitation
grid in neutralization pit.
 Piping required for the back wash and regeneration of the vessels
 Instrumentation as per requirement
 Proprietary treatment chemicals for 3 months to be provided.
5.2. OTHER ITEMS INCLUDE
 Common base frame for each pump and motor, foundation bolts and nuts required for grouting all
equipment within terminal points shall be included in the scope of supply.
 MCC, power and control cables.
 Cable trays and other hardwares as required.
 Signal cables
 Local push button stations
 A portable water analysis kit including SDI testing kit and Jar testing kit.
 Special tools and tackles and Commissioning spares.
 2 years operational spares
 Complete instrumentation consisting of local instruments, flow measuring instruments, PLC based
control panel for UF & RO skid, level and pressure switches as specified in the technical specification.
 Final painting.
 O & M manuals for the complete system with necessary drawings, catalogues and other information
pamphlets for all the equipment covered in the scope.
 Furnishing load data for all equipment foundations.
 Furnishing civil drawings for all RCC structures.
 First fill of lubricants with operating chemicals and lubrication chart showing the lubricants required for
each equipment, interval of topping up, quantity required per annum with the name of the Indian
suppliers.
 Earthing above the ground to be included in the scope.
 All consumable chemicals, spares, and lubricants sufficient for 3 months operation.
5.3 OTHER ACCESSORIES
 Layout comprises Clarifier, UF/RO, DM plant, softener plant, control room & Lab.
 All pumps/blower etc. shall be supplied with base plate, coupling, coupling guard, anchor bolts and nuts,
canopy’s etc. for the equipment.
 All frontal piping / all interconnecting piping / recirculation piping / priming piping / valves/ fittings /
fasteners / ejectors / pipe racks / pipe supports and accessories integral to the plant. All piping shall be
pre-fabricated as per the layout so that they shall be erected directly. All puddle pipes with flanges for all
RCC tanks & pits shall also be supplied.
 All the ion exchangers / filters shall be with the resin/filtering material, all internals, water distribution
drain system and V Notch boards.
 All terminal points shall be provided with suitable dummy flanges.
 Earthing from the equipment to the nearest riser.
 MCC, cables, cable trays, LPBS shall be supplied and erected.
 One(1) lot of necessary field instruments , cables, installation materials, erection, calibration, testing and
commissioning.
 Control panel with annunciation.
 Foundation bolts, base plates, grouting with grouting materials.
 Commissioning spares
 2 year operational spares
 Special maintenance tools and tackles.

6.0. SCOPE OF SERVICES

 Process engineering, basic engineering and design engineering of the complete water treatment system
including that required for pretreatment system.
 Erection of the complete water treatment system
 Testing and Commissioning of the water treatment system
 Pre commissioning, testing, start up and run tests, load test, performance tests
 QA/AC plan, inspection and testing of equipment at works, submission of test certificates. Trial
operation for a minimum period of one month from the date of successful commissioning and achieving
the rated output and recovery
 Training of purchaser’s personnel in operation and maintenance of the complete system.
 Deputation of one engineer for supervision of operation for a period of 4 weeks from successful
commissioning.
 Necessary laboratory facilities for analyzing the raw water and treated water during the PG test.
7.0. EXCLUSIONS
 All civil works.

 Earthing below the ground up to riser flat
 Raw water tank
 DM storage tanks
 Salt saturation tank (in case of RCC)
8.0 BATTERY LIMITS
 Raw water : At the inlet of Clarifier

 DM water : at the outlet of MB
 Effluent water : At the inlet of raw water tank
 Drains & Wash lines : at the nearest trench
 Electrical Power : At the incomer of MCC
 C&I : At the outlet port of RS485
 Earthing : At the nearest riser
 Instrument air / Service air : Will be provided at one point near / in the water treatment plant
building.
Distribution header with individual valve for each equipment will be in vendor scope.

9.0. GENERAL TECHNICAL REQUIREMENTS

9.1. MECHANICAL
9.1.1 Clarifier
The Clarifier is provided to settle the suspended solids / turbidity effectively at the bottom. Thus
clear water is ensured for the down streams. HRSCC shall be inclusive of rotating scrapper arm
assembly, rapid mixing impeller drive assembly, sludge line to waste and all structural items (other
than civil construction work). The clarifier shall be designed for a minimum retention time of 2 ½
hours and with a rise rate of 1.8 m/hr.
All gear drives shall be of enclosed type and shall operate in oil bath. The service factor of the gear
drives with electric motor as the prime mover shall be 2 for spiral bevel and 1.5 for helical on
continuous duty. Drive shafts shall be dynamically balanced. All exposed moving parts of the drive
shall have metallic safety guards. A tray shall be provided at the bottom of the clarifier drive
mechanism to prevent falling of oil / grease into the water in the clarified water storage tank.
The steel ladder with hand rail shall be provided to access the top of the clarifier. The clarifier top
shall be covered with PVC coated metallic sheet. (optional)
1. Chlorine dosing system: The chlorinated feed water kills active microbial content of water
and ensures that there is no further microbial growth during storage or further treatment of
water. In Multi Grade Filter or tanks otherwise there is possibility of microbial growth
during stagnancy.
2. Polymer dosing system: The polymer dosed at the inlet of clarifier is aimed at making
bigger flocs to settle very effectively at clarifier.
3. Coagulant dosing system: The coagulant dosed at the inlet of clarifier is aimed at
effectively make the suspended solids / turbidity to settle at the bottom of clarifier.
9.1.2 Multigrade Filter & ACF
Multi Grade Filter of shall be designed for an operating pressure of 5 kg/cm² (g). Multi Grade Filter
will be used to reduce the turbidity and hardness of the raw water to the required level. Free board
of at least 50% shall be left over the filtering media to facilitate backwash. The filter shall be
provided with the necessary nozzles including water inlet, water outlet, back wash, air scour and air
release nozzles. The filter shall be complete with necessary filtering medium. Scope of supply
shall include automatic backwash system. Raw water shall be used for back washing of MGF.
 Vessel design standard : IS 2825 or ASME Sec. VIII Div.1

 Type : Multigrade filter
 Capacity of each filter : To be sized for output required for both
 softener and DM plant
 Design Pressure : 5 kg/cm² (g)
 Design Temperature : 50°C
 Normal flow velocity : 18m/hr
 Filtering medium : Vendor to specify
 Minimum bed depth : Vendor to specify
 Minimum shell thickness : 6 mm Minimum
 Dish end thickness : 8mm Minimum
 Free board : 50%
 Material of construction : As per IS 2062
 Corrosion Allowance : 1.5 mm
 Effluent Quality : Turbidity not to exceed 1.00 NTU
 Internal coating : Two coats of epoxy
 External coating : As per painting spec
 Dished end : Semi ellipsoidal
Bidder shall separately mention ACF details as per standard.

9.1.3. Ultra filteration (UF)
 No. of units : One

 Design pressure : 5.0 kg/cm² (g)
 Design temperature : 50°C
 UF Filter medium size : 5 micron
 Maximum capacity : to be sized for continuous water pump rated
flow
 Regeneration : As per design
 Type : Replaceable cartridge type
9.1.4. RO high pressure pump

 Quantity : 2x100%
 Type : Vertical multistage
 MOC : Stainless steel
 Make : Grundfoss
9.1.5. RO Block
 Capacity Feed : Vendor to specify
 Recovery : Vendor to specify, However, minimum
shall be 75% Total Dissolved Solids : < 30 ppm at R.O outlet
 Quantity : One
 Material of pressure tube : FRP
 Make of pressure tube : Filmtec or equivalent
The RO system shall be skid mounted consisting of micron filter, high pressure pumps,
pressure tubes, dosing system, PLC, Wet panel etc. along with required interconnecting piping
and instruments and assembled at shop.
9.1.6. Water Storage Tanks
The RO permeate water tank / degassed water tank shall have an effective capacity of 9 KL.
The permeate water tank shall be provided with suitable level gauges and three level switches,
one for high level, one for medium level and one for low level for interlocking with RO feed
pump and MB feed pump. The permeate water tank shall also be provided with vent & drain
facilities.
9.1.7. Degasser
Degasser shall be designed for a maximum operating pressure of 5 kg/cm² (g). One (1)
degasser of design capacity with counter current flow of water and air shall be supplied. The
degasser tower shall have adequate cross –sectional area for efficient removal of carbon
dioxide. The carbon dioxide content in the degassed water shall not be more than 5 ppm as
CO2. The degasser tank shall be filled up with polypropylene packings and shall be provided
with internal distributors. The degasser tower shall store maximum effluent from one cation
exchanger unit for 30 minutes. Degasser sump shall be provided with level gauge glass,
overflow and drain lines, staircase, handrails, platforms etc., as required for each access. The
plant shall be designed such that level in degasser sump shall remain constant during
regeneration of exchanger units. The equipment shall have adequate built in capacity to cater
to the high flow rate during regeneration. The degasser sump shall be of MSRL construction.

Technical Data:
 Type : Forced draft
 No. of units : One
 Capacity of each tower : *
 Design Pressure :
 Atmospheric Temperature : 50°C
 Material of construction : Carbon steel rubber lined or FRP
 Rubber lining : 4.5 mm thk (1.5 x 3 layers as per IS
4682 Part-I)
 Packing : Polypropylene rasching rings or Pall
rings
 Minimum air requirement : * Guaranteed
 effluent quality : *
 Minimum shell thickness : 8 mm
 Mounting / foundation : Requirement preferably mounted on top
of permeate water tank
* Bidder to specify
9.1.8. Degasser Blower

Two (2) air blower air of 100% capacity each, one running + one standby, shall be supplied
complete with drive, intake filters, duct work, pressure indicators and all other accessories as
required, including motors. The blower shall be of electric motor driven oil free type.
Type : Horizontal, Centrifugal, motor driven
No. of blowers : Two (one working & one standby)
Air flow rate of each blower : As per degasser requirement
Head (minimum) : 10 % margin shall be added on the Maximum dynamic
head
Material of construction of blower : Carbon steel, preferably FRP lined Intake filters,
dampers, doors
Etc. : Carbon steel, preferably FRP lined The blower and
motor shall be mounted on a common base frame.
9.1.9. DM feed water Pumps
Two (w) DM feed pumps, each of 100% (unit production plus the regeneration water required
during regeneration time) capacity shall be supplied complete with flexible coupling, common
base plate, valves, discharge pressure gauges and all other accessories, including drive
motors. The pumps shall supply degassed water through the anion exchanger followed by
mixed bed to water tank. Two (2) pumps shall run during service run and a third pump will
meet the water requirement during the time of regeneration also. Necessary recirculation line
from pump discharge to sump shall be supplied.
Type : Centrifugal, motor driven
Capacity of each pump : Vendor to specify.
Head : After pH correction shall be 3.5 kg/cm² (g)

Material of construction :
 Casing : SS 316
 Impeller : SS 316
 Shaft : SS 316
 Shaft sleeve : SS 316
 Base frame : IS 2062

9.1.10. Strongly Acidic Cation Exchanger:
One (1) strongly acid cation exchanger of 100% capacity (12 m³/h unit production) and shall be
designed for a maximum operating pressure of 5 kg/cm² (g) and filled up with adequate
quantity of strongly acidic resin. The flow velocity through the exchanger shall not exceed 40
m/h. Exchanger shall run continuously for 20 hours after which counter current shall be carried
out. At least 100% free space shall be kept over resin bed for expansion during regeneration
and back washing. Water shall be supplied to the unit from a common header and the effluent
shall be discharged to a common header and the effluent shall be discharged to a common
header. Two resin traps shall be provided, one on the main water outlet and the other on the
backwash regeneration distribution water outlet for each unit. The unit shall be vertical shell
type with dished ends having internal collection pipe works and provided with manholes of
proper size and sight glasses. Decationised water shall be used for regeneration purposes.
9.1.11. Strongly basic anion

One (1) strongly basic anion exchanger of 100% capacity (12 m³/h unit production) and
designed for a maximum operating pressure of 5 kg/cm² (g) shall be supplied. The exchanger
shall be filled up with adequate quantity of strongly basic resin. The flow velocity through the
exchanger shall not exceed 60 m/h. Exchanger shall run continuously for 20 hours after which
co-flow regeneration will be required. The free space above resin bed shall be 100% to allow
for bed expansion during regeneration.
Water shall be supplied to the unit from a common header and the effluent shall be discharged
to a common header. Two (2) resin traps shall be provided, one on the main water outlet and
the other on the backwash distribution collection water outlet. The unit shall be of vertical shell
type with dished ends having internal regeneration pipe works and provided with manholes of
proper size and sight glasses. Flow measuring orifice board of PVC shall be supplied in the
sump of the exchanger. Deanionised water shall be used for regeneration purposes.
The resin selected shall be suitable for any organic fouling on its exchange surfaces due to the
presence of organic matter in the raw water. Bidder may analyze the water for organic content
prior to selection of strongly basic anion resin.
9.1.12. Mixed bed Ion Exchanger:
One (1) Mixed bed exchangers of each 12 m³/hr capacity shall be designed for an operating
pressure of 5 kg/cm² (g) shall be supplied. The exchanger shall be filled up with adequate
quantity of strongly acidic and strongly basic resins. The design specific loading shall not be
more than 9 m³/hr/m². 100% free space shall be left over the resin bed to allow expansion of
resin during air scouring/mixing and back washing. The influent water shall be fed from a
common header and treated water discharged to a common header. Two resin traps shall be
provided, one in the main water outlet line and the other in the backwash/regeneration shall be
supplied. The unit shall have sight glasses and manholes of proper size. Flow measuring
orifice board of PVC shall be supplied in the sump of the exchanger. DM water from the mixed
bed exchanger shall be stored in a storage tank. DM water shall be used for regeneration
purposes.

Design : IS 2825 or Sec VIII Div.1

Type : Vertical, dished end (Semi ellipsoidal)
Rubber lined, steel welded vessel
No. of units : Two
Design Pressure : 5 kg/cm²(g)
Temperature : 50°C
Rubber lining : 4.5 mm thk As per IS 4682 Part – I
Free board : 100%
Resin type : Cation and anion resin as required for SAC&
SBA exchanger
Method of regeneration : *
Regeneration water requirement : *
Guaranteed effluent quality : Silica leakage <0.02 ppm as SiO2,
Conductivity : <0.2 Micromhos/cm
pH – : 6.8 to 7.2
Accessories / Instruments : *
Material of construction : IS 2062
Minimum shell thickness : 6 mm
Pressure required at the outlet of MB : 2.0 kg/cm² (g)
* Bidder to specify.
9.1.13. Mixed bed blower

Air scouring blower of 100% capacity each, one running + one standby shall be supplied for
resin mixing of mixed bed exchangers. Provision shall be kept for air scouring of cation and
anion exchangers during periodic maintenance of the units. The blower shall be of oil free type,
and complete with drive, intake filters, piping, pressure gauges and all other accessories as
required, including motors
Type : Rotary, twin lobe, motor driven
No. of units : Two
Head & flow : Vendor to specify.
Material of construction : CI
The blower and motor shall be mounted on a common base frame.
9.1.14. Exchanger Regeneration System

Regeneration system shall consist of one (1) each of acid and alkali day tanks and four(4)
ejectors. Cation resin regeneration shall be done by HCI and anion resin by NaOH.
Commercial grade (30-33%) HCl as per IS:265 and rayon grade (48-50%) caustic soda lye as
per IS : 252 shall have enough capacity for one regeneration of cation/anion plus one
regeneration of mixed bed. Both day tanks will be provided with vent, drain, overflow, gauge
glass, platforms, handrails, ladder, fume absorber for acid tank etc., as required. Both the
tanks shall have automatic level cut-off valve and high-low alarm. The inlet valve shall
automatically close at high liquid level in tank and will be manually opened at low level. All
pipelines for acid shall be of carbon steel rubber lined. Dosing of regenerates shall be made
by ejectors and the motive water shall be taken from the different headers.
Suitable density indicator and flow indicators shall be supplied to detect the exact
concentration and flow rate of regenerant to the exchangers. The alkali day tank shall be
provided with stirrer.
9.1.15. Acid / Alkali / Sulphuric Storage Tank
One (1) 20 m³ capacity acid storage tank in MS construction with epoxy coated shall be
supplied for storing the acid received by road tankers. Two (2) unloading and transfer pumps of

required capacity, one (1) running and one (1) standby shall be included as part of the scope of
supply.
The storage tank shall be provided with vent, drain, overflow, gauge glass platforms, handrails,
ladder, fume absorber etc. as required. All the valves and fittings shall be rubber lined.
9.1.16. Resin
The resins shall be of proven quality and guaranteed to offer stable and trouble-free operation
for minimum five (5) years. The resins offered must have previous satisfactory record for
similar applications in large industrial plants for not less than five(5) years. Resins shall have
good stability and attrition resistance against specified operating conditions.
High capacity type-I strongly basic iso-pours anion exchanger resin shall be used for anion
exchanger and anion part of mixed bed units.
For cation exchanger and cation part of mixed bed, styrene base resins with di-vinyl benzene
cross-linking shall be used. All resins shall be supplied in manufacturer’s original sealed
containers.
All resins shall be suitably sieved for uniform size so that jamming of the collection/distribution
system inside the exchanger vessels due to fines are eliminated. Attrition losses of resins shall
not exceed 3% per year.
9.1.17. Dosing System
All dosing tanks shall be of FRP/ HDPE construction and shall have a capacity of 125% of 24
hours requirement or 240 litres, whichever is higher. All the dosing tanks shall be provided with
low level switches to give alarm. In the case of antiscalent dosing and de-chlorination dosing,
in addition to alarm, tripping of RO High Pressure Pump shall also be envisaged.
All dosing tanks shall be provided with motorized agitator, wherever vigorous agitation is
required and where solids / flakes are dissolved.
All dosing tanks shall be provided with suitable tubular level gauges.
Each dosing system shall have two dosing pumps (one working and one standby). The stroke
length of all dosing pump shall be adjustable when the pump is in operation.

10.0. MATERIAL OF CONSTRUCTION

 For all Vessels and Tanks
All vessels and tanks shall be vertical shell type with dished ends the material of
construction shall be carbon steel conforming to IS : 2062 unless specified otherwise. The
vessels shall be 4.5 mm rubber lined.
 For Pipes and Fittings
All internal pipes and header shall conform to IS : 1239 Part 1 upto 150 mm NB and IS:
3589 Class 3 above 150 mm NB. All pipe and fittings above 50 mm NB shall be 3 mm
rubber lined. Pipes and fittings before activated carbon filter shall be unlined.
Piping upto MGF : IS 1239 (Medium)

Piping from MGF to RO : MSRL
Piping within RO : Stainless steel Piping after RO upto DM outlet
: MSRL Degassed water tank : MSRL
Dosing tanks : FRP
 For Blowers
Impeller and casing shall be of carbon steel conforming to IS : 2062. Shaft shall be of IS
: 2073 Gr. C45/EN8 and sleeve ASTM A 276 TP 316.
 For Pumps
For pumps in SS pump casing and sleeve shall be of ASTM A 276 TP 316. Impeller shall
be of ASTM A 743 Gr GF 8 TP 316 and shaft shall be EN8. The pump shall be provided
with impregnated teflon packing.
 For Flanges
Flanges upto 20 mm thick shall conform to IS : 6392 and above 20 mm thick shall conform
to IS: 2062.
For Gaskets
Gaskets shall be compressed asbestos fibre with nitrlle rubber binder conforming to IS:
2712.
 Fasteners
Fasteners shall be of ASTM A 307 Gr. B carbon steel.
 Valves for Corrosive Water/Acid/Alkali

Valves for corrosive water/acid/alkali shall be diaphragm type with cast iron rubber lined
body and neoprene diaphragm.
 for Clear and Filtered Water

Valves for clear and filtered water shall be unlined, tight shut off butterfly type with cast
iron body, bonnet and stem of SS 304/316.
 Rubber lining
Shore hardness of natural rubber for lining shall be 65 ± 5° in all cases
 Internal and external painting

Two coats of internal painting and two coats of external painting wherever required shall
be done. For unlined vessels, the internal painting shall be with two coats of primer and
two coats of epoxy. For lined vessel, internal painting shall be with two coats of primer.
External painting shall be with two coats of primer and two coats of enamel.
Note: No asbestos based material and cadmium based material shall be used in the RO
system.
10.1. GENERAL
 The design of vessels and tanks shall be as per IS 2825.
 All tanks shall be provided with vent & drain facility.
 For the pumps 10% margin shall be added on the maximum flow and 5% margin
shall be added on the maximum dynamic head.
 All flanges at the terminal point and within the battery limit shall be only as per
ASME B 16.5.
 The maximum noise level of all equipment within the battery limit shall be 85 dba.
 All pipes within the battery limit including that required for backwash and
regeneration shall be included in the scope.
 All pipe supports and auxiliary steel structure required for supporting pipe shall be
included in the scope.
 Any platform, ladder required for operational convenience shall be included in the
scope.
 Minor chipping of concrete and grouting of equipment shall be included in the
scope.
 The commissioning spares shall be included in the basic lump sum price and the
list of commissioning spares shall be indicated
 If after performance test, the treated water quality does not meet the stipulated
quality requirement, BIDDER shall take necessary action to rectify or replace the
system without any extra cost.
 All pressure tapings shall be provided with one root valve.
 All pumps shall be provided with suction strainers with perforated plates and
strainer element made of stainless steel.
 All valve material shall be compatible to the pipe material, wherever they are
used.
Note : * Bidder to specify the relevant data

11. ELECTRICAL
Refer Annexure, for the requirement of LT motor, MCC, Cables and Local push button stations.
12. INSTRUMENTATION AND CONTROL
The Water Treatment Plant (WTP) shall be provided with adequate number of instruments and controls for
ensuring safe, smooth and efficient operation of the plant. The instrumentation and control systems
provided shall be sufficient to control and monitor all significant process parameters continuously and
provide necessary safety controls and interlocks including alarms for abnormal conditions to ensure
adequate safety to man, machine and environment.
12.1. TYPE OF INSTRUMENTATION AND CONTROL
The instrumentation and Control system envisages local control of Water Treatment Plant. Critical
signals to be made available in central control room. All the safety interlocks, sequencing, logic solving
and digital signal handling shall be through a Programmable Logic Controllers (PLC) based system
supplied by the Bidder. Necessary information from these shall be hooked-up to the DCS.
12.2. DESIGN PHILOSOPHY
The instrumentation system shall broadly comprise of

 Gauges mounted locally on equipment and lines for local indication.
 Switches for process trip & interlock.
 Transmitters / Analyzers mounted in the field for control panel indication. PH, Conductivity and Density
Analyzers shall be provided as per the P&ID requirement.
 Instruments mounted on local panels adjacent to the equipment.

12.3. CONTROL PANEL
The Bidder shall supply control panels for the Water Treatment Plant, complete with necessary relays,
switches, lamps and other accessories. The panels shall be completely wired and tubed and with
necessary provision for interfacing with DCS systems (supplied by others).
12.4. CABLING AND ACCESSORIES
All necessary cabling and accessories including junction boxes, cable trays, structural supports, cable
glands, lugs, ferrules, cable ties, etc. up to the control panels shall be supplied by the bidder and from
control panel to marshalling cabinets shall be supplied by others.
12.5. ERECTION, CALIBRATION, TESTING AND COMMISSIONING
All instruments supplied under the contract shall be erected, calibrated, tested and commissioned by the
Bidder. All necessary erection hardware as required shall be supplied by the Bidder. This includes items
like cable glands, junction boxes, instrument valves, stanchions, mounting accessories. Impulse tubing /
piping, tube / pipe fittings, pneumatic signal tubes, cable trays, pipe / tube trays, conduits, name plates,
structural steel requirement, instrument / instrument tray supports, etc. and any other erection.
hardware / accessory required for successful erection, calibration, testing and commissioning of
instruments supplied under this package.

12.6. DESIGN REQUIREMENTS
This general specification together with enclosures if any cover the design of Control and
Instrumentation system, complete with all accessories and materials along with special test equipment
where the supply of such instruments is a part of a larger plant.
The detailed scope of work, specific requirements, exclusions, deviations, additions etc. if any, will be
indicated else wherein this specification.
Bidder shall be fully responsible for design, materials selection, sizing and selection of the proper
instruments for their system.
All equipments supplied shall be of proven quality both with respect to design and materials. No
prototype instrument or instrument of an experimental nature shall be offered or supplied.
Bidder shall prepare and submit a P&I diagram for the system within the scope of his supply, showing
all the instruments and interlock / trip operations. Each instrument shall be given individual tag numbers
from blocks of numbers allotted by the Purchase / Consultant. Symbols shall be as per ISA S5.1.
Bidder shall supply complete process data to the Purchase / Consultant to specify those instruments not
appearing in the Bidder’s scope of supply but are an integral part for the control of this package.
Bidder shall clearly define the operational philosophy suggested by him, which should be in line with
requirements specified in the main package / equipment specification. Bidder shall also clearly specify
the provision of control panel requirements for their package in their offer.
12.7. GENERAL SPECIFICATIONS OF INSTRUMENTS
General
The basic concept for Control & Instrumentation system is the use of electronic instruments throughout
for measurement, transmission and control with 4-20mA DC signal level.
Pneumatic instrumentation may be used for local control loops. Pneumatic signal pressure shall be 0.2
– 1.0 Kg/cm²(g).
Electrical Power
The power source for Control & Instrumentation shall be 240 V AC + 2%, 50 Hz + 3%. Analysers,
conventional panel instruments like indicators shall operate at this voltage level or 24V DC voltage
derived from this.
Solenoid valves and other instruments shall be suitable for 24 V DC / 240 V AC and the same shall be
derived internally by the manufacturer from 240 V AC 50 Hz.
2 wire transmitters powering and field instruments interrogation voltage level shall be 24 V DC.
Any repeat relays used for alarm / interlock purpose shall be working on 24 V DC.
Normal power supply of 240 V AC, 50 Hz shall be used for illumination of panels / cabinets.

Instrument Air
Instrument air at pressure of 5 Kg/cm² (g), temperature 20-40ºC and dew point - 40ºC or below shall be
the source of power for al pneumatic instruments. All pneumatic instruments shall be selected such that
even if air supply pressure selected such that even if air supply pressure falls to 3 Kg/cm²(g),
instruments operate satisfactorily.
Panel
All panel instruments shall be microprocessor based.

Unit of measurement :
Flow Liquid : m³/hr
Steam : T/hr
Gas & Vapours : Nm³/hr
Pressure Gauge : Bar(g)
Vacuum : Bar(abs.)
: mm of H2O(abs.)
Temperature : ºC
Level : %
Analysis : ppm
Graduations
Flow with DP cells : 0 to 10 square root
Rotamerers : 1 to 10 linear
Pressure : Direct Reading
Level : 0 to 100 Linear
Temperature : Direct Reading
Multiplying factors for flow scales shall be specified on manufacturer’s name plate.
Annunciators, in general, shall be solid state type with plug in module, in a cabinet with back lighted
engraved windows and integral power supply.
Field mounted annunciator circuit shall be intrinsically safe with power supply unit in a safe area.
Annunciator alarm sequence shall be as per ISA sequence.
A minimum of 20% spare windows with cards shall be providing as spares.
Control Panels
Control panels shall be free standing type and fabricated preferably from 3 mm thick cold rolled steel
sheet or 5 mm thick hot rolled steel sheet. Angle iron framework shall use a minimum section of 50 x 50
x 4 mm angle. The finish shall include sand blasting, grinding, chemical cleaning, surface finishing by
suitable filter and two coats of high grade lacquer with wet sanding between coats. Two coats of paint in
panel colour shall be given for non-glossy high stain finish. Panel face final colour can be any of the
following to IS:5.
Opaline green : IS:275

Light Admiralty Grey : IS:697
Panel rear surface, frame work and bulk head plates shall have a finish of pale cream IS:353 or beige
IS:388. A final coat of paint shall be given at site.
Control panel inside the control room shall be totally enclosed cubical type with 2100 mm high, 1200
mm wide and minimum 80 mm deep if mounted locally. The panel width to be increased if necessary.

Control panels shall have removable hinged doors, generally at the back for easy maintenance and
accessibility of the instruments. Doors shall be double leaved type with handle and shall be provided
inside the panel. All light fittings shall be suitable for 230C, 50 Hz AC.
No process fluid, except air shall be piped to the control panel.
Mounting heights
a. Annunciators (top row)
b. Miniature and subminiature instruments (next 3 rows)
c. Electric push buttons (last row)
Panel Wiring
 Open terminals shall generally be avoided. Terminal strips shall be of “Klippon” or equivalent type and
shall be mounted in an enclosure.
 1.5 sq.mm multi stranded PVC insulated copper conductor shall be used in general. These shall be laid
in PVC troughs as far as possible.
 Wire carrying measurement signals associated with pH instruments and other low level signals shall be
routed in separate wire ways and not along with power cables.
 All intrinsically safe wires shall be routed in separate wire ways from non-intrinsically safe and power
wiring.
 Intrinsically safe terminals shall be separated from non-intrinsically safe terminals atleast by 50 mm.
Local Gauge Board

 Local gauge boards, where required, shall be constructed such that easy access is available at the rear
for all instruments and accessories for maintenance.
 All pressure gauges shall be provide with block and bleed valves securely fastened with identification
tags.
Instrument Connection
 Pneumatic connection for signal and air supply shall be ¼” NPTF. Electrical connection shall be ½”
NPTF.
 Threaded and connection shall be to NPTF as per ANSI B2.1. Flanged end connections shall be as per
ANSI B16.5
Pressure Measurement
Pressure gauges
 All local pressure gauges shall be bourdon / diaphragm type of material SS 316. Pulsation dampener
shall be used wherever pulsating pressure occurs in process. Diaphragm seat type shall be considered
for corrosive services.
 Dial size for local gauges shall be 150 mm.
 For temperature greater than 70ºC, necessary precautions shall be taken like use of syphon in steam
services.
 All pressure gauges shall be considered with safety vent consisting of rubber grommet at the back of
housing.
Switches
 Pressure switches shall have micro switch with auto reset and fixed differential.
 Level Measurement
 Level Transmitters
 Level transmitters shall generally be differential pressure type with local indication.
 Capacitance type level measurements can also be used as an alternative method wherever
required for highly viscous fluids or bulk materials. PTFE sheathed SS tubes shall be used as
measuring probe.

 All DP type level transmitters shall be of electronic two wire type.

 Level transmitters mounted on tanks shall be of Float & Tape type with two switches with set point
adjustable & local indication.
Gauge Glasses
 Gauge glasses shall be considered generally as per process requirements. Maximum length of
each gauge glass shall be limited to about 1000 mm. If greater distance is to be covered, several
such gauge glasses shall be considered with minimum overlapping of about 50 mm.
 Each gauge glass shall be considered with excess flow ball check valve. Chamber end connected
check value shall be of offset type of facilitate cleaning of chambers.
 For clear / clean colourless liquid services, reflex type shall be preferred. For other services like
liquids containing sediments and coloured liquids, steam services, two phase measurement,
transparent type level gauges shall be considered.
 Level indication with magnetic coupling of follower magnet, shall be considered for corrosive,
dangerous / hazardous fluids.

Level Switches
 For interlock services separate level switches shall be provided. Generally external float type level
switches shall be provided.
Flow Measurement
Orifice Meters
 In general, orifice plates with DP transmitter or DP gauge (where only local indication is required)
shall be used. Orifice bore calculation shall be based on ISO-5167 or BS 1042.
 Flange taps shall be used in general.
Rotameters
 Rotameters shall be used for line sizes upto 3”.
 Metal tube Rotameters shall be used wherever application warrants and glass tube Rotameters
shall be used for non-critical services like cooling water, purge applications, flushing applications
etc.
12.8. ERECTION MATERIAL SUPPLY
The Bidder shall ensure and supply all erection hardware required for installation of all instrumentation
which form a part of the package unit. This includes items like cables, cable glands, junction boxes,
instrument values, mounting accessories, impulse piping / tubing, pipe / tube fittings, pneumatic signal
tubes, air line pipes, filter regulators, steam / electrical tracing, insulation materials, cable trays,
conduits, identification tags, structural material required for instrument supports and trays etc.
The above broadly covers the items required for any typical plant, however the Bidder shall supply all
necessary items to make the erection and commissioning work complete in all respects, irrespective of
whether erection and commissioning is included in this scope or not.
The following are the minimum acceptable salient features of some of the erection materials :
Process Impulse Lines

Impulse lines for instruments shall be ½” OD tubing of SS 316 material according to ASTM A 269 for
pressure rating upto 40 kg/cm²(g). All fittings to be used for tubing shall also be SS 316, double
compression type of standard make.

Pneumatic Tubing
For pneumatic signal transmission, PVC sheathed, ¼” OD, copper tubes shall be used. All fittings shall
be of brass, double compression type.
Instrument Airlines, fittings/valves
Seamless galvanized inside and outside carbon steel pipes shall be used for instrument air distribution,
and shall be as per IS:1239 class heavy.
Isolation valves on instrument air service shall be packless gland type full bore ball / globe valves.
Instrument Valves and Manifolds
 Bidder shall supply instrument values (miniature type) and valve manifolds wherever required.
 Body material and rating shall be as per piping class or SS whichever is better and shall be forged
type.
 Valve trim material shall be 315 SST as minimum or superior as required by process conditions.
 Bidder shall supply a minimum of 10% of such instrument value and manifolds as spare.
Instrumentation Cables
 For 4-20 mA current signal, twisted pair stranded screened cables (1.5 sq.mm) shall be used.
Multipair cables (0.75 sq.mm) stranded shall be considered from DM Plant control room upto
junction boxes. Multipair cable shall have overall screening & Individual pair screening. Required
parameters for intrinsic safe signal handling shall be considered according to Indian Standards or
British Standards, when applicable.
 For control cables, 1.5 sq.mm, 7 stranded, 2 core cables shall be considered between instruments
and junction boxes, and 0.75 sq.mm, 7 stranded, multicore cables shall be considered between
junction boxes and control panels.
 For power supply to solenoid valves, 2.5mm².2 core cable shall be considered.
 All field instrumentation cables shall be armoured type and shall be with electrolytic grade copper
conductor.
 The insulation grade shall be as a minimum 600 V.
Cable Glands
 Bidder shall supply all cable glands required for glanding the above mentioned cables both at field
instrument and at control room (local & main) / control room devices / junction boxes/battery limits.
 All cable glands shall be of anodized aluminium alloy or of nickel-plated brass and they shall be double
compression type suitable for armoured cables. Panel end cable glands shall be with locknut.
 Explosion proof glands wherever required shall be supplied. Bidder shall supply a maximum of 20% of
cable glands as spare.
Junction Boxes
 Bidder shall supply junction boxes wherever required. These shall be of die cast aluminium alloy body
and shall be weather proof.
 These boxes shall have terminals suitable for min 2.5 mm² cable termination (klip on) mounted on rails.
20% spare terminals shall be supplied in each junction box.

 Each junction box shall have a minimum of 10% or 2 nos. whichever is more, spare entry duly provided
with plugs (weather proof / explosion proof, as applicable).
Cable Trays
 All cables / tubes shall run on cable trays.

 These cable trays shall be made out of galvanized MS and shall be of sheet steel of 2.5 mm thick.
 The width shall be so selected that 50% of tray space is available for future use of the complete
installation.
 Suitable cable clamps shall be supplied for binding the cables / tubes at every 500 mm.
 Instrument Support / Structural Steel
 Bidder shall supply instrument stands (stanchions) and other structural steel material required for
supporting the cable trays, impulse lines and instruments.
12.9. INSTALLATION
 Bidder shall be completely responsible for installation of all instruments within his battery limit, as per
the installation sketches (typical) furnished along with this specification.
 All direct mounted instruments like pressure gauges, pressure switches etc. shall be installed in such a
way that they have better readability and accessibility.
 All pressure, differential pressure instruments shall be provided with block and bleed, by-pass, drain /
vent valves etc. as per the installation sketches, and shall have accessibility.
 All primary piping / tubing (impulse lines) shall have a slope of 10% on the horizontal run.
 All threaded joints shall be joined by Teflon tapes only. All impulse lines shall be supported at regular
intervals.
 Instrument drain / vent connections shall be piped to safe area like OWS or above pipe racks to avoid
accumulation of hazardous fluid in the plant atmosphere.
 All tubes / cables shall be properly laid on cable trays which shall be supported at regular intervals.
 Separate routing or physical separation shall be maintained between signal cables and shut down /
power cables.
 The cases of instruments shall be earthed by earthing wire to the nearest earth bus bar provided by
others, for safety reasons.
 In case the cables are to be buried or laid in concrete trench the same shall be carried out by Bidder
with prior intimation to client.
 Painting of cable trays / ducts, M.S. cable ways, angle trays, instrument supports, all structural supports
shall be as under :
 The surface to be painted shall be thoroughly cleaned with brush sand paper to remove all scales. After
cleaning, one coat of red oxide zinc chromate primer shall be given conforming to IS-2074 and allowed
to dry. One coat of final paint shall be applied.
 Second and final coats of paint of final colour shall be given before handling over the plant /
commissioning.
12.10. TESTING AND CALIBRATION
 All impulse lines shall be properly flushed after isolating both the instrument and the vessel / piping.
 All impulse lines shall be tested hydraulically at 1.5 times the maximum operating pressure. Ensure that
instrument and vessel / piping is isolated during this test.
 In case of special conditions where hydrotesting is not permitted due o service conditions, the impulse
lines testing shall be carried out by using air or nitrogen.

 After pressure testing all these impulse lines shall be drained and dried with dry air to remove any
moisture.
 Instrument air lines will be service tested only for any leak after pressurizing and isolating the main root
valve, by soap solution.
 Pneumatic signal tubes shall be flushed and tested with instrument air for any leak at a pressure of 1.5
kg/cm²(g). After pressurizing the line, the source of pressure is cut off and rate of fall in pressure shall
be less than 1 psi for each 100 feet for a period of 3 minutes.
 All instrument cables shall be tested for continuity and insulation. While megger is used for insulation
testing, ensure that all instruments and zener barrier are isolated at both ends. All instruments supplied
by the Bidder shall be calibrated using proper test equipment.
 All instruments shall be calibrated for 0%, 25%, 50%, 75%, 100% and vice versa. All transmitters shall
be calibrated as per instrument ranges.
 All alarm and trip switches shall be calibrated over the entire range and finally set and checked for alarm
/ trip points and reset points as per the alarm / trip set point schedule. After setting these shall be
sealed.
 All special instruments like analyzer shall be checked and calibrated as per manufacturer’s instruction.
Prior to testing, all analyzer sample lines shall be thoroughly cleaned by carbon tetra chloride or any
other cleaning liquid. After cleaning, these lines shall be thoroughly purged with dry nitrogen.
 The accuracy of overall loop shall be within + 1% for electronic and + 1.5% for pneumatic loops.
 After performing the calibration of all instruments, the entire loop shall be checked for proper operation.
 The entire shutdown scheme shall be simulated from the process trip switches and the scheme shall be
tested for its proper operation, prior to start up of the unit.

12.11. COMMISSIONING
 This activity shall be carried out in a systematic manner so as to avoid any accident to plant and
operating personnel.
 During the plant start up all the instruments calibration, trip point settings shall be trimmed so as to meet
the operation requirement.
 Prior to guarantee run of any package unit the vital instruments as required by Bidder have to be
recalibrated and the results recorded.
12.12. SPARES PHILOSOPHY
 Spare instruments :
 10% spare instrument with a minimum of one in each type for instruments like field switches, temp
gauges, pressure gauges etc.
Commissioning spares : This shall be as per vendor standards
Operational spares : The operational spares for all instruments shall be based on
vendor recommendation.
12.14. CONTROL & INSTRUMENTATION AND CONTROL FOR RO/DM PLANT
The pump on off Status and water quality parameters are monitored by PLC. The PLC shall have RS 485 serial
port for communication with plant DCS.
12.15. INSTRUMENTATION LIST
All the instruments specified in the specification shall be of reputed make and no local make will be entertained.

13.0. DRAWINGS / DOCUMENTS TO BE SUBMITTED ALONG WITH THE BID
 P & I diagram within the battery limit indicating the line sizes, controls, interlocks etc.
 Process calculation including Rosa projection
 All chemical dosage levels in milligram / litre and per day requirement
 Process calculation for mixed bed
 Process flow diagram within the battery limit
 Overall layout with the space requirement, clearly indicating the covered space.
 Motor data sheet and characteristic curves
 Instrument schedule and instrument data sheet
 Weight of single heaviest item
 Quantity of water required for regeneration and water quality
 Schedule of Utilities requirement
 Individual and Total power consumption for water treatment package
 BIDDER shall indicate quality and quantity of effluent at various outlet points, suggested neutralization,
effluent pit size etc.
 BIDDER shall indicate the quality and quantity of backwash / regeneration water required for mixed bed.
 List of bought out items with vendor list
 Completely filled up data sheets (Format enclosed)
14.0. DRAWINGS & DOCUMENTS TO BE SUBMITTED AFTER AWARD OF CONTRACT (ALL IN FIVE SETS)
 Process flow diagrams with material plans.

 Process calculation including Rosa projection
 All chemical dosage levels in milligram / litre, per day requirement.
 P & I diagram with line size, controls, interlocks etc.
 General Arrangement drawing of all equipment and handling facility
 Cross Sectional drawing of all equipment with material
 Equipment layout drawing of the water treatment package
 Piping layout drawing within the battery limit of the water treatment package
 General Arrangement drawings of all valves selected and valve schedule
 Instrument schedule and instrument data sheet
 Pump data sheet and characteristic curves
 Motor data sheet and characteristic curves
 Quality Assurance Plan
 Performance test procedure
 Commissioning spare list and Recommended spares list
 Wiring diagram for motor starters with interlocks
 MCC details, Lighting plan & layout
 Instrument hook up and logic diagrams, control detail.
 Operating and Maintenance Manual
 Packing list
 Foundation load data for the equipment
 Schedule of lubrication
 Schedule of special tools and tackles, if any
 Schedule of chemicals to be used, annual quantity, dosage quantity, interval between subsequent
dosing.

15. VENDOR LIST – INSTRUMENTS

S. No. Description Make
1. Level indicators (tubular) for all dosing tanks, DG Pune techtrol
water storage tank, acid measuring tank, caustic
dilution tank
2. Level Indicators (Float & Board) DGWST Pune techtrol
3. Level transmitters (UFWST) ABB / E&H
4. Flow indicator (Rota meter type) Flowmax / Nexus
(MGF inlet, each ejector line, softener outlet)
5. Flow meters (electromagnetic type) ABB / Khrone Marshall
6. pH indicators (MB outlet after pH correction) Nexus / Polymetron / Eutech
7. Conductivity indicators (MB outlet) Nexus / Polymetron / Eutech
8. Pressure switch Dag / Waree
9. Level switches Pune Techtrol
10. Air filter regulators Aira Pneumatics, Jenatics
11. Pressure gauges Waree, Forbes Marshall, Mass, H
Guru, General Instruments
12. Pressure switches Orion, Switzer, Indfoss
13. Level gauges & level switches Punetechtrol, Levcon
14. Rotameters Flow Max, Eureka, Nexus, FIP

16. SUB - VENDOR LIST
S. No. Description Make

1. Centrifugal pumps Ebara, Sumo, Johnson Pumps Ltd, Sam turbo
2. Dosing pumps Injecta
3. HDPE storage tanks Sintex / National
4. PVC pipes FIP Italy, marvelous, Finolex
5. Diaphragm valve Procon Valves Ltd, Alfa Laval, Avcon
6. Butterfly valve Intervalve Ltd, Hawa Valves Ltd, Crane
Process, Alfa Laval
7. Ball valve Hawa, Karan, Norflow Controls Ltd, Audco
Valves Airmax
8. Needle valve Hawa, Norflow Controls Ltd
9. Solenoid valves Rotex, Airmax, Jenatics
10. Cables Avocab, Polycab
11. Cable glands Comet, Electromech, HMI, Cosmos,
12. FRP cable trays Sumip, Ercon, Indiana Gratings
13. GI cable trays Asian Ancillary, Globe Elect., B.M. Engg,
Indiana Gratings, Profeb
14. Relays T&C, L&T, Siltronix, Scheneider
15. PLC Allen Bradley, GE Fanuc, ABB, Schneider,
Messung, Delta
16. Motors Kriloskar, ABB, Siemens
17. Indicating lamps, pushbuttons L & T, Teknic, Vaishnu, Scheneider, Seimens
18. Terminal blocks Elmex, Connectwell
19. Cables / wires Finolex, Universal, CCI, Gloster, Avocab
20. ACB’s and MCCB’s L & T, Crompton, Scheneider
21. Control switches Kaycee
22. Relays L&T, Siltronix, Scheneider
23. Lugs Dowel, Jainson, Lotus
Note:-
Non Deviation will be accepted.
Bidder will quote In Bifurcate manner and only after Technical Freezing.
For any Deviation in Vendor/Sub-vender list, approval from Real Ispat & Power Ltd. must before
quote.

Technical Specification for RO Plant

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Technical Specification for RO Plant

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TECHNICAL SPECIFICATION FOR RO PLANT

Technical Specification of RO Plant RIPL/TMT MILL/18-19/05/WTP/01-REV-0

3. WATER SUPPLY SYSTEM 4

4. SCHEMES & CAPACITIES 4

4.1. DM PLANT WITH CLARIFIER 4

9. GENERAL TECHNICAL REQUIREMENTS 10

12.1. TYPE OF INSTRUMENTATION AND CONTROL 18

12.4. CABLING AND ACCESSORIES 18

12.5. ERECTION, CALIBRATION, TESTING AND COMMISSIONING 18

Real Ispat & Power Pvt. Ltd., Bojhara,Raipur Page 2 of 28

12.14. INSTRUMENTATION LIST 25

CONTRACT (ALL IN FIVE SETS)

15. VENDOR LIST - INSTRUMENTS 27

14. SUB - VENDOR LIST 28

Annexure I RAW WATER ANALYSIS REPORT

Real Ispat & Power Pvt. Ltd., Bojhara,Raipur Page 3 of 28

3. WATER SUPPLY SYSTEM

One (1) no of Clarifier of 150 m³/h capacity (net output)

One (1) stream of MGF and ACF of 18 m³/h capacity

One (1) no of UF of 18 m³/h capacity with min.90% recovery

One (1) no. of RO of 16 m3/hr capacity with min.75% recovery

4. SCHEMES & CAPACITIES

4.1. DM PLANT WITH CLARIFIER

4.1.1. Scheme for the Clarifier, DM plant with UF/RO

Real Ispat & Power Pvt. Ltd., Bojhara,Raipur Page 4 of 28

4.1.2. Pretreatment Scheme

Clarifier --- Storage tank

The capacity of Clarifier is 150 m3/hr.

MGF --ACF---- UF membrane ---- RO Plant For MGF/ACF/UF stream : 16 m³/hr

4.1.4. Plant capacity

The design basis of the DM Plant stream shall be as follows:

SAC/SBA : 240 m³ for each stream

4.1.5. Water Quality required at the outlet of UF, RO and degasser:

(i) R.O Permeate

(ii) Degasser Tower

(iii) Ion exchange water quality

Total reactive silica not to exceed mgl as SIO2 0.1

Real Ispat & Power Pvt. Ltd., Bojhara,Raipur Page 5 of 28

(iv) Guarantee Water Quality at DM Plant Outlet

The guaranteed quality of DM water at mixed bed outlet will be as follows:

Chemical consumption for effluent neutralization as indicated by Bidder shall be guaranteed.

Real Ispat & Power Pvt. Ltd., Bojhara,Raipur Page 6 of 28

Real Ispat & Power Pvt. Ltd., Bojhara,Raipur Page 7 of 28

5.2. OTHER ITEMS INCLUDE

5.3 OTHER ACCESSORIES

Real Ispat & Power Pvt. Ltd., Bojhara,Raipur Page 8 of 28

6.0. SCOPE OF SERVICES

 All civil works.

8.0 BATTERY LIMITS

 Raw water : At the inlet of Clarifier

Real Ispat & Power Pvt. Ltd., Bojhara,Raipur Page 9 of 28

9.0. GENERAL TECHNICAL REQUIREMENTS

9.1.2 Multigrade Filter & ACF

 Vessel design standard : IS 2825 or ASME Sec. VIII Div.1

Real Ispat & Power Pvt. Ltd., Bojhara,Raipur Page 10 of 28

9.1.3. Ultra filteration (UF)

 No. of units : One

9.1.4. RO high pressure pump

9.1.6. Water Storage Tanks

Real Ispat & Power Pvt. Ltd., Bojhara,Raipur Page 11 of 28

9.1.8. Degasser Blower

9.1.9. DM feed water Pumps

Real Ispat & Power Pvt. Ltd., Bojhara,Raipur Page 12 of 28