11V02 Acc SPC M 0001 V2 Part A

SPECFICATION FOR
AIR COOLED CONDENSER

PROJ ECT
1 x 300 MW COAL BASED THERMAL POWER
PLANT, CHHATTISGARH, INDIA
Doc. No. 11V02-201-SPC-M-0001, REV.R0
Date: 04-11-2011
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VOLUME II
PART - A
MECHANICAL AND GENERAL

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VOLUME II
PART - A
SPECIFICATION: M0
GENERAL SPECIFICATION

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I N D E X

CLAUSE_NO. DESCRIPTION

1.00.00 Intent of Specification

2.00.00 General Information and Site Condition

3.00.00 Codes and Standards

4.00.00 Scope of Work and Terminal Points

5.00.00 Services to be provided by Bidder

6.00.00 Services to be provided by Owner/Purchaser

7.00.00 Technical Information & Data to be furnished by Bidder

8.00.00 Work Schedule

9.00.00 Performance Guarantee

10.00.00 Painting

11.00.00 Inspection & Testing

12.00.00 Quality Assurance

13.00.00 Anchor Bolts, Sleeves, Inserts, Foundations, Pack Plates, Lifting
Lugs, Eye Bolts etc.

14.00.00 Tools & Tackle

15.00.00 Spare Parts

16.00.00 Operation & Maintenance

17.00.00 Instruction Manual

18.00.00 Drawing, Document for Approval, Clearances

19.00.00 Co-operation with other Contractors & Consulting Engineers

20.00.00 Bid Evaluation Criteria

21.00.00 Noise Level

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22.00.00 Brand Name

23.00.00 Specification Drawings

24.00.00 Plant and equipment identification, labeling

25.00.00 Safety & Security

26.00.00 Packaging & Marking

27.00.00 Protection

28.00.00 Project Management Services

29.00.00 Site Services

30.00.00 Training of Owner's Personnel

ANNEXURES:

ANNEXURE I Site and General Plant requirement

ANNEXURE II Scope of work and Terminal Points

ANNEXURE III Site work and Erection requirements

ANNEXURE IV Inspection and Testing

ANNEXURE V Quality Assurance

ANNEXURE VI Tools and Tackles list

ANNEXURE VII Documentation

ANNEXURE VIII Drawings, Documents for approval, Clearances

ANNEXURE IX List of Mandatory spares

ANNEXURE X Training requirement

APPENDIX

APPENDIX-A Approved Vendor List

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M0: GENERAL SPECIFICATION

1.00.00 INTENT OF SPECIFICATION

1.01.00 This specification is intended to cover the design, engineering,
manufacture, testing at manufacturer's works and site, delivery duly
packed for transportation for Site of the entire Air cooled condenser
complete with all equipment and accessories and all relevant Electrical,
Control, Instrumentation, Civil & Structural works as specified hereinafter
as a turnkey Air cooled condenser Package for 1 x 300 MW Thermal
power plant of MCCPL (Owner) at Korba.

1.02.00 The scope of work shall include Detailed Design, Construction Drawings
for Civil, Architectural, and structural works, the fabrication and execution
of all structural steel. However, civil works will be carried out by purchaser
(IOT).

1.03.00 The scope of work also includes site unloading, handling, intra-site
transportation, site storage, fabrication, erection, final check-up, testing
and commissioning services and all other incidental works thereto (like all
labour, supervision, supply of erection equipment and consumables, as
necessary) of the equipment and accessories to be supplied under this
specification, as specified hereinafter.

1.04.00 It is not the intent to specify completely herein, all aspects of design and
construction of equipment. Nevertheless, the equipment shall conform in
all aspects to high standard of engineering, design and workmanship and
shall be capable of performing in continuous commercial operation in a
manner acceptable to the Owner/Purchaser who will interpret the
meaning of the specification, drawings and shall have a right to reject or
accept any work or material which in his assessment is not complete to
meet the requirements of this specification and/or applicable
Indian/International Standards.

1.05.00 Bidders are requested to carefully examine and understand the
specifications and seek clarifications, if required, to ensure that they have
understood the specification. The bidders' offers should not carry any
sections like clarifications, interpretations and/or assumptions.

2.00.00 GENERAL INFORMATION AND SITE CONDITION

2.01.00 Site condition

A. LOCATION AND EXISTING INFRASTRUCTURE
Country : India

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State : Chhattisgarh
District : Korba
Tehsil : Pali
Village : Bandakhar
Next Town : Korba (approx. 30 kms from site)
Road access : State highway connecting Bilaspur &
Katghora - approx 8.0 kms from site
Nearest Railway Station : Korba (approx. 30 kms from site)
B. GEOLOGICAL CONDITIONS
Seismic intensity
Seismic Intensity : As per IS : 1893
Zone : II
Zone factor (Z) : 0.1
Importance factor (I) : 1.75 for power plant buildings(As
per provisions of IS: 1893, Part 4)
Response Reduction Factor
(R)
: As per IS: 1893- 2005
C. METEOROLOGICAL CONDITIONS
Site Elevation
Site Elevation above MSL : Varying 320 meters - 334 meters
Ambient Air Temperature
Average ambient air temp. : 35C
Maximum summer temp. : 48.4C
Maximum dry bulb temp. : 41.3C
Minimum dry bulb temperature : 12.9C
Relative humidity
Maximum humidity : 86%
Minimum humidity : 27%
Annual Average : 62%
Rainfall
Annual Rainfall (Average) : 1390 mm
Maximum one (1) hour rainfall : 40 mm

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Maximum twenty four (24)
hour rainfall
: 325 mm
Duration : Mainly from J une to October
Wind
Maximum direction : Predominantly from NE & SW
Maximum wind speed : 19.0 Km/hr
Minimum wind speed : 1.5 Km/hr
Basic wind speed (Vb) : As Per IS 875 Part 3 -1987
Risk coefficient (K1 factor) : 1.06 for plant structures
1.00 for non-plant structures
Terrain category (K2 factor) : Category 1
Topography factor (K3 factor) : 1.0
FGL at ACC area
Finished Grade Level : 331.000 meters

2.03.00 All documents and drawings enclosed/issued with this specification forms
a part of the specification.

2.04.00 The layout of the air cooled condenser and the relevant information have
been furnished in the drawings enclosed. The above mentioned drawings
are conceptual and are indicative and give a guideline for design of the
system, layout of equipment and other relevant data for the purpose of
estimation. Bidders must study the drawings in details. The bidder must
visit the site to assess the complete scope of work. Bidder shall develop
actual drawings on the basis of tender drawings and his site visit without
major deviation and shall submit them along with the offer.

2.05.00 In case any discrepancy exists between data sheets furnished and
equipment/system details given, the stringent of the conditions given shall
prevail.

2.06.00 Additional details on site condition and general plant requirement (as per
EPC tender) are indicated in the Annexure-I.

2.07.00 The power plant will be operated in the base load mode for a
minimum 8000 hours of operation in a year.

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3.00.00 CODES AND STANDARDS

3.01.00 Except as stated otherwise in this Specification, Indian / British /
American or equivalent standards shall be followed. And EPC Contractor
shall provide the relevant standards. However for civil works the
specifications as stipulated in Indian standard codes shall be followed
strictly.

3.01.01 In case of any contradiction between the stipulations of the above
standards and those made in this bid document, the latter will prevail.

3.02.00 All electrical equipment supplied shall comply with the latest revision of
the Indian Electricity (Supply) Act, Indian Electricity Rules, Indian
Standard (IS) or International Electric Technical Commission (IEC)
Publication and also within the statutory requirements of the Government
of India and Government of Chhattisgarh as regards safety, earthing and
other provisions specified therein for installation and operation of
electrical equipment.

3.02.01 The responsibility of obtaining the necessary approvals of
Inspection authorities of Government on behalf of the Owner/Purchaser,
as may be required for design and design calculations, manufacturing
and erection procedure, testing etc as called for, shall rest with the
Contractor. All such documentation submitted to statutory authorities
shall also be submitted to the Owners Engineer for his review.
However, all the fees for procedure in the form of challan or DD shall
be paid by the Owner/Purchaser to the government for statutory
approvals. Any addition/alternations required for this shall be done by the
contractor free of additional cost to the Purchaser.

3.03.00 All moving parts of equipment which can conceivably cause injury to the
operator and otherwise authorized personnel within the vicinity of working
area shall be suitably guarded according to the safety regulations. The
complete assembled units shall be designed so that all parts subject to
wear including shafts and bearings, shall be easily accessible for
inspection, maintenance and replacement, with minimum loss of time.

3.04.00 Reference to special codes and standards, where designated either
directly or as "relevant", is intended to provide a measure of
performance, safety, in-shop and on-site testing, and methods of
construction and/or installation which must be equaled or exceeded in
order to be considered acceptable for use under this specification. If
more than a single degree of quality or accuracy is permitted within
the scope of particular code or standard, the highest quality shall be
applicable and the degree of accuracy commensurate with the intended
function shall be selected, but with the understanding that the final

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decision will be made by the Owner. In all instances, the finally accepted
applicable code or standard shall be the version, which is last published.

3.05.00 Where no appropriate standard is available, tests shall be
conducted in accordance with the manufacturer's standard practice,
subject to the approval of the Owner.

In such cases the Contractor shall submit to the Owner complete data
and a suggested procedure for the testing to be performed. Manufacture
commenced before receipt of the Owner's approval shall be at the
Contractor's risk.

If the proposed procedures are accepted, the Contractor shall provide
the Owner with four additional copies in English before any test is
performed.

3.06.00 Equipment furnished by the bidder shall be complete in every respect with
all mountings, fittings, fixtures and standard accessories, which are
normally supplied even though not specifically detailed in the
specification. The Purchaser shall not be asked for any extra payment in
respect of such mountings, fittings, fixtures and accessories which are
needed for the safe operation of the equipment as required by applicable
codes within Indian territory though they may not have been included in
this document.

3.07.00 Derating Standards

The Bidders attention is drawn to the climatic conditions in the site area.
Derating factors shall apply in accordance with the relevant and
approved standards if not specified in the specification.

4.00.00 SCOPE OF WORK AND TERMINAL POINTS

4.01.00 The scope of work will include all equipment, items and services as
detailed in various volumes Part A, Part B, Part C & Part D of the
specification and tender drawings enclosed. The contractor shall design,
manufacture, assure quality, deliver document & equipment, erect,
connect electrically, test, commission and make performance test. The
items, though not specifically mentioned but needed to make the system
complete and reliable for safe trouble-free operation and guaranteed
performance shall be treated as included and the same shall also be
furnished, unless specifically excluded elsewhere.

Scope of work and terminal points have been furnished in
Annexure-II of this section

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4.02.00 Protection & Care
All construction and erection activities are to be carried out in the Air
cooled condenser with great care so that the nearby structure is not
affected. Any damage to structure erected by other shall be rectified by
the Contractor at their cost speedily.

5.00.00 SERVICES TO BE PROVIDED BY BIDDER

Services to be rendered by the Bidder are described below. The services
shall also conform to the requirements of "Conditions of Contract."

5.01.00 The Bidder shall take the responsibility for all the Testing and Inspections
at Manufacturer's Works to be conducted in manner as specified in this
specification.

5.02.00 Transportation of all equipment packed for transportation in the specified
way from the Manufacturer's works to the Project Site inclusive of all
intermediate handling.

5.02.01 The storage-cum-erection insurance of the material under his custody
shall have to be arranged by the Contractor. Transit insurance shall be
arranged by Purchaser.

5.03.00 Unloading of the equipment at site, transporting and proper storing at site
in the approved way under security.

5.04.00 Opening of packages, checking, tallying, sorting out and inspection of
equipment received at site and lodging of insurance claims.

5.05.00 Taking delivery of equipment/material from stores, transportation at site
and arrange for proper storage of the equipment/material in approved
way pending erection.

5.06.00 Erection including erection supervision, Inspection, Testing, Start-up and
commissioning of the equipment.

5.07.00 Performance Guarantee Test

5.08.00 Painting at Site

5.09.00 Trial Run, Performance & Guarantee Tests

For Trial Run, Performance & Guarantee Tests. Refer Volume-I.

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5.10.00 Notes to Erection Work

5.10.01 The Contractor shall arrange for his own supervisory personnel, skilled
and unskilled workers, erection equipment, transport vehicles, lifting
tackle, tools, precision levels including micro- levels, dial and other
gauges, straight edges, testing equipment/instruments/gadgets and all
other elements in sufficient numbers as may be required for timely
erection, checkup, testing and commissioning of the plant.

5.10.02 All stair cases, ladders, platforms, temporary supports and structures,
scaffolding, facilities required for handling of heavy packages at site etc.
required for erection are to be provided by the contractor.

5.10.03 Any rectification of the equipment prior to erection shall be done by the
contractor in proper manner with the help of the Manufacturer and with
Purchaser's knowledge and approval.

5.10.04 For erection of all equipment to correct level and position, the contractor
shall take all necessary measurements of foundations, anchor bolt hole
sizes and location; set up correct reference lines for foundations and
carry out all final adjustments by chipping, bedding and dressing of the
foundation surfaces and anchor bolt holes, pockets etc. wherever
necessary.

5.10.05 Erection, leveling, bedding grouting of all foundation frames, bed plates,
inserts, foundation and anchor bolts, plates etc. for all equipment and
auxiliaries are included in the scope of work. The contractor shall make
his own arrangements for shuttering work, mixing, laying and curing of the
grouting.

5.10.06 Any existing civil, structural or electrical work, if damaged by the
contractor during erection due to his fault shall be made good by him at
his own cost to the satisfaction of Purchaser/Consultant.

5.10.07 All work shall have to be done with proper liaison with the purchaser as
stated in the "Conditions of Contract" with skilled & qualified personnel
and adopting the best engineering practice.

5.10.08 For further details on site and Erection requirement, refer Annexure-III.

6.00.00 SERVICES TO BE PROVIDED BY PURCHASER

6.01.00 Civil design and engineering above ground (RCC +Structural steel) will
be in Bidder's scope. Supply, Erection and construction of structural steel
shall also be in Bidder's scope. RCC civil construction work will be carried
out by IOTL. Fan deck shall be in structural steel and columns with tie
beams upto fan deck level shall be of RCC.

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Bidders to indicate BOQ for RCC works for bid evaluation loading and LD
on reinforcement steel and cement. Bidder to note that above ground
RCC work will be designed by them and constructed by Purchaser
(IOTL).

Optional price for total structural steel construction above ground (in
bidder scope) shall be provided. Bidder shall provide schematic drawing
for both the options with the bid document.

7.00.00 TECHNICAL INFORMATION & DATA TO BE FURNISHED BY BIDDER

7.01.00 All data and information as asked for in different parts/ sections of this
Specification.

7.02.00 Duly filled up Proposal Data Sheets.

7.03.00 Duly filled up price tabulation sheets in specified manner.

7.04.00 Without the duly signed drawings, documents, data and filled-up proposal
data sheets the proposal is liable to be rejected.

8.00.00 WORK SCHEDULE

8.01.00 The Air cooled condenser shall be commissioned as per Schedule given
in GCC/ SCC.

8.02.00 The bidder must submit schedule of completion in line with the above in
his offer, which will be treated as the prime pre-requisite for the
acceptance of the offer.

8.03.00 The bidder shall include in his proposal the programme of supply,
erection and commissioning of the Air cooled condenser. The programme
shall be in the form of a master network identifying the key phases in
various areas of the total work like design, procurement, manufacture and
field activities, inspection, erection, testing and commissioning etc.
Bidder shall indicate clearly in his proposal total time required by him for
completion of the entire Air cooled condenser, so as to match with
schedule as given in Volume-I.

9.00.00 PERFORMANCE GUARANTEE

9.01.00 The successful bidder shall be responsible for proper design, smooth
and trouble-free operation of all the systems, equipment and components
offered by him.

9.02.00 The successful bidder shall guarantee that the material of construction
and workmanship of all the equipment and components supplied by him

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are as specified under this specification and wherever there is nothing
specifically mentioned shall correspond to the best available grade and
quality.

9.03.00 The successful bidder shall also guarantee that the system, equipment
and components covered by this specification shall be as per relevant
standard and code and shall be suitable for continuous operation (i.e. 24
hours per day).

9.04.00 Performance/Acceptance test for the condenser shall be conducted in
accordance with the latest edition of ASME PTC-30.1 / VGB R-131. The
condenser pressure shall be measured at turbine exhaust flange under
100% TMCR condition, 0% make-up and design air flow and ambient air
inlet temperature without considering the 5% margin on heat transfer area
and 10% tube plugging margin. For LD on performance guarantee and
acceptable limit of increase in turbine back pressure, refer Volume-I.

9.05.00 Schedule of guarantees which attract penalties for various equipments as
follows:

9.05.01 Turbine exhaust pressure (0.022 MPa (abs)) at turbine exhaust box
flange at 100% TMCR condition with 0% make-up and all heaters in
service and design ambient temperature of 40 Deg.C without considering
5% head load margin on heat transfer area and 10% tube plugging
margin.

9.05.02 Auxiliary power consumption for all the auxiliaries including fans, pumps
etc. under rate steam conditions and at condenser pressure of 0.022 MPa
(abs)) with 3% make-up and with ambient temp of 40 Deg.C for ACC fans
and RH 51% shall be guaranteed. The total auxiliary power consumption
shall also include losses of the transformers supplied by the bidders
based on works tests reports. While guaranteeing auxiliary power
consumption the bidder shall include all continuously operating auxiliaries
under complete package.

9.05.03 The unit availability shall be computed as follows: The unit availability
shall not be less than 90% and the same has to be guaranteed. Any
shortfall in the availability of the unit will be subject to liquidated damages.

Unit availability = TB + TR x 100%
TN
Where
TN = Nominal time covering one year (8760 hrs.) from the date of
successful completion of Performance Guarantee tests
TB = Actual operating hours of the unit during the one year starting from
date of successful completion of Performance Guarantee tests.

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TR = Time in hours when the unit was idle in period TN due to reasons
not attributable to the Contractor.

(a) Any time taken by the Contractor for attending to the defects only
that would have warranted shutdown of the unit will be reduced
from TR.
(b) The time shall be reckoned from safety/work permit (LC Line
Clear book) kept in unit control room and the period shall be
between issue of LC and return of LC.
(c) The time TB & TR shall be reviewed jointly by the
Purchaser and Contractor on weekly basis and the above such
periods shall be noted accordingly.
(d) The availability of each unit shall be worked out separately
and LD shall be levied accordingly.
(e) In case of dispute in reckoning the period for TB & TR, the
Purchasers verdict will be final and binding.
(f) Actual operating hours of the unit (TB) shall mean the time
during which the unit is in synchronization with the grid.

9.05.04 Vibration Level as per relevant standards.

9.06.00 Schedule of guarantees which do not attract penalties for various
equipments as follows:

9.06.01 Air Cooled Condenser and Condenser Vacuum pumps:

1) Turbine exhaust pressure (vacuum back pressure) at turbine exhaust box
flange during warranty period at 105% TMCR (VWO) and 80% TMCR
condition and design ambient temperature of 40 Deg.C without
considering 5% head load margin on heat transfer area and 10% tube
plugging margin.

2) Time required to maintain vacuum up to 0.35 kg/cm
2
(abs) when
both pumps are in operation.

3) Temperature of condensate at outlet of air cooled condenser shall not be
less than saturation temp. corresponding to the condenser pressure at all
loads.

4) Oxygen content in condensate at hot well outlet shall not exceed 0.015 cc
per liter over the entire load range and shall be determined according to
an internationally approved code/standard.

5) When one half of the air cooled condenser fans are stopped, condenser
capability shall be demonstrated to take at least 60% T.G. load.

6) Pressure drop on tube side with design ambient temperature of 40 Deg.C.

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7) Capacity and Power consumption at design conditions.

8) Utility consumptions. Bidder to indicate with bid document and
demonstate.

9.07.00 Bidder shall submit declaration along with bid documents in
specified proforma to furnish all his guaranteed parameters, short fall in
which shall attract levy of liquidated damages as applicable.

9.08.00 Liquidated Damages for Short Fall in Performance

For Liquidated Damages for Short Fall in Performance, Refer Volume-I.

9.09.00 Liquidated Damages for Power Consumption

For Liquidated Damages for Power Consumption, Refer Volume-I.

10.00.00 PAINTING

All exposed metallic surfaces subject to corrosion shall be protected by
shop application of suitable coatings. Surfaces not easily accessible after
shop assembly shall be treated before hand and protected for life of the
equipment. Two coat each primer and finish paint at shop shall be
provided to reduce erection time and avoid blockage of free space. Patch-
up paint shall be applied, if spoiled due to handling, shall be done at Site.
In case of pipes and ducts, complete painting would be done at Site after
fabrication. For Bought out items this shall be brought in at Site duly
finished painted.

All paints shall be used in accordance with the manufacturer's
instructions. No thinners or other substance shall be added to the coating
material without the approval of the Engineer. The quality and vendor of
the paints shall require approval of the Owner/Purchaser.

All paints, when applied in a normal full coat, shall be free from runs,
sags, wrinkles, patchiness, brush marks or other defects.

For detail of painting and surface preparation, refer Specification - M2,
Surface preparation and painting of this specification.

11.00.00 INSPECTION & TESTING

For detail of inspection and testing, refer Annexure-IV of this specification.

12.00.00 QUALITY ASSURANCE

Quality assurance is indicated in the Annexure-V of this specification.

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13.00.00 ANCHOR BOLTS, SLEEVES, INSERTS, FOUNDATIONS PACK
PLATES, LIFTING LUGS, EYE BOLTS ETC.
This specification includes supply of all anchor bolts, foundation plates,
sleeves, nuts and inserts to be embedded in concrete for the equipment
to be supplied by the bidder under this specification.
Each equipment shall be provided with suitable lifting attachments, e.g.
lifting lugs, eye bolts, etc. to facilitate maintenance.

14.00.00 TOOLS AND TACKLE

14.01.00 Special tools and equipment for the maintenance, inspection and repair of
the individual main equipment and auxiliary equipment shall be supplied
by the Contractor in sufficient quantity to equip the shift personnel,
maintenance personnel and workshop craftsman. The bidder shall furnish
a complete and new set of all tools and tackle.

14.02.00 The special tools and equipment for maintenance and repair shall be
delivered by the Contractor in lockable steel boxes and they shall be
marked in an approved manner for identification purposes and a
corresponding tool chart shall be supplied with the steel boxes.

14.04.00 Supply of all tools and tackle are included under bidder's scope of work.

14.05.00 All necessary maintenance tools for Electrical System in addition to the
minimum requirement given in Annexure-VI.

15.00.00 SPARE PARTS

15.01.00 General

15.01.01 The Contractor shall indicate and include in his scope of supply all the
necessary start-up, commissioning spares, recommended (category-1)
and operational (category-2) spares in addition to mandatory spares as
specified in the specification. The Owner/Purchaser reserves the right to
buy any or all recommended and operational spares. The contractor shall
also state for each item of spares both recommended and operational the
normal expected service life.

15.01.02 The spare parts must be able to replace the original part completely and
have the same technical specifications in quality, material, inspection and
mechanical aspects All spare parts supplied shall be packed and stored
for a 5 years preservation based on the local climatic conditions. Small
spare parts shall be packed and sealed by transparent plastic bags and
drying agents will be used if necessary. Every spare parts shall have
operation instructions and design marks of the factory when it is supplied.

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15.01.03 When multiple spare parts are packed in one packing box or container,
the general indication to the spare parts outside the packing boxes or
containers shall include a detailed list. All packing boxes, containers, and
other such tanks shall be marked properly and numbered clearly. All
electrical equipment including switches, fuse connection easy melting and
other similar apparatus shall be protected and insulated.
15.01.04 Contractors shall supply all measurement testing data of any spare parts
supplied, if applicable.

15.01.05 The identification of all spare parts shall be in the English language.
Spare parts shall be supplied 6 months before start of acceptance test of
the respective unit. The Contractor guarantees the availability of all spare
parts within 15 years after Award of Contract. Wear and tear parts, to be
replaced by the Owner at his own cost, shall be marked separately.

15.01.06 Contractor shall identify spare parts having a delivery time of more than 3
months.

15.02.00 Mandatory Spare Parts

15.02.01 The list of mandatory spares which are considered essential by the
Owner/Purchaser is indicated in the Annexure-IX. The Bidder shall
include the itemized and total price for all these spares. Where the spares
are indicated as a percentage and result in a number plus fraction, the
same shall be converted to the near higher whole number.

15.02.02 The prices for mandatory spares must be given separately and shall be
used for bid evaluation purposes.

15.03.00 Recommended (Category-1) and Operational (Category-2) Spares

15.03.01 In addition to the mandatory spares, the Contractor shall also provide a
list of recommended spares (Category-1) and Operation spares
(Catergory-2). This list shall take into consideration the mandatory spares
specified elsewhere in the specification and should be a separate list.

15.03.02 Recommended spares (Category-1): These Spare parts shall be as per
the recommendations of the Contractor and required for the first 3 years
of plant operation, following the successful completion of Test on
Completion. These spare parts are included in the scope of the bidder
and shall be considered for bid evaluation. Spare parts replaced during
the warranty period will be paid for by the Contractor.

15.03.03 Category-2 (Operational Spares): Spare parts required for a major
overhaul after 4 or 5 years of operation.

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15.03.02 While the award for mandatory spares will be finalized at the time of the
award of mechanical equipment, award for Recommended spares will be
finalized within six (6) months thereafter.

15.04.00 Start-up and Commissioning Spares

15.04.01 Start-up commissioning spares are those spares which may be required
during the start-up and commissioning of the equipment/system. All
spares used until the plant is handed over to the Owner/Purchaser shall
come under this category.

15.04.02 The Contractor shall submit a complete list of all such start-up and
commissioning spares. Costs of the above spares which are consumed
before the handing-over of the plant shall be deemed to have been
included in the lump sum proposal price of the Package, and the
Contractor shall have no claim on this account to the Owner/Purchaser.

15.05.00 When a particular item of spares is indicated as percentage, it shall be
considered as percentage of total number of that item in the station,
unless specified otherwise. The fraction shall be rounded off to the next
higher whole number. Whenever the item of spares has been indicated as
set, the same shall mean the supply for single equipment / system. One
set of spares for particular equipment shall mean the total quantities of
that particular spares for the single equipment e.g., set of bearings for a
pump shall include the total number of bearings in a pump.

16.00.00 OPERATION & MAINTENANCE

16.01.00 The plant shall be designed and constructed so that operation and
maintenance component requirements are minimised.

The design and layout shall facilitate inspection, cleaning, maintenance
and repair. The importance of continuity of operation is second only to
that of safety.

16.02.00 Spare parts for equipment shall be interchangeable with the original
components and, so far as possible, be of common design and
manufacture.

16.03.00 All similar standard components/parts of similar standard equipment
provided shall be interchangeable with one another. Further identical
equipments shall be provided for similar duties so that the same are
interchangeable with one another in totality and component wise.

16.04.00 All heavy parts (500 Kg and above) must be provided with a convenient
arrangement for slinging and handling during erection and overhaul. Any

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item of plant normally stripped or lifted during periods of maintenance and
weighing one tonne or above, shall be clearly marked with its weight.

16.05.00 On completion of commissioning a complete set of tools for the
maintenance of the entire plant shall be provided by contractor. This shall
include all necessary spanners, special wrenches, extraction equipment
and any special tools reasonably required by the Engineer. Tools used
during commissioning will not be accepted except with the specific
approval of the Engineer.

17.00.00 INSTRUCTION MANUAL

17.01.00 The instruction manual shall furnish the following basic categories of
information in practically complete and comprehensive manner prepared
for use by operating and/or maintenance personnel:

a) Instructions for initial commissioning, short duration and long
duration shut down.

b) Instruction for operation, routine inspection and maintenance
including preventive maintenance.

c) Recommendation for inspection points, method of inspection and
period of inspection.

d) Information on detection, cause and rectification of troubles and
faults.

e) Instructions on normal repairs and overhaul.

f) Complete parts list and ordering information for all replaceable
parts. Wherever any oil seal, bearings, `O rings, gasket etc. are
used, the same shall be in the drawing/part list. The identification
details of equivalent and alternative makes for these spare parts
which are not manufacturer's own product shall also be listed.

g) Lubrication charts.

h) List of all special tools, tackle and spares and instructions for use of
such tools and tackle and spares.

17.02.00 The information shall be organized in a logical and orderly sequence. A
general description of equipment including significant technical
characteristics shall be included to familiarize operating and maintenance
personnel with the equipment.

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17.03.00 Necessary drawings, curves and other illustrations shall be included and
copies of appropriate approved drawings shall be bound in the manuals.
Tests, adjustment and calibration information, as appropriate, shall be
included. Safety and other warning notices and instruction, maintenance
and operating cautions shall be emphasized.

17.04.00 If a standard manual covering more than one equipment and/or model is
furnished, the information for the model and equipment supplied shall be
clearly marked and identified.

17.05.00 The instruction manuals will need approval of Consulting Engineer in the
same fashion as that for drawings.

18.00.00 DRAWING, DESIGN AND DOCUMENT APPROVAL PROCEDURE

18.01.00 Within seven (7) days of issue of Letter of Award (LOA) by the
Owner/Purchaser, the Contractor shall furnish a schedule of drawings
and design document to be submitted by him to the
Owner/Purchaser/Engineer indicating dates against each document.
However, this schedule to match with engineering schedule as mentioned
in Volume-I.

The documents shall be divided into two categories: (a) for approval and
(b) for information/further engineering and co-ordination by the
Owner/Purchaser.

In preparing this schedule, the Contractor shall allow two (2) weeks from
date of receipt for review and comments by the Owner/Purchaser for
each submission of a document.

This document submission schedule shall require approval by the
Owner/Purchaser.

18.02.00 All contract documents shall be marked, without fail, with the name of the
Owner/Purchaser, the Project, the specification title and number. For
further details on documentation refer Annexure-VII.

18.03.00 Documents/drawings, submitted during tender stage, shall be revalidated
or revised as required and submitted as certified contract document for
approval/information of the Owner/Purchaser.

18.04.00 Unless specified otherwise, the following categories of documents/
drawings would require approval of the Owner/Purchaser.

a. List of sub-vendors.

b. System scheme and instrumentation diagrams.

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c. Design basis justifying selection of equipment & process parameters
where not specified in the Contract.

d. Equipment data sheets and general arrangement drawings.

e. Materials of construction.

f. Layout drawings.

g. Operation logic diagrams.

h. Typical control circuit.

i. Civil construction drawings.

18.05.00 For further details on drawings, documents for approval and clearances,
refer Annexure-VIII.

18.06.00 Upon review, the Owner/Purchaser shall put his remarks and one of the
following action stamps on the drawing/document.

a. Approved.
b. Approved except as noted, forward final drawing.
c. Approved except as noted, resubmission required.
d. Disapproved.
e. For information/reference only.

For action stamps in category (c) & (d), documents must be resubmitted
for review by the Owner/Purchaser. For action stamp in category (b),
further review by Owner/Purchaser would not be necessary provided the
Contractor agrees & incorporates the minor components made on the
document.

18.07.00 Drawings/documents generated by Contractor will be submitted to
DCPL/IOTL/OWNER/FITCHNER INDIA (FI) in the soft copy through e-
mail for their review and approval which shall be followed by Hard copies
as indicated below.
Sl.
No.
Type / Status of
Drawings/Documents
No. of copies
to DCPL
No. of copies
to IOT (OWNER/FI)
1. For Approval Soft Copy Soft copy in .pdf format +
Four (4) hard-copies
2. For Information /
Reference
Soft Copy Soft copy in .pdf format +
Seven (7) hard-copies
3. Final / RFC Issue Soft Copy Seven (7) copies +one
(1) CD of .pdf soft copies
4. Progress Report Soft Copy Soft copy in .pdf format+
Seven (7) hard-copies

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18.08.00 IOT (DCPL) will receive comments from the OWNER with the action
stamped which will be sent back to Contractor. Upon receipt of approval,
Seven (7) hard copies and soft copy (with RFC stamp in pdf) will be sent
to IOT (DCPL) for RFC (Released for Construction) distribution which will
be forwarded to OWNER (FICHTNER INDIA). OWNER/FI will be
stamping the same and will be distributed by the IOT to all the concerned
as per protocol.

The distribution of Seven (7) RFC copies will be IOT-Site (2 Copies),
Fichtner India (1 Copy), Owner (3 Copies) and IOT-HO (1 Copies) shall
be carried out by IOTL

19.00.00 CO-OPERATION WITH OTHER CONTRACTORS AND
CONSULTING ENGINEERS

The Contractor shall agree to cooperate with the Owner/Purchaser's other
Contractors and Consulting Engineers and freely exchange with them
such technical information as is necessary to obtain the most efficient and
economical design and to avoid unnecessary duplication of efforts. The
Engineer shall be provided with copies of all correspondences addressed
by the Contractor to other Sub-contractors and Consulting Engineers in
respect of such exchange of technical information.

20.00.00 BID EVALUATION CRITERIA

For Bid Evaluation criteria, Refer Volume-I.

21.00.00 NOISE LEVEL

21.01.00 The Plant will be designed and constructed to operate with the least
practicable amount of noise.

i) Maximum noise level shall not exceed 85 dB (A) when measured
at 1.0m away from the noise emission source.
ii) Maximum noise level within the premises (10-15m from the
respective equipment) shall not exceed 70 dB (A) during day time
and night time, as per Environment (Protection) Rules 1986,
Schedule III, Ambient Air Quality Standards in respect of noise.
iii) Any statutory changes in stipulations regarding noise limitation
that may occur in future according to the State Pollution Control
Board, or Central Pollution Control Board or Ministry of
Environment and Forests regulations during tenure of the contract,
the contractor shall comply with the requirement.

An exception will be made for the plant at startup operation and other big
pressure reducing devices operating during emergency periods and for
the safety valves.

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22.00.00 BRAND NAME

The "Make" of equipment which would be required/would constitute the
proposed air cooled condenser, the bidder shall furnish at least 2 (two)
makes of such equipment and shall also furnish/support with
"performance certificates" to prove that such makes of the equipment are
operating satisfactorily in similar duties at least for 2 (two) projects for
more than 2 years. The performance certificates would be obtained from
Electricity Boards/Public Undertakings/Reputed Private enterprises. The
choice of sub-vendor shall be subject to approval of Owner/Purchaser.

23.00.00 SPECIFICATION DRAWINGS

The drawings, enclosed in Volume III of the specification, form a part of
the specification and are for guidance only. These drawings shall
supplement other requirements as specified within the specification and
they should be read in conjunction with the text of specification. The
bidder shall have to prepare working drawings, during detail engineering
following the basic parameters as specified. Work shall be carried out as
per the drawings approved by Owner/Purchaser.

24.00.00 PLANT AND EQUIPMENT IDENTIFICATION, LABELLING

24.01.00 Nameplates which are to be firmly fixed on all the equipment shall be
provided. For equipment of small size, these are to be fixed on the piping
or structure adjacent to the equipment. The contents of nameplate are to
include the designation and principal parameters of the equipment.

24.02.00 The nameplate within the field shall be made of stainless steel, with
designation permanently engraved on them. Inside installed equipments
(e.g Panels, Cabinets, Switchgear etc.) shall also be labeled by
appropriate name plate of stainless steel.

24.03.00 The form, size, base color and color of contents of the nameplates and
prompting plates will be agreed between the Contractor and the Owner.
They shall be readily seen by the operator and the designation of warning
tags shall be different from that of other tags.

24.04.00 Necessary caution plate shall also be provided.

24.05.00 The Contractor shall follow a common identification system showing the
name and number of each item and its respective drawing number etc. as
per whole plant equipment, facilities and systems to fully identify the
plant. The structure of the designations shall be developed in such a way
that the symbols used can be handled by electronic data processing
equipment. The identification system must be used by all subcontractors,
vendors, etc and shall be a proven system for power plant application.

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Each item of plant shall be separately designed with a reference number,
which shall be used consistently on the drawings, in the documents and
on the catalogues as well as on the equipment items themselves.

25.00.00 SAFETY AND SECURITY

25.01.00 The design shall incorporate every reasonable precaution and provision
for the safety of all personnel and for the safety and security of all
persons and property. The design shall comply with all appropriate
statutory regulations relating to safety. All structures and equipment shall
be designed and constructed to withstand every foreseeable static and
dynamic loading condition, including loading under earthquake conditions,
with an adequate margin of safety.

25.02.00 Ready and safe access shall be provided to all parts of the plant for
operation, inspection, cleaning and maintenance.

25.03.00 Escape routes and clear ways shall be provided to allow speedy
evacuation of the plant in the event of fire or explosion, and the plant
layout shall allow for ease of access to all parts of the Works by rescue
and fire fighting teams. The plant layout shall be designed to localize and
minimize the effects of any fire or explosion. The recommendations of
NFPA, OSHA, TAC etc. as necessary shall be followed in all respects.

25.04.00 The use of corrosive, explosive, toxic or otherwise hazardous materials
shall be kept to a minimum during construction and the design of the
plant shall minimize the requirement for such materials during operation
and maintenance. Where such materials must be used, all necessary
precautions shall be taken in the design, manufacture and layout of
equipment to minimize the resulting hazard, and all equipment necessary
for the protection and first-aid treatment of personnel in the event of
accidents shall be provided. Particular attention is drawn to the use of
materials containing asbestos in any form.

25.05.00 The Contractor shall notify the Owner/Purchaser of his intention to bring
to site any equipment or material which may create hazard. The
Owner/Purchaser shall have the right to prescribe the conditions under
which such equipment or material may be handled and the Contractor
shall adhere to such instructions. The Owner/Purchaser may prohibit the
use of any construction machinery, which according to him is unsafe. No
claim for compensation due to such prohibition will be entertained by the
Owner/Purchaser.

25.06.00 Storage of petroleum products & explosives for construction work shall be
as per rules and regulation laid down in Petroleum Act, Explosive Act and
Petroleum and Carbide of Calcium Manual. Approvals as necessary from

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Chief Inspector of Explosives or other statutory authorities shall be the
responsibility of the Contractor.

25.07.00 The Contractor shall be responsible for safe storage of his and his sub-
contractor's radioactive sources.

25.08.00 All combustible waste and rubbish shall be collected and removed from
the worksite at least once each day. Use of undercoated canvas paper,
corrugated paper, fabricated carton, plastic or other flammable materials
shall be restricted to the minimum and promptly removed. Temporary
disposal area as instructed by the engineer shall be used by the
contractor for the said purpose.

25.09.00 The Contractor shall provide adequate number of fire protection
equipment of the required types for his stores, office, temporary
structures, labour colony etc. Personnel trained for fire-fighting shall be
made available by the Contractor at site during the entire period of the
Contract.

25.10.00 All workmen of the Contractor working in construction site shall wear
safety helmets, safety boots and safety belts. The Contractor shall take
appropriate insurance cover against accidents for his workmen as well as
third party.

26.00.00 PACKAGING & MARKING

All the equipment shall be suitably protected, coated, covered or boxed
and crated to prevent damage or deterioration during transit, handling and
storage at site till the time of erection. While packing all the materials, the
limitations from the point of view of availability of railway wagon sizes in
India should be taken account of. The details of various wagons normally
available with Indian Railways for transportation of heavy equipment shall
be considered by the Bidder. The Contractor shall be responsible for all
loss or damage during transportation, handling and storage due to
improper packing.

As per the information available, the dimensions of OD consignment
for transportation of the equipment by rail are as below:

a) Width of the Package : 3.2 Meters
(from centre-line of rails
- 1.6 metres on both sides)

b) Height of the package : 4.47 Metres
from rail top

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The above indicates the dimensions which can be normally transported
on the wagons without infringement of the "moving gauge". This is
however not indicative of the consignment which can be carried out with
infringement of "moving gauge" duly authorised and approved by the
Indian Railways. There may be difference between the "moving gauge"
and the "fixed structure gauge" and consignments infringing the "moving
gauge" can be moved after investigation regarding possible infringement
with the fixed structures. As the critical fixed structures in each route are
different, consignments infringing moving dimensions have to be
individually investigated to select a route and also determine the
restrictions under which such movement is to be carried out. Such routes
selected or other mode of transport envisaged is to be clearly brought out
in the proposal wherever transport of over dimensional equipment is
involved.

The identification marking indicating the name and address of the
consignee shall be clearly marked in indelible ink on two opposite sides
and top of each of the packages. In addition the Contractor shall include
in the marking gross and net weight, outer dimension and cubic
measurement. Each package shall be accompanied by a packing note
quoting specifically the name of the Contractor, therefore number and
date of contract and names of the office placing the contract,
nomenclature of contents and Bill of Material.

27.00.00 PROTECTION

Equipment having antifriction or sleeve bearings shall be protected by
weather tight enclosures. Coated surfaces shall be protected against
impact, abrasion, discoloration and other damages. Surfaces which are
damaged shall be repainted.

Electrical equipment, controls and insulations shall be protected against
moisture and water damages. All external gasket surfaces and flange
faces, couplings, rotating equipment shafts, bearings and like items shall
be thoroughly cleaned and coated with rust preventive compound as
specified above and protected with suitable wood, metal or other
substantial type covering to ensure their full protection. All exposed
threaded parts shall be greased and protected with metallic or other
substantial type protectors.

All piping, tubing and conduit connections on equipment and other
equipment openings shall be closed with rough usage covers or plugs.
Female threaded openings shall be closed with rough usage covers or
plugs. Female threaded openings shall be closed with forged steel plugs.
The closures shall be taped to seal the interior of the equipment. Open
ends of piping, tubing and conduit shall be sealed and taped.

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Returnable containers and special shipping devices shall be returned by
the manufacturer's field representative at the Contractor's expense.

28.00.00 PROJECT MANAGEMENT SERVICES

28.01.00 Responsibility

The Bidder shall identify a separate and independent project
management team headed by a Project Manager for the execution of this
project. Responsibilities of this project Management team shall cover the
areas listed below:

a) Planning and Monitoring

b) Engineering Management

c) Contracts Management

d) Quality Assurance, Inspection & Expediting

e) Construction Management (Execution of civil works by separate
contractor to be appointed by Owner/Purchaser)

f) Fabrication and Erection management

g) Commissioning & Spares Management

Detailed responsibilities in the above areas are discussed below:

28.02.00 Organisation

28.02.01 Headquarters

The headquarters of the project management team shall be headed by a
senior level executive designated as the Project Manager who shall be
responsible to Owner/Purchaser for the execution of the project.

Separately, designated leaders shall be identified for each of the areas
mentioned under 28.01.00, who, in turn, will report to the Project Manager
for all matters relative to this contract.

28.02.02 Central Co-ordination Cell

The central coordination cell shall preferably be based in Mumbai and
shall have sufficient technical personnel to coordinate technical matters
and to quickly resolve day to day queries or references made by
Owner/Purchaser and his Consultants.

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28.02.03 Organisation Chart

The Bidder shall furnish a detailed organisation chart for the project
management team, clearly identifying the key personnel in each of the
areas mentioned at 28.01.00 above. The expected number of executives
at different levels shall also be indicated, separately for headquarters,
central coordination cell and site organisation.

28.03.00 Implementation Schedule

To achieve the completion schedule indicated elsewhere in this
specification, the Contractor shall furnish to the Owner/Purchaser, various
schedules as defined below:

28.03.01 Engineering Schedules

These schedules shall cover various design submissions indicating
different engineering activities to be performed. Such schedules shall be
furnished by the Bidder for each and every plant/systems/ equipment item
covered in the scope of this specification.

28.03.02 Manufacturing Schedule

The Contractor shall submit to the Engineer his manufacturing and
delivery schedules for all equipment within Twenty one (21) days from the
date of acceptance of the Letter of Award. Such schedules shall be in
line with the detailed network for all phases of the work of the Contractor.
Such schedules shall be reviewed, updated and submitted to the
Engineer, once in every two months thereafter, by the Contractor.
Schedules shall also include the materials and equipment purchased from
outside suppliers.

28.03.03 Erection Schedules

In order to achieve the overall completion schedule, the Contractor shall
provide the Owner/Purchaser all the information covering erection
sequence, testing and commissioning activities. These schedules may be
based on the recommended erection procedures and will be subject to
discussions/agreements with the Owner/Purchaser subsequent to the
award of contract.

28.03.04 The successful Bidder shall have to provide all the above schedules in a
tabular form in addition to that in the form of network and these shall
necessarily include information not limited to the earliest and latest dates
for various activities/submissions and also any related constraints.
However, the Bidder shall include in his proposal a Level-1 (L-1) network

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showing the major activities and various milestones to achieve the above
mentioned completion schedule.

28.04.00 Detailed Responsibilities

28.04.01 Planning & Monitoring

a) Planning

The Bidder shall prepare a Master Network Schedule in the form of
PERT network. The master network should be submitted along with
the bid which would be mutually discussed and finalized before the
Award of Contract.

b) Monitoring & Progress Reporting

The progress reports would be emanated every month, once from the
head office of the Contractor and another from the site office. The
progress report emanating from the head office should necessarily
include the following sections:

i. Report on key milestones.

ii. Management summary indicating critical areas with details of
actions initiated and effect of any on the project.

iii. Action needing attention of the Owner/Purchaser/Consultant.

iv. Detailed status of engineering submissions, quality plan
submissions and approval, procurement manufacture and
dispatch.

28.04.02 Engineering Management

Based on the ground master network for the project (L-1) the Contractor
will prepare an exhaustive list of engineering activities for the
equipment/systems covered in his scope and a detailed programme of
accomplishing the same within the time frame specified in the master
network. This schedule will form the Level-2 (L-2) network for engineering
activities.

The engineering management team should also co-ordinate all interface
engineering activity between the Contractor and the equipment sub-
vendors so as to ensure the correctness and completeness of related
engineering documentation before the same is submitted to the
Owner/Purchaser.

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28.04.03 Contracts Management

Based on the master network, the Contractor shall submit L-2
programmes of manufacture and despatch. In addition, the master
network shall also include periods considered for site activities viz.
erection, commissioning etc. These L-2 programmes would be submitted
in 1 months time from the date of award of contract and finalized within 15
days thereafter. The Contractor will also submit site mobilization plan.
This programme would be submitted at the time of finalization of award of
contract and agreed immediately thereafter so that immediate
development of the various activities at site could take place.

In case all the manufacture is being done by the Contractor then the L-2
programmes would be themselves amplified to cover details of the
manufacture, inspection, clearance by Owner/Purchaser and despatch.

The Contractor shall also submit the programme for procurement of
boughtout items, detailed delivery schedule and cash flow statement for
Owner/Purchaser's approval.

28.04.04 Quality Assurance, Inspection and Expediting

The Contractor shall submit the name of sub-vendor from whom the
equipment will be procured and the quality assurance plans thereof for
the manufacture shall be approved by the QA group of Owner/Purchaser
before the manufacture is commenced. The list of major suppliers would
be submitted along with the bid and this shall be mutually discussed and
agreed to at the time of award of contract. On the quality plans, the
customer hold points will also be identified based on which
Owner/Purchaser would give clearance for the manufacture to proceed
further.

Quality assurance/Inspection group of Owner/Purchaser or its
representative would issue a material dispatch clearance certificate
(MDCC) after the inspection clearance which will enable the Contractor to
dispatch the equipment and claim the payment. In the dispatch
programme, the Contractor shall indicate a schedule of estimated
programme, tonnages specifically identifying various oversize
dimensioned consignments (ODC). All dispatch details & item lists shall
be made available to both Owner/Purchaser & site immediately after
dispatching.

The Contractor shall also expedite all dispatches from their own
works/works of their sub-vendors, so as to match with the various
activities mentioned at 28.00.00 above.

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28.04.05 Construction Management

Based on the L-1 Master Network Programme, within one (1) month of
the award of the Contract, the Contractor shall submit a programme of
construction/erection/commissioning, either in continuation with the
manufacture and dispatch or separately for the implementation.

These programmes would be amplified showing when the civil drawings
shall be released by him and construction of civil works shall be
completed by Owner/Purchaser through other agency to facilitate start of
erection and subsequent activities and shall form the basis for site
execution and detailed monitoring. The Contractor shall also be involved
along with the Owner/Purchaser to tie up detailed resource mobilization
plan over the period of time of the contract matching with the performance
targets.

Erection and commissioning of the equipment shall also be done under
the supervision of experts from the respective equipment/ system
supplier.

29.00.00 SITE SERVICES

These services shall be rendered by the Bidder as part of the overall
project management service. The services shall broadly include but not
be limited to the following:

29.01.00 Arranging material dispatch from the shop by rail/road and/or sea as
applicable.

29.02.00 Monitoring movement of materials & follow-up as necessary with
Railways, transport, port clearance etc. from the time of dispatch F.O.R.
works by Contractor till receipt of the same at site.

29.03.00 Unloading of materials at Railway Station/Railway Siding inside project
area, transportation to site store, assessment of lost/damaged items in
transit and arranging insurance claims and replacement of lost/damaged
items. The Contractor shall submit to the Engineer a report detailing all
the receipts during the week.

29.04.00 Issuing materials from site store/open yard from time to time for erection
as per the construction programme. The Contractor shall be the custodian
of all the materials issued till the plant is officially taken over by the
Owner/Purchaser after complete erection and successful trial run &
commissioning.

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

29.06.00 Trial run and commissioning of individual equipment/sub-systems and the
plant as a whole to the satisfaction of the Owner/Purchaser, including
supply of temporary equipment & services for chemical cleaning, steam
blowing as well as performance guarantee tests.

Provision for preservation of individual equipment after trial run and
commissioning as necessary shall also be in the scope of the Bidder.

29.07.00 Supply and application of the final paints on all the equipment to be
erected under this specification.

29.08.00 For the purpose of erection and commissioning the Contractor's scope of
work shall include but not be limited to the following:

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

29.08.02 Deployment of all erection tools & tackle, construction machinery,
transportation vehicles and all other implements in adequate number and
size, appropriate for the erection work to be handled under the scope of
this specification.

29.08.03 Supply of all consumables upto taking over the plant by the Purchaser
including welding electrodes, cleaning agents, diesel oil, lubricant etc. as
well as materials required for temporary supports, scaffolding etc. as
necessary for such erection work except those listed under exclusion
elsewhere in this specification.

29.08.04 Construction of all civil/structural/architectural works, including
construction of foundation for all equipment supplied as required, grouting
of equipment on foundation after alignment, and all other incidental civil
activities as detailed elsewhere.

29.08.05 All structural steel fabrication and erection work as detailed elsewhere in
the specification.

29.08.06 Providing support services for the Contractor's erection staff e.g.
construction of site offices, temporary stores, residential accommodation
and transport to work site for erection personnel, insurance cover, watch
& ward for security and safety of the materials under the Contractor's
custody etc. as required.

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29.08.07 Maintaining proper documentation of all the site activities undertaken by
the Contractor as per the proforma mutually agreed with the
Owner/Purchaser; submitting monthly progress reports as also any such
document as and when desired by the Owner/Purchaser; taking approval
of all statutory authorities e.g. Factory Inspector, Inspector of Explosives
etc. for respective portions of work under the jurisdiction of such statutes
or laws.

29.08.08 The Contractor shall provide `Industrial Relations' unit and `Medical' unit
to take care of his erection staff and the Owner/Purchaser shall have no
obligation in the regard.

29.09.00 Site Organization

The Contractor shall maintain a site organization of adequate strength in
respect of manpower, construction machinery and other implements at all
times for smooth execution of the contract. This organization shall be
reinforced from time to time, as required, to make up for slippages from
the schedule without any commercial implication to the Owner/Purchaser.
The site organization shall be headed by a competent construction
manager having sufficient authority to take decisions at site.

On award of contract, the Contractor shall submit to the Owner/Purchaser
a site organization chart indicating the various levels of experts to be
deployed on the job. The Owner/Purchaser reserves the right to reject or
approve the list of personnel proposed by the Contractor. The persons,
whose bio-data have been approved by the Owner/Purchaser, will have
to be posted at site and deviations in this regard will not generally be
permitted.

The Contractor shall also submit to the Owner/Purchaser for approval a
list of construction equipment, erection tools, tackle etc. prior to
commencement of site activities. These tools & tackle shall not be
removed from site without written permission of the Owner/Purchaser.

29.10.00 General Guidelines for Field Activities

29.10.01 The Contractor shall execute the works in a professional manner so as
to achieve the target schedule without any sacrifice on quality and
maintaining highest standards of safety and cleanliness.

29.10.02 The Contractor shall co-operate with the Owner/Purchaser and other
Contractors (like civil contractor for foundation works) working in site and
arrange to perform his work in a manner so as to minimise interference
with other Contractors' works. The Owner/Purchaser's engineer shall be
notified promptly of any defect in other Contractor's works that could
affect the Contractor's work. If rescheduling of Contractor's work is

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requested by the Owner/Purchaser's engineer in the interest of overall
site activities, the same shall be complied with by the Contractor. In all
cases of controversy, the decision of the Owner/Purchaser shall be final
and binding on the Contractor without any commercial implication.

29.10.03 The Engineer shall hold meetings of all the Contractors working at Site at
a time and a place to be designated by the Engineer. The Contractor shall
attend such meetings and take notes of discussions during the meeting
and the decisions of the Engineer and shall strictly adhere to those
decisions in performing his Work. In addition to the above weekly
meeting, Engineer may call for other meetings either with individual
contractors or with selected number of contractors and in such a case the
Contractor, if called will also attend such meetings.

29.10.04 Time is the essence of the Contract and the Contractor shall be
responsible for performance of his Work in accordance with the specified
construction schedule. If at any time the Contractor is falling behind the
schedule, he shall take necessary action to make good of such delays by
increasing his work force or by working overtime or otherwise accelerate
the progress of the work to comply with the schedule and shall
communicate such action in writing to the Engineer, satisfying that his
action will compensate for the delay. The Contractor shall not be allowed
any extra compensation for such action.

29.10.05 The Engineer shall however not be responsible for provision of additional
labour and or materials or supply or any other services to the Contractor
except for the co-ordination work between various Contractors as set out
earlier.

29.10.06 The works under execution shall be open to inspection & supervision by
the Owner/Purchaser's engineer at all times. The Contractor shall give
reasonable notice to the Owner/Purchaser before covering up or
otherwise placing beyond the reach of inspection any work in order that
same may be verified, if so desired by the Owner/Purchaser.

29.10.07 Every effort shall be made to maintain the highest quality of workmanship
by stringent supervision and inspection at every stage of execution.
Manufacturer's instruction manual and guidelines on sequence of erection
and precautions shall be strictly followed. Should any error or ambiguity
be discovered in such documents, the same shall be brought to the notice
of the Owner/Purchaser's engineer. Manufacturer's interpretation in such
cases shall be binding on the Contractor.

29.10.08 The Contractor shall comply with all the rules and regulations of the
local authorities, all statutory laws including Minimum Wages, Workmen
Compensation etc. All registration and statutory inspection fees, if any, in
respect of the work executed by the Contractor shall be to his account.

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29.10.09 All the works such as cleaning, checking, leveling, blue matching,
aligning, assembling, temporary erection for alignment, opening,
dismantling of certain equipments for checking and cleaning, surface
preparation, edge preparation, fabrication of tubes and pipes as per
general engineering practice at site, cutting grinding, straightening,
chamfering, filling, chipping, drilling, reaming, scrapping, shaping, fitting-
up bolting/welding, etc., as may be applicable in such erection and are
necessary to complete the work satisfactorily, are to be treated as
incidental and the same shall be carried out by the Contractor as part of
the work.

29.10.10 In case of any class of work for which there is no such specification as
laid down in the contract such as, blue matching, welding of stainless
steel parts, etc., the work shall be carried out in accordance with the
instructions and requirements of the Engineer.

29.10.11 It may sometimes be necessary to remove some of the erected structural
members to facilitate erection of bigger/pre-assembled equipment. In
such cases, the removal and re-erection of such members, which are
essential, and if so agreed by the Engineer, will have to be done by the
Contractor.

29.10.12 Preservation of all materials/equipment under custody of the Contractor
during storage, pre-assembly & erection, commissioning etc., shall be the
responsibility of the Contractor. All necessary preservatives and
consumables like paints, etc., shall be arranged by the Contractor.
Necessary touch up painting, periodic application of preservatives/paints
on pressure parts/other equipment even after erection until completion of
work shall be carried out by the Contractor.

29.10.13 It is responsibility of the Contractor to do the alignment etc. if necessary,
repeatedly to satisfy Engineer, with all the necessary tools & tackles,
manpower, etc. The alignment will be complete only when jointly certified
so, by the Contractor's Engineer & Owner/Purchaser. Also the Contractor
should ensure that the alignment is not disturbed afterwards.

29.10.14 Additional platforms for approaching different equipment as per site
requirement, which may not be indicated in drawings, shall be fabricated
and erected by the Contractor. The materials required for these works
shall be supplied by the Contractor and he will have to fabricate them to
suit the requirement.

29.10.15 Equipment and material which are wrongly installed shall be removed and
reinstalled to comply with the design requirement at the Contractor's
expense, to the satisfaction of the Owner/Purchaser/ Consultant.

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29.10.16 Before erection of any equipment on a foundation, the Contractor shall
check and undertake if necessary rectification of foundation bolts,
reaming of holes, drilling of dowels, matching of bolts and nuts, making
new dowel pin, etc.

29.10.17 Assistance for calibrating/testing the power cylinders, valves, gauges,
instruments, etc., and setting of actuators coming under various groups
shall be provided by Contractor.

29.10.18 It shall be the responsibility of the Contractor to provide ladders on
columns for initial works till such time stairways are completed. For this,
the ladder should not be welded on the column and should be
prefabricated clamping type. No temporary welding on any structural
member is permitted except under special circumstances with the
approval of Owner/Purchaser.

29.10.19 Structural materials required for the supporting/operating platforms
required for the valves at various levels for the same operation of valves
will be arranged by the Contractor.

30.00.00 TRAINING OF OWNER'S PERSONNEL

30.01.00 The scope of services for training of Owner's/Purchasers personnel shall
necessarily include training module covering at least 3 man months. This
shall cover all disciplines viz. Mechanical, Electrical, C&I, Civil, etc. and
shall include all the related areas like Construction / Erection,
Commissioning, Quality Assurance & Testing, Operation & Maintenance
aspects at Manufacturer's/ Sub-vendors office/ works.

The Bidder shall ensure that training of Owner/Purchasers executives
should be comprehensive & should ensure adequate/appropriate access
to all information in the relevant field so as to enable these executives
either undertake individual responsibility i.e. O&M of the Air cooled
condenser and/or serve as the key resource person to train other officers
in the Owner/Purchasers organization. For this purpose the Bidder shall
ensure that necessary documents/training manuals, drawings etc should
be provided as a training kit for Owner/Purchasers personnel.

Sr.
No
Area Discipline Duration
Man Months
1 Air cooled condenser- design
familiarization, erection and
commissioning
Mechanical
Electrical
Civil
1
2 Plant operating features &
performance improvement.

Mechanical
Electrical
1

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3 Maintenance of Air cooled
condenser Equipments.PLC
hardware, software,
troubleshooting, modifications,
logic building etc.
Mechanical
Electrical
C&I
1

30.02.00 Bidder shall furnish in his offer, details of training module(s) covering
above requirements, which shall be subject to Owner/Purchaser's
approval. Consolidated training period included above (i.e. 3 man
months) is indicative only.

30.03.00 Exact details, extent of training and the training schedule shall be
finalised based on the Bidder's proposal within two (2) months from
placement of award.

30.04.00 In all the above cases, wherever the training of Owner/Purchaser's
personnel is arranged at the works of the manufacturer's it shall be noted
that the lodging and boarding of the Owner/Purchaser's personnel shall
be at the cost of Owner/Purchaser.

30.05.00 For further details on Training requirement, refer Annexure-X.

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ANNEXURE - I
SITE AND GENERAL PLANT REQUIREMENT

1.00.00 SITE CONDITIONS

1.01.00 Location of site

The proposed Project will be located near village Bandakhar at Tehsil:
Pali, Dist: Korba, Chhattisgarh State. The site is accessible by road and
rail. The site is 8 km from the State highway connecting Bilaspur &
Katghora. The nearest Railway station is Korba railway station which is
about 30 km from the site. The nearest town is Korba which is about 30
km from the site. The site is 320 meters Above Mean Sea Level.

1.02.00 Geological conditions, Soil data: Refer civil specification.

1.03.00 Metrological conditions: Refer General specification M0, Cl. 2.00.00.

1.04.00 Coal supply

Coal (F-Grade) will be the main fuel for this power plant. Coal is planned
to be sourced from Dipka Gevra coal fields located in Korba with in 15
kms from the project site.

1.05.00 Ash disposal

Fly ash will be collected in dry form in Silos. Ash from the silos will be
loaded in to closed bulk carriers for dispatch to users. In case if not
utilized then, the ash will be disposed in the form of high concentrated
slurry (HCSD) to ash dyke through pipe line.

1.06.00 Fuel oil supply

The boiler will be designed for cold start-up using Light Diesel oil (LDO)
for light up and warm-up, stabilization & as support fuel at low load
operation of the plant when operating on coal. Based on the above
requirements, adequate numbers of LDO tanks of suitable capacity are
envisaged. The fuel oil will be received from the depots at Raipur
(270 kms from proposed site) by road tankers.

1.07.00 Water supply

The source of make-up water will be from the Lilagarh River
(anicut) and Khallari Reservoir shall be located at a distance of 1 kms
from the proposed site. The make-up water requirement will be met
from this river by the pipe line

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between dam on the river and reservoir in the plant site. However,
during exigencies make up from bore well is also envisaged.

1.08.00 Effluent disposal

All plant effluents such as from the pre-treatment plant, DM plant, CT blow
down etc., will be collected in a common monitoring basin (CMB) after
neutralization and treatment. The treated water from the CMB will be
utilized for green belt development, coal yard sprinkling or ash slurry
preparation prior to ash disposal.

1.09.00 Power evacuation

Power evacuation is planned through 400 KV lines to PGCIL substation
and also through 400kV lines to the grid of Chhattisgarh State Electricity
Board.

2.00.00 GENERAL PLANT REQUIREMENTS

2.01.00 General

The design of the 1 x 300 MW coal fired power station will be based on
unitized principle i.e. there will be one boiler and one turbine and a set of
auxiliaries for the unit.

The auxiliary systems and plant facilities shall be designed for serving the
whole power station with adequate redundancy.

Secondary system components shall be designed generally for
100% redundancy in order to achieve high reliability and availability of the
power unit.

The life span to be considered in the design, equipment and component
selection shall be at least 30 years.

For the design of the power plant, it is necessary not only to
consider the requirements of operation, but also, by suitably planning
the layout, the convenience of inspection, cleaning, maintenance and
repair.

In order to achieve reliability, high efficiency and safe operation of
the power plant, it is also necessary to consider various precautions
to safeguard the operating and maintenance personnel.

The design of the power plant shall ensure that the plant can, in
the state of normal operation, adapt itself to load, pressure and
temperature variations within the allowable range of design.

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The various parts and systems of the power plant shall be designed to
achieve the object of providing an integrated and coordinated power plant.

In the design of the power plant and selection of equipment, the special
features of this project and likely occurrences have to be taken into
consideration to ensure that the power plant can, under these
circumstances, operate continuously, safely and with high efficiency. The
selection of building materials shall be suited to local conditions. It is
required that equipment shall be of a rustproof, moisture proof and
waterproof type.

Equipment installed outdoors shall be able to operate in all-weather
conditions and to withstand the work site environment. For equipment in
operation or in standby that may be influenced by direct sunshine,
shelter or cover shall be provided.

All equipment materials, spare parts, special tools and tackles
supplied under this contract will be new and unused.

The power generated will be supplied to state electricity board/ Power
Trader/ PGCIL. It should be noted that the power demand of the
SEB/PGCIL grid would be widely fluctuating daily and also it is seasonal.
The frequency can vary between 47.5 to 51.5Hz and the voltage also
would be fluctuating. The control system shall be designed to respond
fast enough to match with varying operating parameters.

2.02.00 Plant layout

The layout along with all the auxiliary systems for the 1 x 300 MW
Thermal Power Plant is shown in Plot Plan.

2.02.01 Layout requirements

Apart from the above layout considerations, the additional features
to be considered by the Contractor for the development of the plant
layout & arrangement of equipment and facilities are described below.

In compliance with the needs of normal operation of the power
plant, the Contractor shall consider the vehicles passing the buildings
& entering and leaving the plant by proper planning of the layout of paths
and building in the plant area.

In arranging the paths, the conditions of communication during the
period of operation and overhaul have to be considered. For the
design of paths, the possible types of vehicles that might run on the

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paths have to be taken into account, so that the radius of curvature,
section and noise levels of these paths can thereby be determined.

In the power plant layout design, consideration shall be given to
maintenance and overhaul, i.e. also to free access of equipment. In the
equipment hoisting floor and platform, sufficient means shall be provided
to meet the requirement of shifting, maintaining and overhaul of
equipment.

According to the request of overhaul outline, it is necessary to
consider the requirement of lifting up the upper cover and dismounting
main components of steam turbine generator units during general
overhaul. For this reason the operating floor around the steam turbine
shall have a very clean and open space provided. The amount of space
shall be specified by the turbine island supplier.

The arrangement of main area in the turbine room shall also require that
some components have to be transported to stores or repair shop during
the period of overhaul.

The Contractor shall provide all platforms, foot paths and stairs
conforming to the requirements of safety and of providing exclusive
entrance and exit to equipment operation and maintenance.

For design of all platforms and footpaths, the minimum clearance height is
2.5 m and all the lifting platforms and walkways shall be provided with
stop bar.

For oil and any chemical substance which is likely to leak, dykes
and containment areas shall be provided.

Dangerous areas for equipment shall be designed in conformity to
the appropriate safety regulations by striving to reduce the hazard to the
minimum.

The complete arrangement of equipment buildings & other service
and safety facilities shall also meet the statutory requirements of
various Indian Government Agencies.

All structures must be properly located vis a vis equipment to avoid
any hindrance to maintenance of equipment.

No two facilities must be installed so close as to affect the
approach, normal operation and emergency operation (like removal of
material or reject by pocking etc)

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ANNEXURE - II
SCOPE OF WORK AND TERMINAL POINTS

SL.
NO.
ITEMS
SCOPE
Yes indicates Items under ACC Contractors Scope
No indicates Items under Owners Scope
A. Mechanical

1.
Air cooled condenser assembly including heat exchanger
bundles, fans, fan drives, gearboxes, flexible coupling etc.
Yes
2.
Axial flow fans with proven design with vibration protection
devices, manual blade adjustment during still stands.
Yes
3.
Fan support bridges, Fan guards and protective grid.
Yes
4.
Automatic tube bundle cleaning system one per face.
Yes
5
Steam duct from the turbine exhaust box to the Air cooled
condenser (ACC) including transition duct, steam distribution
ducts along with associated expansion joints, rupture disc
assembly (100% capacity), Steam traps, Vacuum breaker,
supports & supporting structure.
Yes
6.
Pressure equalizing piping between steam duct and condensate
tank.
Yes
7.
Operating steel structure floor of ACC, A frame structure
supporting tube bundles, windwall structure, intermediate
platform, stair cases, walkways with handrail, monorail beams
for lifting arrangement of motors, gearboxes etc.
Yes
8.
Condensate piping from ACC upto TEB with associated valves,
NRVs, bellows, strainer etc. as per approved PID. Yes
9.
Platforms, stairs and ladders required for operation or
maintenance. Access stairways, grating, doors, handrails,
ladders.
Yes
10.
Condensate drain pot in steam piping for drain collection,
support structure & operating steel platform.
Yes
11.
Piping and pipe fittings including all valves
Yes
12.
Supports & support structure for the piping. Associated drain &
vent Piping & valves, Dump tube.
Yes
13.
Side walkway, End walkway, central walkway, mechanical
maintenance walkway,
Yes
14.
Tube bundle supports, suction partition walls, bottom panel. Fan
support Bridges, Plenum chamber, Fan deck, fan rings, fan
Guards. Surrounding wind wall
Yes
15.
Inserts, embedments, Anchor bolts, nuts sleeves and structural
steel components as required for equipment foundation and
piping supports shall have to be supplied.
Yes
16. Inspection Manholes. Yes

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SL.
NO.
ITEMS
SCOPE
17.
2 x 100% or 3 x 100% vacuum pumps with associated piping
and valves
Yes
18.
Lifting arrangement for Vacuum pumps shall be provided based
on their location.
Yes
19.
Electric operated hoist for equipment handling at fan and
accessories
Yes
20. Painting of component and piping, as required. Yes
21. Insulation of equipment and piping, as required. Yes
22. Compressed air (Service air/instrument air) distribution system. Yes
23.
Potable and Service water distribution within battery Limit.
ACW at 33 Deg.C and DM water within battery limit
Yes
24.

Associated electricals comprising MCC, cables / cable trays from
MCC to ACC electrical components, local push button stations,
Earthing above ground, illumination and lightning protection.
Yes

25.

Bidder to optimize and indicate % of VFD drive required for
efficient operation of ACC throughout year meeting the design
criteria as per specification. VFD will be free issue from
Purchaser.
Yes
26. Associated control and instrumentation Yes
27.
For the operation and supervision of the system, the detection of
operating faults, equipment protection and safety measures all
necessary instruments and control equipment shall be provided
Yes
28.
Compressed air (service air/instrument air) station with air
compressors, drying plant, distribution system etc.
No
29.
Ventilation and air conditioning system as applicable. No
30.
Pipe supports and associated civil/structural works, including pipe
racks, trestles, trenches etc. as required including all temporary
frames for transport and erection.
Yes
31.
All lifting and handling equipment to facilitate the handling and
transportation of all plant and equipment (heavier than 500 kg).
For Handling equipments >10 T - Double Girder EOT crane
For Handling equipments <10 T - Single Girder overhead / under
slung EOT crane.
For Handling equipment >2 T <10 T - Electrical hoist with electric
travelling trolley.
For Handling equipment >0.5 T <2 T - Manual Hoist.
For hoisting any equipment by more that 10m - Electrical hoist.
If the equipment layout calls for all direction movement of handling
equipment, crane shall be provided.
Permanent Crane / hoist for tube bundle is not envisaged.
Yes
32.
Any other supply items not specifically mentioned but deemed
necessary for safe, reliable & satisfactory operation of the plant.
Yes

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SL.
NO.
ITEMS
SCOPE
B. ELECTRICAL SYSTEM (SCOPE OF ENGINEERING & SUPPLY)

1. HT Switchgear No
2. 415 V PCC Yes
3. 6.6/0.433 V LT Transformers No
4. 415 V Bus duct Yes
5. Electric Motors Yes
6. Electric Motor Actuators Yes
7.
415 V Motor Control Centre (MCC), 415V ACDB & 220V SUB-
DCDB, Lighting DB & SUB-UPS DB
Yes
8. All LT Power and Control Cables Yes
9. HT Power Cables & HT termination kits No
10. Local Starter Panels and Other Panels No
11. Push Button Stations Yes
12. Battery & Battery Charger No
13. Uninterruptible Power Supply (UPS) system No
14. Illumination System of ACC area Yes
15.
Erection, testing and commissioning of all Electrical Equipments
including supply as per E0, including Cable Tray & Cabling,
Illumination System, Grounding System & Lightning Protection
System of the Air cooled condenser.
Yes
C. CONTROL AND INSTRUMENTATION SYSTEM
2.
All primary sensors like Flow elements, Temperature sensors
etc.
Yes
3.
All field instruments - process switches, transmitters, local
gauges etc.
Yes
4.
All final control elements like Control valves, dampers / gates
etc. with actuators.
Yes
5.
All field cables, field to J B, J B to Remote I/O panel terminal block
including supply, laying, cable trays and termination at Remote
I/O panel terminal block.
Yes
6.
All junction boxes, cubicles, enclosures, local panels, pneumatic
and process hook up hardware, cables and other erection
materials and accessories.
Yes
10. DCS, remote I/O module and remote I/O cabinet. No

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SL.
NO.
ITEMS
SCOPE
D. CIVIL, STRUCTURAL AND ARCHITECTURAL

1. Engineering, Design, Construction purpose drawings / documents
related to Civil, Structural and Architectural works for above
ground structures and works.
Bidders to note that underground foundation will be designed and
constructed by Purchaser. Over ground RCC construction will only
be carried out by the Bidder as per design of Bidder. Fan deck
shall be in structural steel and columns with tie beams shall be of
RCC.
Yes
2 a). Supply of Structural steel (Plates, beams, channels, Angles
required)
Yes
2 b). Supply of Technological Steel / Structural steel Yes
3. Fabrication and erection of Structural steel / Technological steel Yes
4 a). Execution of all Civil works including design of underground civil
work and foundation
No
4 b) Final grouting of Equipment Yes
5. Demolishing / removal of debris for any existing structure /
foundations
No
6. Breaking/clearing of any existing concrete/paving etc. No
7. Landscaping including green belts No
8. Topographical survey.
No
9. Geo-Technical Investigation (See note below) No
NOTE:- Geo-technical investigation has already been carried out by the
Owner/Purchaser. However, for any additional information, further such detailed
investigation shall be under ACC package contractors scope.
E. SERVICES & GENERAL ITEMS
1. Obtaining statutory/Regulatory clearances/approvals from
concerned government agencies related to ACC system.
Yes
2. Consents, licenses and permissions other than those to be
obtained by the Owner/Purchaser related to ACC system.
Yes
3.

Packing & transportation (ocean and inland), custom/port
clearance, reconciliation with custom authorities, receiving and
unloading at site.
Yes
4. Co-ordination & Project Management.
Yes

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SL.
NO.
ITEMS
SCOPE
5. Shop tests & Quality Assurance.
Yes
6. Site temporary services (telecom, water, power, discharges etc.)
during construction period.
Yes
7. Arranging construction stores, residential accommodation of
contractor's staff and labour etc
Yes
8. Fabrication, Erection of all Structural, Mechanical, Electrical and
C&I items and equipments, Trial run, Commissioning and Testing
of Air cooled condenser
Yes
9. Supply of lubricants/consumables etc for the complet
commissioning, trial operation and a further period of 12 months
at design load.
Yes
10. Supply of Mandatory, start-up and commissioning Spares. Yes
11.

Spare parts/services, as required, for the Air cooled condenser
Handling System for three (3) years (covering defects liability
period).
Yes
12. Taping points complete with isolation and all necessary
instrumentation for performance testing
Yes
13. Complete detailed labeling of all installation as required.
Documentation and interface engineering
Yes
14. All necessary venting, draining and emptying equipments,
completer
Yes
15. All necessary safety measures Yes
16. Tools and tackle including all special tools and tackle, calibration
and testing instruments etc. as required, for the Air cooled
condenser. Equipment necessary during inspection for storing
dismantled parts for carrying out specific inspection work.
Yes
17. After Sales Services during & after warranty period.
Yes
18. Furnishing all documents, drawings, optimization, study reports,
design calculations, data sheets, quality assurance plans, testing
procedures, operating and maintenance instruction manuals,
commissioning documentation etc including "As-built" drawings.
Yes
19. Training of the plant Owner's personnel on plant operation and
maintenance.
Yes
NOTE :
The above list of work is not exhaustive. Any additional works,
whether or not specifically described in this bid document,
incidental to complete the power plant in all respects shall be
deemed to be in the scope of work of the Air cooled condenser
Please also refer respective sections of mechanical, electrical,
civil and C & I.

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F. TERMINAL POINTS
The terminal points of the Air cooled condenser to be supplied
shall be as follows. For all terminal points, scope of this contract
shall include making the joint including supply of mating flanges,
gaskets, bolts, nuts etc. Terminal Points mean Engineering,
Procurement and Erection in entirety, unless otherwise stated
herein.

Mechanical
1. Main Steam
Piping/Ducting
From the Turbine exhaust flange box
2. Condensate Piping Connection with the turbine exhaust box in
STG building

3. Condensate drain
Piping
Connection with the turbine exhaust box in
STG building

4. Vacuum piping From Turbine exhaust box in STG building
5. Service Water At one point near STG building
6. Drinking Water At one point near STG building
7. Compressed Air At one point near STG building

8. ACW and DM
Water
At one point near STG building

9. HVAC By Owner
10. Fire fighting By Owner
11. Counter flanges All flange interface terminals should be
provided with counter flanges, nuts, bolts,
gaskets etc. by the Bidder.

12. Drainage system

At ACC area drain sump near STG building
/ DG set room. Drains by ACC Bidder.

Electrical

12 Electrical From 6.6kV/ 0.433kV transformer LV cable
box onward for ACC system electrification.

13. Grounding From Pigtail of 40mm Dia. M.S. ground
conductor grid around ACC area

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14. Distribution boards
(Lighting, DC &
UPS)
From 220V SUB-DCDB, SUB-UPS DB,
MLDB & local ELDB (if required) including
routing & providing necessary tray/ trench/
G.I. pipe

Control & Instrumentation
15. Remote I/O cabinet terminal block of DCS.

Civil
16. Sub-structure Foot plates and bolts
Fan deck shall be in structural steel and
columns with tie beams shall be of RCC.
Dowels will be left as per beam size of
bidder for their design of above ground
structures.

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ANNEXURE - III
SITE WORK AND ERECTION REQUIREMENTS

1.00.00 General Requirements

1.01.00 Site Description

The proposed Project will be located near village Bandakhar at Tehsil Pali
of District Korba, Chhattisgarh State.

Run of mine of F grade Coal will be the main fuel for this power plant.
Coal is planned to be sourced from the linkaged coal from SECL owned
Dipka Gevra coal mines in Korba District or Chhal Coal mines in
Raigarh district of Chhattisgarh State. Coal will be transported from the
mines to nearest railway siding of M/s Spectrum Coal and Power Limited
at Ratija and further to the proposed plant site by through pipe conveyor
and or by road.

The source of make-up water will be from proposed anicut over Lilagarh
river and enhancement in storage capacity of existing Khallari Reservoir
at near to the proposed site. The make-up water requirement will be met
by making Anicut in the river and pumping water from this Anicut to the
power plant site, which is around one (1) km away from the proposed
power plant site.

Power shall be evacuated through 400 kV transmission line systems.

Owner (MCCPL) has envisaged constructing the new plant through the
Engineering, Procurement and Construction (EPC) route on a Turnkey
basis by IOTL who would be responsible for all the activities from detailed
design, project management, procurement, construction, manufacturing,
and testing through to final commissioning and putting into commercial
operation.

1.02.00 Present Status of Site

All basic grading works of main plant area of power plant site has been
completed. Complete power plant on the EPC basis has been awarded to
IOTL (Purchaser). BTG has been ordered on the CWPC, China. IOTL has
opened up the site work and boiler foundation will be started by 4
th
Oct.
2011. Multi level concept may be adopted for siting various buildings to
optimize time and money.

1.03.00 Construction Power Source

The Owner will arrange the construction power at 415 V, 50 Hz, 3 phase
level through the State Electricity Board at one point near the plant

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boundary. Power supply and electrical power distribution to the
construction site are within the Purchaser's responsibility. Purchaser will
provide power for construction at one point free of cost.

Purchaser will not be responsible for any interruption in power supply
from grid. In such case, Bidder shall make necessary arrangement to
ensure un-interruption of work and meeting time schedule.

1.04.00 Construction Water Source

The Owner will arrange construction water at one or two point near the
plant boundary on chargeable basis. Purchaser will provide power for
construction at one point free of cost.

1.05.00 Construction Communications

Any communication system which the Bidder might need is within the
scope of the Bidder's supply.

1.06.00 Access to Construction Site

The site is accessible by road. The site is around 8 km from the state
highway connecting Bilaspur & Ambikapur. National highway connecting
Bilaspur and Raigarh (NH 200) is at distance of twelve (12) km from the
proposed site. The site can be approached from Korba through state
highway to village Bandhakhar. The nearest Railway station is Korba
which is about 30 km from the site. The nearest towns are Korba and
Bilaspur which is 30 and 80 km from the site respectively.

1.07.00 Site Safety & Security

It would be Bidder's duty to organize and constitute a safety system for
providing protection to installation work, contracting material storage,
warehouse, field office, accommodation etc within the Bidder's scope of
supply and services.

Guards shall be provided by Bidder.

The Bidder is responsible for the storage of material and the upkeep of
equipment at the working site. There shall be fencing for temporary
storage and material storing yard with special duty personnel on day and
night.

Temporary safe railings shall have safe lighting equipment to send out
indications such as material warehouse, field or site office and
accommodation.

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The duty of the Bidder includes the site management and safety
engineers.

1.08.00 Field Safety and Health Organization

According to both, local safety and health regulations, field safety
organization shall provide necessary tools, documentation and other
measures especially with respect to handling of dangerous goods and fire
risks and medical service.

Bidder shall be in charge of examining field safety under the control of a
field safety engineers.

1.09.00 Cleaning on Site

Bidder shall be responsible to keep the construction site clean and
remove any waste material or hazardous waste to an appropriated waste
disposal site approved by authorities in a safe and orderly way.

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ANNEXURE - IV
INSPECTION AND TESTING

1.00.00 General

This section contains general requirements for inspection & testing of
material, parts, equipment and workmanship of the plant during
manufacture, assembling and erection, upon completion and
commissioning to demonstrate compliance with specification, codes and
standards to ensure overall reliability of plant operation and performance.

The Owner/Purchaser and/or authorized representatives shall, at any
time, be allowed free and ready access to the Bidder's premises and
those of his suppliers as well as to the site installation and the Bidder has
to make the plant items available for the purpose of inspecting the
specified equipment components and obtaining information as to the
progress of the work. Failure on the part of the Owner, at this or any other
time, to discover or reject materials or work which do not meet specified
requirements shall not be deemed an acceptance thereof nor a waiver of
defects therein.

The approval of the Owner shall not prejudice the right to reject
equipment if it does not give complete satisfaction in service.

2.00.00 Scope

The Bidder has the primary responsibility for ensuring the quality of items
of equipment supplied under the contract and remains accountable when
manufacture or erection is subcontracted. It is therefore a requirement of
the specification that work is only subcontracted to companies with
effective quality control organizations and that the Bidder monitors the
performance of these by the attendance at tests of experienced
inspectors employed by the Bidder. The Bidder shall, at the appropriate
time, prove that his material and/or equipment comply with all the
requirements of this Section, such proof being the successful completion
of tests and inspections. Certified routine test and type test certificates
shall be submitted for each item of equipment, where applicable.

3.00.00 Inspection

The Owner/Purchaser reserves the right to appoint his own
representative for inspection services and the Bidder/sub-
vendor/suppliers/manufacturers shall allow the owner and /or owner
representatives (inspection agency) to carry out inspection at the
manufacturers premises /required premises.

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The Bidder shall provide all necessary means for execution of inspection
and testing, according to the requirements.

All materials, components and equipment supplied under the contract
shall be subject to inspection by the Owner, his representative, Inspectors
of Boilers (India) or his authorized Agency or any other Inspector of the
Government, should they so require during manufacture, erection and
after completion. Inspection by an approved independent agency shall
also apply when required by the Owner and/or specified. The necessary
inspection charges including travel charges of the authorized agency of
Inspection shall be borne by the Purchaser. The inspection and tests shall
include but shall not be limited to the requirements of this section of the
specification. Further requirements to be applied are specified in the
detailed specification.

The type and extent of inspection of items shall be in accordance with the
relevant International/Indian Standards/Indian Boiler Regulations and
other standards approved by the Owner, supplemented or amended by
the requirements of this section of the specification or as specified
elsewhere in the Specification.

4.00.00 Inspection Program and Test Notifications

Before manufacture commences and no later than 90 days after award of
contract, the Bidder shall submit an outline of his proposed inspection
program, which shall include all major stages during manufacturing. The
inspection and test program shall include for the various items the
designation No., name of equipment, part of equipment, the kind of test,
test standard, company which carries out the test, place, date and
witnesses by the Bidder or Owner's Representative.

The Owner will return a copy of the Bidder's proposed inspection program
with marking those inspection stages for which notification is required.
Notification shall be by telex or Fax in a format to be agreed and shall be
sent at least 30 days prior to the intended test in accordance with
Conditions of Contract. If the Owner intends to be represented at the
test he will provide at least 24 hours notice and if his representative does
not attend on the notified date the test may proceed unless an alternative
date has been requested by the Owner.

Before erection commences and not later than three months before start
of erection, the Bidder shall submit the proposed erection test program
and the commissioning test program with all proposed erection and
commissioning tests and checks. Together with the test programs the
proposed test procedures have to be submitted.

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The test programs should consider:
That the sequence and duration of the proposed activities are logical,
realistic and in accordance with safety and permit regulations in force.
That the commissioning of any item of plant would not interrupt the
normal operation of any previously commissioned item.
That allowance for training the Owner's operation personnel during
this period has been made.
The Bidder has to mark all stages which are subject to the Owner's
acceptance and has to notify at least 30 days in advance when such
inspection for acceptance becomes due.

5.00.00 Test Certificate Documentation

The results of all tests shall be certified by the manufacturer, Bidder or
independent agency as appropriate.

Document files containing material certificates, welding procedures, test
report etc shall be compiled for each item of plant and shall be suitably
identified (including equipment classification reference) and bound.

Three (3) copies of each document file containing inspection reports and
certificates of site erection testing activities of a particular item of plant or
system shall be supplied to the Owner 20 days prior to commissioning.

Copies of the performance and acceptance test reports shall be prepared
and distributed as specified in Clause Performance and acceptance test
data and reports of this Section. All documentation as required by IBR
and other statutory authorities shall also be prepared and submitted.

6.00.00 Certification of Equipment by Owners Representatives

The Personnel & traveling costs in connection with the owners
Representative engineers inspection and witnessing of tests of
equipment, components and material manufactured in India and abroad
will be borne by the Owner.

7.00.00 Services prior to and During Inspection and Testing

In accordance with and in addition to specified standards the Bidder shall
submit procedures for material testing, manufacture, quality control and
performance testing as they apply from the procurement phase of raw
materials to the finished product. Manufacture commenced before receipt
of the Owner's approval of material specifications and testing procedures
shall be at the Bidder's risk.

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No inspection shall commence unless the Bidder and manufacturer are in
possession of relevant approved drawings and procedures for the item to
be tested. On request, the Bidder shall supply to the Owner's
representative, a copy of drawings and procedures at the time of the test.

All instruments and apparatus required for the inspection or used for the
performance tests shall be subject to the approval of the Owner at his
discretion and shall be calibrated to an agreed standard in approved
laboratories. The cost of making such calibrations shall be borne by the
Bidder in all cases.

If the Bidder wishes to apply for a concession in respect of a departure
from an approved procedure or standard, this shall be made in writing
with full information substantiating the technical acceptability of the
proposed change. The Owner's
decision shall be final.

Concessions granted shall not absolve the Bidder from any of his
responsibilities under the Contract.

8.00.00 Quality Control of Materials

To be developed later along with the successful bidder.

9.00.00 Quality Control during Manufacture of Plant


10.00.00 Tests on Completed Equipment In The Manufacturers Works


11.00.00 Testing at site during installation

11.01.00 Erection Tests

During erection all required erection tests as well as final erection checks
of the mechanical completion of the systems and part thereof have to be
performed.

After successful mechanical completion Mechanical Completion
Certificates will be issued.

The activities necessary for mechanical completion shall include but not
be limited to following testing:
Visual inspection after unloading at site.

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Checking of completion of relevant systems.
Completion of buildings and civil works.
Test of ventilating and air-conditioning units.
Alignment of rotating equipment coupled on site.
Safety audit.
Testing of site welds (non-destructive examinations).
Pressure testing, leak tests, tightness tests.
Checking of pipe hangers, supports, guides, etc.
Pipe line and equipment flushing and cleaning.
Chemical protection of piping systems.
Checking of coating.
Testing of cranes and hoists.

11.02.00 Pre Commissioning Tests

Preconditions for the commissioning are the issue of the Mechanical
Completion Certificate and the availability of the accepted commissioning
program and the Bidder's commissioning procedures. The Pre-
commissioning tests shall cover the requirements indicated in part-I of the
specification and shall also include the functional tests of the individual
items and their alarm and tripping systems. The above mentioned tests
shall include:

1. Mechanical equipment
Individual pre-commissioning runs of all rotating equipment such
as pumps, compressors, dosing equipment etc.

Functional tests of the mechanical equipment.

Testing and adjustment of safety devices.

2. Control equipment
Calibration tests of Instrumentation, loop checking, functional
testing of control equipment, interlocks, protection inputs etc.

3. Electrical system
Pre-commissioning checks shall be carried out for all electrical
equipments/systems such as Generator, Bus-duct, Transformers,
motors, switchgear, etc.

The various commissioning checks/tests to be carried out on the various
equipment shall be in accordance with applicable standards and
equipment Suppliers recommendation.

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The Bidder shall submit to the Purchaser, a checklist for testing and
commissioning and the activities shall be carried out in accordance with
the checklist.

All documents/records regarding test data and all other measured values
shall be submitted to Owner for record and reference.

11.03.00 Commissioning Tests

Commissioning tests shall be performed in accordance with the
procedure contained in the commissioning program approved by the
Owner for individual equipment/system & on whole as a plant. The same
shall necessarily cover the requirements of Characteristic Tests (PPA
Tests).

On completion of each commissioning activity to the satisfaction of the
Owner/ Owners Engineer, the commissioning schedule shall be signed
and dated by the Bidder and countersigned by the Owner and Owners
Engineer.

Commissioning test shall prove that the plant is prepared and adjusted to
ensure the correct functioning of the individual components and of the
complete plant.

The Commissioning test shall cover at least following tests:
Protection tests
Fire protection
SG protection
Turbine protection
Method of alarm/trip condition reset for subsequent starting.
Isolation procedures method of isolation of plant equipment for safe
shutdown and maintenance procedures including as a minimum

11.04.00 Start-up tests

Normal automatic start to preset load
Start up of the unit to be achieved within the stipulated time
mentioned elsewhere in specification.
Staged automatic including start to synchronous speed, manual
synchronizing, automatic synchronizing, manual and automatic
loading
Starting with stand-by auxiliaries

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Verification of startup times and loading rates of power units and
steam generators at various downtime conditions
Power unit(s), to test partial and full load rejection to demonstrate
Full load rejection tests to measure transient maximum speed and
steady state speed at normal governor droop setting
Turbine bypass operation capability
Operating stability when operated in the full range of load conditions
with load variations by increasing or decreasing the electric load
Demonstration of the capabilities of the Power Units to operate at
rated voltage and frequency, at power factors and reactive conditions
between 0.85 (lag) and 0.95 (lead) start-up tests of the Plant
equipment, facilities and systems including checking of automatic
change-over of standby facilities
Verification of vibration and noise emission guarantees
Environmental monitoring equipment, water quality monitoring
equipment, functioning tests and verification of guarantees
Verification of active power response and voltage control response
according to the requirements specified in the network connection
conditions
Demonstration of proper controlling, monitoring and recording
according to the requirements of the grid code
Verification of 24 hours uninterrupted MCR operation.

11.05.00 Performance Tests

Any time after start of trial operation and successful completion of
Commissioning / Characteristics tests as above, the Bidder may offer to
start Performance tests which consist of Reliability Test and Guarantee
Tests.

The Bidder shall submit for Owners approval the detailed Guarantee Test
procedure not later than seven months prior to the scheduled start of
commissioning of each Unit. The test procedure shall also cover the
following aspects:

11.05.01 Objective of the test

The parameters which have an impact on commercial viability of the
station are Gross power output & weighted average gross heat rate of
each of the unit and the auxiliary power consumption for the each unit.

Performance guarantee shall be provided for operation at contract
specific site reference conditions as specified and the guaranteed

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performance parameters of the unit shall be proved by the Bidder during
the test. Should the results of these tests show any deficiency from the
guaranteed value, the Bidder shall modify the equipment as required at
no extra cost to enable it to meet the guarantee and contractual
agreement.

The two operating modes at which the tests to be conducted for
determining the weighted average gross heat rate shall be 100% TMCR
(Constant Pressure mode of operation), & 80% of the TMCR (Sliding
Pressure mode of operation).

All heat rates shall be based on the analysis of the performance fuel as
specified in the General technical specification. Detailed quality
assurance plans/inspection schedules should be prepared and submitted
at least 4 to 5 months before the manufacture / supply / start of erection
for approval for equipment / materials / construction and erection
respectively.

Note: The Bidder shall get prior approval as per approved quality
assurance plan of the Purchaser / Consultant before any installation work
starts. If any work is carried out by the Bidder before prior approval from
Purchaser / Consultant and modification is sought by Purchaser /
Consultant later, then the work will be redone by Bidder without any cost /
material implications to the Purchaser / Consultant.

11.05.02 Test Documents

1. The procedure shall include the following for each test or group of
tests.

2. The sequence of the tests to be conducted.

3. The time duration of each test.

4. The number of test runs.

5. A list of instruments that will be used for each test. The list shall define
which instruments are (a) special test instruments, (b) certified, (c) to
be calibrated before and after each test, (d) check instruments, (e)
station supply instruments (f) A schematic diagram showing all test
points and cross referenced to the instrument list and (g) method of
data logging. Data logging through satellite communication is not
permitted.

6. All formulae, calculations, conversion factors, curves, correction
curves etc., to be used in the conducting of the tests and the

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calculations of the test results. All such items shall be to an accuracy
level of four decimals.

7. Sample test reports to data sheets and all specific result sheet forms
that will be used for the test.

8. Written procedure and description of conducting the test.

9. In the event of the plant (or portions of plant) failing to give the
required performance, further tests which may be considered
necessary by the Owner, shall be carried out in a similar manner. The
entire cost of the repeated test shall be borne by the Bidder.

10. For each of the Performance & Guarantee Tests, the Bidder shall
evaluate the test figures and within Seven (7) days of the completion
of the relevant test, shall submit to the Owner for approval, four (4)
copies of the Test Report containing a complete analysis of the test
results.

11. The Bidder shall prepare test reports for each performance test in
which the methods followed, instrument readings, graphs,
observations, final results obtained etc., shall be recorded.

12. Bidder shall examine and sign the reports and certificates of all tests.
The Owner shall review and comment on all test protocol and
procedures, reports and certificates. Written evidence of the test data
shall be issued by Bidder who shall also perform the necessary
calculations. The basic information and figures to be used for the tests
shall be compiled by Bidder.

13. For the checkout turnover packages, Performance tests, Bidder shall
prepare reports. The reports shall contain a summary of any tests and
certifications as well as results, recorder charts, observations and
comments derived from the testing and turnover procedure as
applicable. Six copies of the reports signed by Bidder and
accompanied by all the corresponding detailed testing reports shall be
delivered to the Owner's office on Site. Six (6) copies of each test
report shall be delivered to the Owner (the Owner).

11.05.03 Testing Method

The testing shall be carried out as per PTC - 46. There shall be at least
two tests for each of the operating modes indicated above. The test
boundary shall include the cooling towers air cooled condenser.

To arrive at the Gross power output of the plant the Gross Power output
of each generator shall be measured. The power exported by the station

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shall be measured at Switchyard energy meters at outgoing transmission
line feeders and recorded to arrive at the Auxiliary power consumption.

Auxiliary Power Consumption is identified into two varieties:

1. Aux. Power Consumption for each Unit at 100% TMCR is to be tested
and guaranteed. During the test, other auxiliaries which are essential
for Unit operation such as Fuel oil forwarding pump etc. which are
connected to Station supply is to be specifically measured and will be
added to the Unit Aux. Power consumption and all other loads
connected to the Station supply will be deducted.

2. In addition, Common facilities or Common Auxiliaries (which are
connected to Station supply) are to be tested separately and
guaranteed. However, when the aux. power consumption for common
auxiliaries is measured, other auxiliaries which are essential for Unit
operation such as Fuel oil forwarding pump etc. which are connected
to Station supply is to be specifically measured and will be deducted.
This test is to be done when both units are running at 100% TMCR
and all common auxiliaries are running at rated capacities to the
extent feasible and during the test it is to be ascertained that total ash
should be delivered to the ash pond.

Both the tests have to be conducted during day time only and
minimum of two test runs are to be accounted for the purpose.
Duration of the test period shall be mutually agreed upon by the
Owner and the Bidder.

11.05.04 Measurements

The following measurement has to be taken during performance and
guarantee test:

11.06.00 Output
Gross power output of each unit at 100% TMCR conditions & VWO
Conditions.
Energy measurement at switch yard and Station Transformers to
arrive at Aux. Power Consumption.

11.07.00 Input & Waste

As per PTC 46

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11.08.00 Specific Site Conditions

Ambient pressure
Ambient temperature
Relative humidity
Grid frequency
Power factor
Fuel analysis (Coal)
Cycle blow down

Correction curves shall be applied only on the above measured specific
site conditions to arrive at the Plant Performance Parameters at the
contract specified specific site reference conditions.

11.09.00 Contract Specific Site Reference Conditions

Plant performance tests shall be carried out considering the Basic
conditions for the site as specified elsewhere in the specification.

However, Design Emission Standards for the whole plant shall adhere to
the Central Pollution Control Board and State Pollution Control Board
norms and requirements and deviation/correction in this regard is not
acceptable.

11.09.00 Specific Conditions of Testing Method

The correction method stated under Cl.5.6 in PTC 46 shall be applied to
correct the performance parameters measured and corrected as per the
above stated method Tolerances are applied over these corrected
performance parameters in such case.

11.10.00 Test Uncertainties

The test uncertainty shall be calculated based on the accuracy and
number of test instruments utilized. The same shall be done as per PTC
46 and the maximum expected test uncertainty shall not exceed 3.0% for
corrected gross heat rate and 1.0% for corrected Gross power output.
Accordingly the bidder shall state in the proposal the permitted
deviations/fluctuations of design parameters that are permitted during the
test for each operating mode testing.

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11.11.00 Correction Curves & Tolerance

The correction curves shall be provided as mathematical equations in
addition to the curves to an accuracy of four decimals. The equations
supplied shall be utilized to perform the test result calculations.

11.12.00 Measuring Equipment

All test instrumentation and test equipment shall be provided by the
Bidder. All the instruments shall be calibrated by a certified body before
and after the tests. The calibration certificates shall be submitted to the
Owner prior to the tests. The calibration certificates shall be considered
valid for a period of not more than six (6) months from the date of its
calibration.

The anticipated points of measurement together with necessary isolation
during the tests shall be indicated by the Bidder.

11.13.00 Model for Evaluation of Guarantees

The Bidder shall provide a model for the evaluation of guarantee Tests at
least six months prior to commencement of the Guarantee Tests. The
model shall provide for implementation of all correction factors. The
model provided by the Bidder shall be tested and accepted by the
Owner/Owners Consultants and Lenders Engineers. Upon acceptance
of the model, the same shall be used for cross-checking Guarantee Tests
results. After the conductance of Guarantee Tests, the Bidder shall
submit the test evaluation report of Guarantee Test results to owner prior
to or along with the COD Notice. Owner/Owners Consultants shall review
the test(s) result and reports submitted by the Bidder and respond to
Bidder regarding Guarantee Tests within 10 days from the date of receipt
of such reports.

11.14.00 Demonstration Tests

Bidder shall conduct and establish the performance of equipments,
systems etc as specified in this specification.

11.15.00 Shop Test (As Necessary)

11.15.01 Fuel Oil Pumps

Impeller and rotor shall dynamically balanced.

Pumps assembly shall be subjected to hydraulic test.

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All pumps including spare cartridges shall be subjected to performance
test at the manufacturer works under as near actual site conditions as
possible and strip examination after the test.

11.15.02 Fans & Pumps

Fans & pumps which are not mentioned in clauses above shall be
dynamically balanced and functionally tested at manufacturers works.
Complete performance tests shall be carried out on First pump / fan of
each type and capacity to verify its output against total head, power input,
efficiency, vibration, noise level. Head /volume, efficiency and power input
curves corrected for site conditions shall be furnished.

11.15.03 Shop Performance Tests

1. Pumps
Each pump shall be hydrostatically tested at a minimum of 1.5 times
the design pressure.
Head, capacity & BHP of each pump covering the entire range of
operation at rated speed and temperature. For variable speed pumps,
the tests shall cover the entire range from maximum speed to
minimum speed at intervals of not more than 500 rpm.
NPSH tests shall be carried out for each rotor at rated speed and
temperature, over the entire operating flow range for head drop as
specified elsewhere in the Specification.
Tests run to demonstrate performance and NPSH tests shall be
governed by ASME Performance Tests Codes and Hydraulic Institute
Standards. The test procedures shall be submitted to the Owner /
Consultant for review, comment and acceptance.

2. Gear Boxes, Hydraulic Couplings
Mechanical running tests for each of the units.
Shop performance test for one unit of each type as follow Hydraulic
couplings & Gear boxes: Full load and full speed test or back-to-back
locked torque test.

11.15.04 Electronic Equipment

Electronic cards/systems shall be subjected to following type test. In case
type tests have already been carried out, the test reports shall be
submitted for Owners review and approval.

a) Drop test.
b) Vibration test.

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c) Environmental test (Dry heat, low temperature and damp seat) as per
BS: 2011 or equivalent IS codes.
d) Electrical environmental tests as per IEEE 472 or equivalent (surge
withstand capability test.)

All solid state electronic system/equipment shall be tested as a complete
system / equipment with all devices connected for a minimum of 168
hours continuously under energized condition prior to shipment from
manufacturing works. During the elevated temperature test for 48 hours
the ambient air temperature shall be maintained at 50C and at relative
humidity of 95%. The equipment shall be interconnected with devices
which will cause it to repeatedly perform all operation it is expected being
equal to those which will be experienced in actual service.

During the test, the cubicle doors shall be closed (or shall be in the same
position as they are supposed to be in the field) and inside temperature in
the zone of highest heat dissipating components / modules shall be
monitored. The temperature rise inside the cubicle should not exceed
10C above the ambient air temperature at 50C.

The 48 hours test period shall be continuous but divided into four
segments each of 12 hours. The input voltage during each 12 hours
segment shall be nominal voltage for 11 hours, followed by 110 percent of
nominal voltage for 30 minutes. followed by 90% of nominal rated voltage
for 30 minutes. The performance of the system prior to, during and after
above test shall be satisfactory.

The solid state control/logic systems shall be subjected to the elevated
temperature test and burn in test as complete assembly.

The equipment shall be checked at works and at site for
electrical/functional operation in service/simulated conditions to ensure
performance to satisfy their intended function. A detailed procedure shall
be submitted for Owners review. The equipment shall be calibrated at
least at 5 points.

The enclosure of each type shall be tested for specified degree of
protection as per IS: 2147.

All individual components like relays, meters, CTs, PTs, major electronic
components like thyristors, etc. shall be tested as per relevant
National/International standard.

Insulation test shall be carried out before performance test.

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The Bidder shall submit detailed procedure/set up for shop and site tests
separately along with relevant documents, etc. as per good engineering
practice and intended functional requirements.

11.15.05 Structurals

Only material which has been identified against a mill sheet or test
certificate shall be used for construction.

Welds shall be subjected to MPI examination on random basis.

Trial structural sub-assembly of one hopper and mouth piece shall be
carried out.

11.15.06 Electrical Equipment

All electrical equipment shall be subjected to the routine and type tests as
indicated in the relevant section of the Specification.

11.15.07 Control and Instrumentation

All control and instrumentation equipment/system covered under this
Specification shall be designed as per good engineering practices and
finalised quality assurance requirements. These shall cover factory tests,
site tests and trial operation tests for the control and instrumentation
system. The Bidder shall bring out in this proposal all such tests under
categories type tests/routine tests etc. The tests shall include but not be
limited to the following:

a) Surge protection test for solid state equipment

b) Burn in and Elevated Temperature Test

c) The Bidder shall furnish full details regarding shop test and site tests
as per good engineering practices. The Owner shall approve all such
tests and the Bidder shall demonstrate all such tests without calling
for additional price. The test shall cover factory tests, burn in and
elevated temperature tests, simulation and functional tests, insulation
tests as applicable withstand capability test, conformity of other
conditions deemed to be necessary with the system/equipment items.

The representative of Owner/technical specialist shall be given
opportunity to witness the factory tests, which shall be mutually
finalised during the progress of the contract.

d) All instruments and control equipment supplied against this contract
shall be factory calibrated at 5 points through the range and also

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checked for its functional performance requirements. The instruments
shall also be calibrated at site prior to commissioning. Insulation tests
shall also be carried out as applicable.

e) All panels, instrument enclosures, junction boxes etc., shall be typed
tested for degree of protection as applicable in accordance with IS:
2147.

f) Type, routine and acceptance testing of equipments supplied against
this contract shall be in accordance with relevant NEMA
/IS/IEC/ANSI/BS/ISA Standards in addition to Owner approved
Quality Plan requirements and 6 copies of test report shall be
submitted to the Owner for approval prior to despatch of the same.

g) Following tests / inspection shall be carried out in local panels:

1. Compliance with approved drawings data sheet and
Specifications.
2. Visual check for workmanship.
3. Wiring continuity and functional checks
4. Calibration of instruments, relays and meters
5. High voltage test.
6. Insulation resistance measurement.

h) All control cubicles are to be checked tested for dimensional details,
wiring/tubing, insulation, burn in test, performance by simulation etc.
Bidder shall furnish type test reports to indicate that the equipment
have undergone climatic/ transport conditions tests.

i) All local instruments will be tested for performance, leakage
(pneumatic), insulation etc. Type test reports to be furnished.

j) All types of cables, fittings, etc. shall be tested as per relevant
standards. Special tests for FRLS properties screened cables shall be
tested for capacitance unbalance, characteristic impedance and cross
talk.

k) For flow elements (orifices, flow nozzles, etc.) material test certificates
shall be submitted. Devices shall be tested as per relevant standards.
Non-destructive tests for the welded nozzles shall be carried out as
per requirement.

l) Control valves will be checked/tested for dimensional correctness,
body-seat diaphragm chamber leakage, lift characteristic, etc.

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11.15.08 Flow nozzles

Only material, which has been identified against a mill sheet or test
certificate, shall be used for construction.

Carrier pipes and pressure tapping bosses shall be subjected to UT
examination at the mill or prior to use.

Welds on the nozzles shall be tested by MPI.

Calibration of flow nozzles shall be carried out as per relevant
international standard and as stated in C&I Specification.

All other QA and routine and type test requirement on C&I equipments
shall be governed by C&I Specification.

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ANNEXURE - V
QUALITY ASSURANCE
1.00.00 General

Bidder shall provide effective quality assurance according to ISO 9001
standard or other equivalent quality standard. The preliminary quality
assurance program is part of the contract agreement. The program gives
the description to all the management and regulations about the
necessary quality assurance activities in relation to the execution of the
contract.

Quality achievements shall be ensured by combined factors such as the
application of quality system regulations, technical specifications
(including acceptance regulation of quality control requirements), the
examination of quality achievement, precautionary methods and the
control of corresponding data.

All manufacturing, processing, testing and inspection operations affecting
the equipment or material shall be subject to surveillance by
Owner/Purchaser or Owner's Representative. These will be identified by
customer Hold Point.

2.00.00 Quality Assurance System

The quality assurance system of the Bidder shall illustrate its organization
process, duty and obligation, quality supervision and standards, and
subject to reexamination by the Owner/Purchaser.

The implementation of the system shall be ensured by the following: the
guidance and training of all staff by management council in application of
the quality assurance program and the ordinary supervision through
reexamination and management of the quality assurance program.

If an international joint venture is established, the responsibilities shall be
specified so as to let the quality assurance group perform its duty,
communicate with the Owner/Purchaser formally, and be responsible for
the development of the quality assurance program. An agent should be
involved to prepare a report book and introduce it to the quality assurance
management staff. The report book illustrates the responsibilities to be
fulfilled in management and supervision of the quality assurance program
and examine the implementation of the quality assurance guarantee
program by the staff of the international joint venture enterprise.

3.00.00 Basic Files

The basic working files influencing quality implementation and
examination will be developed and kept updated in an orderly manner.

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The copies of these files should also be supplied to the construction site
to be available for the Owners representative to take examination.

4.00.00 Project guidance and manufacture drawings

Design shall be based as close as possible on the approved design.
Some modifications can also be made in order to make major
improvements in the manufacture and building technologies and to meet
the special needs of the Owner/Purchaser.

Any improvements on the former design shall be checked and examined
individually. Those results that have been discussed carefully shall be
reflected in project directions and order files of Owner/Purchaser. The
plan about the output and input of design, independent design check and
evaluation and design change shall be controlled and quality acceptance
standards shall be established.

5.00.00 Quality assurance plan/ overhaul and test plan

The quality assurance plan to ensure necessary quality shall be included
in the quality assurance system of the Bidder. This document shall outline
overhaul and test principles and record the procedures and steps of the
inspection and the requirements for authorizing the inspection as
stipulated in the Contract.

The supply of the main elements of equipment to the Owner/Purchaser
shall be included in the quality assurance plan and be submitted to the
Owner for re-examination.

The Owner/Purchaser can challenge the inspection point and the required
quality assurance records illustrated in the combined plan of inspection
and test procedures that have been agreed upon. These and other
inspection and test procedures used in the manufacturing period shall be
illustrated in detail in a separate document for adjusting and formulating
the plan.

The Bidder shall give Owner/Purchaser adequate notice 15 working days
prior to each test.

The confirmation of the inspection and test data shall be delivered to the
Owner/Purchaser in less than 15 days.

Instruction manuals on operation procedures shall be supplied to the
Owner/Purchaser.

The content of the instruction manuals ensures that special operation
procedures are carried out in a controlled way. All the documents in

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relationship to the quality assurance plan shall be supplied to working site
for the convenience of reexamination.

6.00.00 Working Guidance

Working guidance shall control quality and production activities mainly
and should be supplied to the working site for reexamination.

7.00.00 Nonconformity Point

Nonconformity terms shall be reexamined to make it acceptable or
modified or renewed with the final goal of attaining the approved
standards. The documents for correct operation shall be provided to
manufacturing or construction site for inspection.

8.00.00 Quality Guarantee Record

Bidder shall keep the records for quality guarantee. These records should
prove that the system and equipment has satisfied the requirements of
the contract; all staff, operation programs and equipment are qualified in
special operation procedure, and that the supervision to the Sub-vendor
is in accordance with the contract requirements.

The specified quality assurance record that is as approved in the
combination plan of inspection and test shall be provided to the
Owner/Purchaser.

9.00.00 Supervision

Bidder shall supervise Sub-vendors implementation of combining quality
and production.

10.00.00 Material Purchase

Material shall be purchased according to project specification and stated
standards. The related control data, such as, chemical analysis,
mechanical performance, nondestructive tests shall be illustrated in these
standards in detail.

Supervision activities shall be performed in Sub-vendor's office in
connection with the Bidders orders and quality plan and standards.

Before the delivery of all goods, the goods shall conform to the random
examination and parameter rightness examination and pass the check
and acceptance of the records of documents of the Sub-vendor's to
ensure that goods are up to standards.

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11.00.00 Standard Equipment and Parts

Standard equipment and parts shall be manufactured by a company that
has passed quality assurance inspection.

All parts must be manufactured by the standard criteria and quality
assurance standards.

12.00.00 Production Control

Working guidance shall illustrate in detail about the program procedure,
control files and the field procedures.

Inspections and acceptance tests shall be performed and recorded.

The corresponding type of quality management (IS09001, 9002, 9003 or
equivalent standards) shall be illustrated in Bidders order in such detail
that it corresponds to the type and scope of the equipment supply. The
standard industrial products that are purchased with no reference to list or
manufacturers directions need not be illustrated.

In the procedure of planning inspection, adjustment, evaluating
adjustment and the corresponding quality examination and confirmation,
the production control of the Sub-bidder should be supervised.

13.00.00 Third Party Inspection

The Owner reserves the right to appoint third party inspection agency and
the Bidder/ sub-vendor / suppliers/ manufacturers shall allow the
Owner/Purchaser and /or owner representatives (third inspection agency)
to carry out inspection at the manufacturers premises /required premises.

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ANNEXURE - VI
TOOLS AND TACKLES

The bidder shall furnish a complete and new set of all tools and tackles which are
necessary for erection, commissioning, maintenance and overhauling of any of the
equipment/system provided under this specification.

List showing minimum requirement is furnished below. Bidder to indicate additional tools
and tackles as necessary in their offer.

a) 1 set of Complete J igs/Fixtures with all tools for erection and removal of
generator rotor.

b) 10 numbers Breaker handling trolleys for all type of breakers

c) 5 numbers of Panel keys each type.

d) 10 numbers Breaker rack in/out, spring charging handle each type.

e) 2 sets of Earthing rods/trucks.

f) 2 numbers of Megger with selection of voltage from 200V to 5000V, battery
operated.

g) 2 sets of Battery cell lifting and shifting tools

h) All special tools used during erection will be retained in the station for use in
regular maintenance in all the areas of power plant.

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ANNEXURE - VII
DOCUMENTATION

1.00.00 Format of Documentation

All engineering documents and drawings will be of international A series
sizes, that is: AO, A1, A2, A3 and A4.

One set of CDs containing all the drawings in .pdf will also be supplied in
addition to hard copies. Need based requirement for Auto-cad format
drawing file for some of the drawing such as overall GA etc. may be
furnished based on Owner/Purchasers request.

Grouped documents will be provided by size A4, with the inclusion of
size-A3 drawings which, however, have to be folded as size-A4.

2.00.00 Numbering and Identification of Documents

All the drawings will be identified through a common way of numbering in
accordance with the requirement of contracting. The numbering system of
drawings and documents proposed by the Contractor shall be in
compliance with the plant identification system and to be agreed with the
Owner. Apart from this, some drawings may also be numbered in the way
which the Contractor or Subcontractors are used to. But, there shall be a
common title block on all published drawings which include the following
contents:

Owner
Project
Contractor
System
Drawing No.
Sheet No.

Before some copies are produced made with the drawings, the above
contents shall be fixed on the original and designations of drawings.

The measuring units and dimensions marked on the project engineering
drawings shall be of SI system conforming to ISO 1000.

English words shall be used as descriptions on drawings.

In case dimensions are not marked in conformity with the scale of
drawings and any dimension on the drawing does not conform to those
dimensions and sizes measured through certain scale, the actual marked
dimensions shall be applicable.

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For revision of drawings, the revised part will be clearly and definitely
shown on the drawing. For revision of documents which have been
grouped together, a brief description shall be shown on the front sheet of
the document, which shall be a perpendicular line with the margin of the
revised copy closely following it.

3.00.00 Provision for Documents

Generally, documents and drawings with patented nature will also be
required to be provided wherever required.

However, to know whether the Contractor has performed its obligations,
the Owner has the right to examine those drawings within the
Contractors working scope.

The Contractor shall meet the Owners reasonable demands to files and
do the following to satisfy the Owner:

Contractor will work according to the requirements specified in the
contract.
Contractors working has been arranged properly and developed
according to the plan.
The quality control system is reliable.
After receiving all documents necessary for power plant operation and
maintenance, Contractor shall supply equipment and systems.

Having received all necessary documents for Contractor to perform its
legal obligations or other relevant responsibilities.

4.00.00 Owner/Purchasers Responsibilities

It is the Contractors duty to assure that design standards and conditions
meet the requirements and that the power plant shall operate safely and
reliably and with high efficiency, having the same performance as
stipulated and guaranteed.

The Owner/Purchaser shall examine and check the drawings and
documents with the aim of assuring all these drawings and documents
meet the demands and duties written in the documents. The Contractor
shall have an active and cooperation working relationship with the Owner,
if there is a disagreement over an issue, Owner and Contractor shall work
together to reach the same conclusion through proper mutual
consultations.

If drawings and documents have been supplied to the Owner, the
Contractor may not delay further design waiting for the Owners opinion.
The Owner will arrange the time for submitting opinion and examination

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results for delivered documents. If the Owner finds that the Contractor
cannot meet the contract requirements, the Contractor has the duty to
modify the design and drawings to meet the Contract demand.

5.00.00 Drawing Title block

Typical drawing title block followed is indicated below.

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ANNEXURE - VIII
DRAWINGS, DOCUMENT FOR APPROVAL, CLEARANCES

1.00.00 General

The Owner/Purchaser/Purchaser reserves the right to ask the Contractor
to submit copies of drawings and other documents for approval to his
Head Office or to the Office of his Representatives. If the
Owner/Purchaser or his Representatives are satisfied with the drawing,
one copy will be returned to the Contractor marked with an 'Approved'
stamp. If the Owner/Purchaser or his Representatives are not satisfied
with the drawing, one copy stamped 'Reviewed and Returned with
Comments' will be returned to the Contractor with comments marked
thereon and the drawing shall be amended and re-submitted for approval.

The purpose of having drawings checked and approved by the
Owner/Purchaser/Purchaser is to assist the Contractor in interpreting the
Technical Specification so as to eliminate mistakes in the equipment or
material actually shipped to the site of the work. The formal approval
given to the Contractor is to be considered as in conformity with this
purpose and in no manner shall be construed so as to release the
Contractor from any liability or responsibility for proper design, fabrication
or compliance with the Contract Documents.

Equipment drawings shall clearly indicate the general arrangement of the
equipment to be furnished, give principal dimensions, and show sufficient
details required for a complete power station.

When submitting drawings for approval, including any prepared by a Sub-
Contractor, the Contractor shall certify that he has fully examined such
drawings and that they comply with the requirements of the Contract.

If any item, equipment or work shown in the drawings does not
completely comply with the requirements of the Specification or any other
requirement of the Contract Document, the Contractor is obliged to clearly
inform the Owner/Purchaser and his Representatives of the differences
giving full explanations and reasons for such changes.

For the purpose of this Clause the term "drawing" shall include design
calculations, equipment specifications, technical write ups, system
description, operation & control philosophy, diagrams, schedules,
performance curves and all other relevant docs etc. Approval of a drawing
by the Owner/Purchaser or his Representatives will imply that:

Arrangement and layout drawings and key diagrams have been
examined and appear to be in accordance with the basic design
concept of the project and meet the requirements of the Specification.

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Other drawings of components and equipment have only been
examined in relation to compatibility of the items and equipment with
the Specification and in respect of interconnection with other items
and equipment.
Any approval given by the Owner/Purchaser or his Representatives
shall in no way relieve the Contractor of his responsibility under the
Contract.
Further procedures and norms will be discussed mutually and
finalized at the time of the start of the contract.

The Owner/Purchaser will not normally require to receive copies of
detailed manufacturing drawings but the Contractor shall make these
available if requested to do so.

The Contractor shall ensure that drawings are submitted in due time to
permit amendments to be made and the drawings re-submitted for
approval without delaying the program deliveries or the guaranteed
competition dates according to the Contract.

If, during the Contract period, the Contractor is required to modify the size
of any buildings, foundations etc. from that shown on his Tender drawings
to accommodate the finally approved arrangement of the Works (with due
allowance for access, laydown, maintenance etc), then such modification
shall be deemed to be included in the scope of the Contract.

Requirements about the format of drawings and documents, the provision
for documents and the Owner/Purchaser's responsibilities with regard to
documentation are specified in various sections of this specification.

The Contractor shall be responsible for any discrepancies, errors or
omissions in the drawings and other particulars supplied by him, whether
such drawings and particulars have been approved by the
Owner/Purchaser and his Representatives or not.

2.00.00 Documentation by Contractor

The drawings to be submitted by the Contractor for approval shall cover
the complete Scope of Contract work as defined by the Contract
Specification and shall generally include, but not be limited to, the
following:

General layout drawings.
Arrangement drawings of associated buildings on site, foundation
drawings and plant weights showing loadings and shock loadings.
General assembly drawings of the equipment to be supplied by the
Contractor together with sufficient sub-assembly drawings, details,

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control and wiring diagrams to demonstrate fully that all parts will
conform with the provisions and intent of the Contact Documents
Detailed Construction drawings as applicable for civil and structural
works in bidders scope.
Single-line, instrumentation and schematic diagrams of the various
systems including control, indication, protection, alarm, synchronizing
and interlock circuits.
Drawings/ Documents as listed in Electrical section
Piping and instrument diagrams of the various systems,
Schedules for drawings, valves, instruments, cables, alarms, controls
etc, in such a form as may be required by the Owner/Purchaser or his
Representatives
General arrangement drawings showing cable and earthing conductor
routes with location of earth rods, test links and bonding connections
to steelworks.
General arrangement drawings of the emergency lighting showing
proposed location of fittings
Any calculations required by the Owner/Purchaser to substantiate the
Contractor's designs shall also be submitted by the Contractor.
Up-to-date lists of all drawings, lists, etc, prepared and/or submitted
by the Contractor at intervals of four weeks.

All Contractor's drawings which are found to be incorrect during the
construction period or which require changes due to field conditions, shall
be corrected by the Contractor to an "as built" condition to reflect any
necessary changes.

The stipulations and requirements specified elsewhere in the specification
shall also be followed with respect to preparation and submission of
drawings.

The Contractor shall submit within 15 days of award of contract a detailed
Master Document Submission List indicating the scheduled dates for
submission. This list shall be subject to Owner/Purchasers review and
approval.

The following data and documents shall be submitted by the bidder with
his proposal. It includes for the purpose of completeness documents also
listed in the other sections of this specification.

3.00.00 Data and Documents to be provided with the proposal

3.01.00 General

Completely filled in Data sheets and Schedules for guarantee and
design data.

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General Plant Lay outs.
List of deviations from the request of proposal, indicating the section,
page, specified requirement and bidders deviation.
Reference lists for delivery and installation of plants of similar type
and size.
Detailed overall time schedules showing design, manufacturing,
shipping, erection and commissioning of each component.
A detailed pre-testing, commissioning, start-up and testing time
schedules, with interface dates.
Documents on the quality assurance Program, System & Procedures.
List of major workshop inspections
Training program and schedule for O&M personnel
Lists of Recommended spare parts for 3 years operation
Proposed inspection and testing programs
Spare parts storage and supply policy
List of personnel to operate the relevant systems and to perform day-
to-day maintenance
Complete description of the systems and components offered
including description of the process and the equipment along with
P&ID.
Schematics of the principal plant systems
General descriptions of individual systems and descriptions of
operation including description of start-up, shutdown and emergency
shutdown procedures
Auxiliary power requirement of the individual plant units
Detailed layout drawings
Dimensioned drawings and sectional views of the principal plant
components
Preliminary building requirements, including dimensions and special
requirements for each individual building
All other documents necessary for comprehension of the offered
plants and equipment.
List of Sub-vendors.

3.02.00 Mechanical

Process flow diagrams of all systems
Plant and major equipment start-up curves for cold (all material on
ambient temperature), warm, hot and very hot start up to MCR
General outline of installation
General arrangement and Equipment layout of all systems and sub-
systems.
Graphs showing the performance characteristic versus the load.
Correction curves
Degradation curves for the power units and the plant

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Heat cycle calculations for the different load points to achieve the
requested outputs.

3.03.00 Electrical

3.03.01 Applicable for all the equipment/system

Completely filled in technical Datasheets
Single line diagram for Auxiliary power distribution
Description & Catalogues of all Electrical equipment

3.04.00 Controls & Instrumentation (C&I)

Reference list with capacity of plant, year of commissioning & control
system implemented along with minimum two (2) nos. users
certificate for the control system configuration offered.
Control philosophy / operation philosophy / Design philosophy /
Redundancy philosophy for control system and Utility.
Grouping philosophy of control loops in controllers controls.
Control system configuration drawing / system architecture drawings
including HMI.
P&ID (Process and Instrumentation drawings) indicating primary and
secondary Instruments and the destination/functionality of the signals
for main Plant and for each Utility package.
Clause wise confirmation / deviation list with respect to C&I
requirements specified in sections
Duly signed schedule of performance guarantees.
System Architecture highlighting the applicable standards for control
and information domain; networking and security features; graphic
capabilities data exchange procedure, engineering tool, system
capability such as graphic displays, trending, archiving, history, logs,
reports, etc.
List of software included for control system.
Confirmation certificate for the latest version of software and hardware
offered.
QAP for control system.
Codes and applicable standards followed for the project.
List of closed loop controls included with write up. Redundancy
concept for CLCS controls with details.
List of open loop controls included. Redundancy concept for OLCS
controls.
Evidence that the offered control system is upgradeable and
evolutionary in both hardware and software

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3.05.00 Civil and Structural

A report on foundation proposed for various structures, buildings and
facilities based on the data furnished by Owner/Purchaser and further
data collected by the bidder. Allowable safe bearing capacity for open
foundation, depth of foundation, need for pile foundations, soil
improvement if any required, special precaution against aggressive
soil etc shall also be covered in the report.
General arrangements / architectural drawings for all buildings and
structures showing dimensions, levels, plans, sections, elevations,
materials proposed, types of framing, wall/cladding, floors, roofs,
types of finishes etc.
Detail design criteria proposed to be adopted for each building,
structures, foundations, facilities etc.
List of software proposed to be used in various areas for analysis,
design, drafting as well as project monitoring along with their sources
and validation report for software.
List of all sub-contractors that the bidder proposed to employ, in case
the contract is awarded to him, indicating their addresses with
telephone number, experience on similar jobs, name, qualification and
experience of persons who shall be employed in the job on behalf of
the sub-contractor etc shall be submitted to the Owner/Purchaser.
Only the Sub Contractor, approved by the Owner/Purchaser shall be
engaged by the contractor on the job.
Details of quality control laboratory with a list of testing equipment
shall be furnished.
Schedule of unit prices duly filled in with rates.
All deviations from bid document shall be furnished by BIDDER in the
format given in the specification document. Deviation furnished
elsewhere in the bid other than at the place titled Deviations will not
be considered as deviations.
Any exclusions from the scope mentioned and implied in these
specifications, shall be clearly mentioned by the bidder separately in a
section titled EXCLUSIONS. Only the details mentioned in this
section shall be considered as exclusions. All works, other than these,
shall be deemed to be in the scope of this contract and shall be
executed by the contractor at no extra cost to the Owner/Purchaser.

4.00.00 Data and documents to be provided after award of contract

The sections below list the major documents to be provided by the
Contractor after Commencement Date. This list shall be extended by
the bidder as required to cover all aspects considered relevant. The
time in weeks after Commencement Date provided in this list is
preliminary and shall be reviewed by the bidder. During contract
negotiations this list will be coordinated and finalized.

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After award of Contract, the Contractor shall submit a detailed list
comprising all drawings or other documents the Contractor will
produce. Based on this list the Owner/Purchaser will decide which
drawings or other documents will have to be submitted for approval.
Apart from those documents named in the Conditions of Contract and
the various sections of the Specification including Boiler, Turbine, I&C
parts, the Contractor has to submit as minimum requirement to the
Owner/Purchaser or his representatives within the periods specified in
weeks/ months, starting from the "Commencement Date" according to
the Definitions of the Contract. The delivery time as far as not
specified, shall be proposed by the Bidder in his Tender in
accordance with his overall implementation schedule and will be
defined finally during Contract negotiations.

4.01.00 General

Monthly list of drawings
Complete list of documents with proposed submission deadlines
(Monthly)
Monthly Progress reports (including Engineering, Procurement,
Erection etc.)
Detailed program for commissioning
Detailed procedure for Reliability run
Testing documents
Report of results of all tests
Training program
As-built-documentation including drawings of all equipment
Declaration of conformance with regulations.
Spare part lists
Space requirement for lay down area, construction site and equipment
Description of road improvements for site access outside the plant
limits considered necessary

4.02.00 Time schedule

Overall time schedule for design, manufacture, supply, assembly,
erection and commissioning for the principal plant packages & systems
and all construction works, stating dates for completion of any preparatory
work from others which may be necessary.

Detailed erection, installation and commissioning schedule

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4.03.00 Mechanical Engineering

General Arrangement drawings of all systems, equipments &
buildings with ducts and platform layouts.
General Arrangement drawings of Main & auxiliary equipments
Detailed technical write ups of all systems
Process flow diagrams.
Piping and Instrumentation schematics and isometric drawings,
including list of pipelines and valves, stating materials, nominal
diameters and pressure, dimensions, insulation thickness of all pipes
and piping bill of materials (system-wise), Hangers & support
drawings with loads & movements.
Plans, Sections & Isometrics of all pipelines including location of cable
routes
Performance / Characteristic curves for all equipments viz. pumps,
fans, butterfly valves, etc.
Details of auxiliary energy sources and consumer consumables (e.g.
electricity, steam, fuel, chemicals, instrumentation air, working air)
with condition data and consumption values.
Sectional and detail drawings of all components
Lifting plan for all lifting operations (repair, maintenance, etc.)
Design and sizing calculations of all equipments.
Detailed equipment drawings for all equipments.
Complete data sheets of all equipments and systems.
Equipment maintenance schedules for major equipment.
Sizing and selection criteria for all equipments, Thermal insulation and
cladding
Catalogues for all equipments, systems, piping, valves etc.
Surge/impact analysis calculations
Line designation schedule
Piping, Valve & specialities schedule
Performance diagrams of all equipments/systems.
Quality, Inspection, Shop & Site Testing QAP, Test schedules, Test
procedures, Test Certificates, & Test reports.
Performance guarantees test procedures. (With relevant drawings
indicating the test point positions etc., Sample calculations, Correction
curves)
Erection & Commissioning manuals.
O&M manuals.
As built drawings system wise, etc. duly certified by Site after
execution of work.

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4.04.00 Electrical

General (As Applicable for all the equipment/system)
Completely filled in technical Datasheets for all Electrical equipments
Single line diagram
Description & Catalogues of all Electrical equipment
General arrangement drawing of all Electrical equipment
Schematic diagrams for all Switchboards & Control panels
Sizing calculations for all the equipment.
Relay setting calculations
System studies
Electrical equipment layouts for various Electrical rooms
Cable tray layouts
Earthing layouts
Lightning protection layouts.
Lighting layouts.
Cable Schedule
Interconnection charts
Type test reports
List of tests and test procedures for all the equipment.
Quality Assurance Plan
Test certificates
Erection & Commissioning Manual
Operation & Maintenance Manual
As built drawings.

Battery & Charger
Dimensional General arrangement drawing for Battery & Charger
Sizing Calculation for battery & Charger
Sizing calculation for heat loss & ventilation air requirement.
Drawings for battery rack & fixing arrangement
Schematic diagram for Charger

Bus Ducts
Bus-duct layout & Sectional details
Termination detail at equipment
Wall frame assembly drawing
Dimensional General Arrangement drawing for bus duct
Design calculations for short circuit withstand capability.
Painting details.
Test procedure
Test certificates
Control schematics with space heating circuit

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DG Set
General arrangement, layout drawing and Section
Single line diagrams
Foundation plan, loading & fixing details
Protection & Synchronising scheme diagram
Sizing calculation for various equipment
General arrangement of ventilation system
Equipment control schematics
Wiring diagrams & terminal list for all equipment

Cables
Technical Parameters
Catalogues.
Derating factors

Switchgear
Dimensional General Arrangement drawing
Single line diagram & Schematic wiring diagrams
Relay setting calculation.
Sizing Calculation for busbar
Foundation Plan & loading details

UPS
Dimensional General Arrangement drawing of UPS.
Dimensional General Arrangement drawing for Batteries
Dimensional General Arrangement for Distribution board.
Schematic & Wiring diagram for UPS.
Sizing calculation for Battery.
Foundation plan & Loading details

Switchyard
General arrangement, layout drawing and Section
Design Basis
Single line diagrams
Equipment layout for Control Building
Complete technical particulars
Foundation plan, loading & fixing details
Protection & Synchronizing scheme diagram
CT/VT sizing calculation
Relay co-ordination & setting calculation
Civil & Structural design calculations
Civil & Structural drawings
Sizing calculation for various equipment
Equipment control schematics
Wiring diagrams & terminal list for all equipment

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Cable Schedule
Interconnection Schedule
Cable routing layout
Earthing drawings
Lightning protection drawings
Illumination drawings

Motors
Dimensional General Arrangement drawing
Characteristic curves
Terminal box details

4.05.00 Controls & Instrumentation (C&I)

Level-II PERT for C&I system.
Purchase specification for PLC, and all other C&I equipment
Plant design manual
Grouping philosophy of control loops in controllers.
PLC configuration drawing / system architecture drawing including
HMI.
Control room layout / Utility Local panel
Loop schematics

Engineering documents:

Bill of quantity for PLC
Input / Output list (PLC I/O list)
Instrument list.
Drive list / Solenoid valve list
Annunciation list
I/O Assignment
Hardware and software design manual (covering exhaustive details of
compete PLC engineering).
Control schemes / logic diagrams for Main Plant / Package systems.
Factory Acceptance Test (FAT) procedure / Availability test
procedure/ PG test procedure for all C & I equipment.
Process & Instrumentation Diagram (PID) indicating primary sensors
and secondary instruments, destination reference (alarm, control etc)
for main plant and for each Utility Package.
Installation sketches and Installation isometric drawings
Process mimics indicating Analog and digital parameters
List of logs with point assignment & format of logs and reports
Cabling philosophy
Cabling scope diagram
J unction box schedule

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Cabinet / Panel wiring diagrams and internal layout drawings
Cabinet / Panel terminal details
Wiring diagrams for panel, local panel, junction boxes, actuators,
starters etc.
QAP for all equipments
GA drawings of control panel / local panel
Annunciator window inscription
Essential & start-up Spares list
Heat load and Power consumption data for PLC.
UPS distribution drawings
List of J B.

Notes:
i) All engineering documents shall be in Owner/Purchaser / Consultants
formatted be furnished after award of contract.

ii) The format and point details for logs and process mimics shall be
considered approved only while taking over of the system.

4.06.00 Civil & Structural

The following documents are to be submitted for the approval of the
OWNER/PURCHASER, prior to commencement of fabrication & erection
/ construction. All drawings shall be of standard sizes (Metric system) and
shall be made on AUTOCAD. The list is not exhaustive but indicative
only:

Design calculations and drawings for foundations / substructure and
superstructure of all buildings including pump houses, Air cooled
Condenser and other structures.
Design calculations including dynamic analysis and drawings for all
foundations subjected to dynamic loads like foundations for ACC.
Design and drawing of vibration isolation system shall also be
furnished.
Drawings of all architectural works including finish schedule, colour
scheme (both internal and external), doors and windows, flooring and
false ceiling, architectural facia and projections, coping, flashing,
water proofing, roof decking, wall cladding, rain water down comers,
sanitary, plumbing, etc.
Design calculations and drawings for plumbing and building drainage.
Design calculations and drawings for structures for raw water / make
up water system such as, but not limited to, intake, raw water
reservoir, pump house, over head tank, etc.
Design calculations and drawings for structures and foundations in
switchyard, transformer yard, etc.

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Design calculations and drawings for structures and foundations of
ACC including condensate storage tank, supporting structures
loading of exhaust duct from TG building to ACC.
Design calculations and drawings for structures pertaining to Cooling
water system.
Design calculations and drawings for civil structures / works
associated with fuel oil handling system, ash handling system, coal
handling system.
Detailed hydraulic calculations, designs & drawings for CW system,
effluent treatment plant, water treatment plant.
All other designs, details / drawings or any other submissions as
indicated elsewhere in this specification and as required by the
Owner/ Purchaser.
Details of corrosion protection measures for all structures.
All design and drawings for the Cooling towers.
Design calculations for important joint / connections for structural steel
works. Shop drawings/fabrication drawings of all structural steel
works- only for reference.
As built drawings with quantities of various items of work-system wise,
building wise, structure wise etc. duly certified by site after execution
of work for information/record.
Construction and erection procedure for all major structures with
specific reference to main plant building, bunker structures, transfer
towers, conveyor galleries, TG foundation and other machine
foundations, Boiler, Chimney, Cooling Towers, ACC etc.
Specifications, design & drawings for profiled roof metal deckings and
metal claddings
Write up on various statutory requirements and their compliance for
various buildings and facilities.
Copies of all reports on investigation and studies carried out by the
CONTRACTOR as per the scope.

4.07.00 Other documentation

Schedules of workshop tests
Quality assurance manuals
Manual of Codes and Standards
Operating manual
Operating procedures and instructions of the Plant with description of
all systems, processes and functional groups, as built documentation,
general and individual control concept description, Plant and
equipment protection and signal processing description with all alarm
and trip signal settings, all operating conditions including electrical
grid supply and connection conditions
Service and maintenance manual, maintenance procedures and
instructions with description of all equipment and facilities

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The schedule of submission of above contract drawings shall be
furnished with the bid which shall be discussed and finalized with the
successful Bidder prior to the award of contract.

Categorization of documents for approval and information shall be
indicated. Owner/Purchasers Engineer shall give the comments on the
documents within 6 days of receipt of the documents in Hard copies.
Similarly, re-submission of the documents by the Contractor shall be done
within 6 days subsequently.

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ANNEXURE - IX
LIST OF MANDATORY SPARES
Sr.
No.
Description Unit Quantity
A ACC unit
Low vacuum condenser protection device
(set of internals required to complete one
protection device assembly except for
housing)
1 set

Vacuum breaker valve 1 no.
Condenser manhole cover gaskets (set
comprising of complete replacement for one
condenser)
1 set

Level gauge glass with packing 1 no.
Instrumental source valve 1 set
Condenser tubes 10%
Tube plugs 10%
Gaskets 2 sets
Nozzles for ejector of vacuum pump (set
comprising of complete replacement for one
vacuum pump)
1 set
Condenser air evacuation pump (complete
set of spare internals required to form one
pump except for pump body)
1 set

B Thermal Insulation Refractory, Lagging
and Cladding
5%
of the total quantity/
population used
for each type, size
and class with
minimum : 2 nos.
C Low Pressure Piping System
Valves 5% of the total
population of each
type, size and class
or minimum 2 nos. of
each type, size and
class whichever is
higher
D Electric Hoists
Brake linings 2 sets of each type
Rope guide and rope tighter 1 no. of each type
Limit switch 2 nos. of each type
and size
E Miscellaneous valves(Specifically not
covered)
10% of each type
and size with
minimum

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one (1) no.
E ACC Fan
Gear box Set 1
Fan drive shaft Nos. 1
Fan blade assembly Set 1
Fan bearings Sets 2
Motor Bearings Sets 2
Oil seal I/O rings % 50% of total
requirement
F Piping / Fittings & Valves
Pipes 5% of total straight
length for each size
and material grade
of pipe
Gaskets 100% total
requirement of
gaskets
Fasteners (Flanges, Unions, etc.,) and
fittings
10% of total
requirement
of fasteners
Hangers and supports 5% spare spring box
assembly
for each type and
rating of
spring provided
Pipe clamps 20% spare pipe
clamp /
attachment for
each size
& category.
G Valves(Gate, globe, check, Diaphragm
and ball type etc., except butterfly val ves)
10% or minimum 2
nos (whichever is
higher) of valves for
each size, type,
rating and MOC
H Spares for Long Travel Unit
Set of Axle Bearings 1 set for each Crane
Set of Gearbox bearings with sleeves 1 set for each Crane
Long Travel end shaft bearings 1 set for each Crane
Coupling Set 1 set for each Crane
Seals for Travel Gear box 1 set for each Crane
Long Travel Brake shoes lining 2 sets for each
Crane
All oil seals for all gear boxes 1 set for each Crane
I Spares for Cross Travel Unit

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Axle Bearings 1 set for each Crane
Set of Gearbox bearings with sleeves 1 set for each Crane
Set of seals for Gearbox 1 set for each Crane
Cross travel end shaft bearing 1 set for each Crane
Coupling 1 set for each Crane
Cross travel brake shoes lining 2 sets for each
Crane
All oil seals for all gear boxes 1 set for each Crane
J Spares for Hoist
Hoist Pulley Bearings 1 set for each Hoist
Set of Bearings for Gear box 1 set for each Hoist
Set of seals for Hoist 1 set for each Hoist
Hoist Brake Shoes 1 set for each Hoist
Hoist Brake Springs 1 set for each Hoist
Hoist Brake shoe liners 1 set for each Hoist

K Electrical Equipment
415 V Motors
Bearings : 2 sets of each type
and size of 5%
whichever is higher
Actuators
Torque switches : 3 nos. of each type
Limit switches : 3 sets of each type

415 V PCC

Bus bar support insulators of each type

4 Nos

Breaker control switches

2 Nos.

Indicating lamps/LEDs

8 Nos of each type

CT's of different ratings

2 sets

Control fuses of different ratings

4nos of each rating

Power fuse of different ratings

4 Nos of each rating

Breaker closing coil

4 Nos.

Breaker tripping coil

4 Nos.

Breaker fixed contact assembly

2 sets for different
capacity

Spring charging motors

2 Nos.

Arc chutes of each type

4 sets

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Arcing contacts fixed and moving type

2 sets

Power contacts of each type (a) fixed, (b)
moving

2 sets

Auxiliary contact assembly

2 sets

Relays of each type

2 Nos. each

Thermal over load relay of each rating

2 Nos. of each rating

Current & voltage transducer

2Nos each

Terminals for outgoing

20% of installed
quantity
415 V Motor Control Centre / DB

Switches / MCCB : 5% of total quantity
Fuse (Power & Control) : 10% of total quantity
Thermal overload relay : 10% of total quantity
for each type &
rating
Contactor : 10% of each rating &
type
Indication lamp : 10% of total quantity
Control transformer : 10 nos.
Bimetallic type thermal overload relay of each
type
10 %

Under voltage relay (2 pole) 2 Nos.

Over voltage relay (2 pole) - DO -
3-pin plug socket - DO -
VTD/CTD (current/voltage transducer with
dual output).
- DO -

Cables
Cable jointing kits and straight through joint
kits
5% of each type of
the total quantity
Cable glands and lugs 5% of each type and
size of the total
quantity
Illumination
Lamp 10 % of each type
Ballast and capacitor 10 % of each type
MCB/ HRC fuse 20 % of each type

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Variable Frequency Drive
Cell inverter 2 no.
Printed Circuit Boards of each type 2 no.
Fuses of each type & rating 2 no.
Power supply units of each type 2 no.
Cooling fan for panel 2 no.

L CONTROL & INSTRUMENTATION
Pressure gauge Minimum one(1)
number or 10%of each
type/model/size and
range ,whichever is
higher
Temperature gauge Minimum one(1)
type/model/size and
range ,whichever is
higher
Flow indicator Minimum one(1)
type/model/size and
range ,whichever is
higher
Flow switch Minimum one(1)
type/model/size and
range ,whichever is
higher
Pressure switch Minimum one(1)
type/model/size and
range ,whichever is
higher
Temperature switch Minimum one(1)
type/model/size and
range ,whichever is
higher
Level Gauge Minimum one(1)
type/model/size and
range ,whichever is
higher
Level switch Minimum one(1)
type/model/size and
range ,whichever is
higher
Solenoid valve Minimum one(1)

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type/model/size and
range ,whichever is
higher
Flow transmitter Minimum one(1)
type/model/size and
range ,whichever is
higher
. Air Filter Regulator Minimum one(1)
type/model/size and
range ,whichever is
higher
.
Temperature Element(RTD) with Thermowell
Minimum one(1)
type/model/size and
range ,whichever is
higher
.
Air Filter Regulator
Minimum one(1)
type/model/size and
range ,whichever is
higher
.
Instrument J unction Box
Minimum one(1)
type/model/size and
range ,whichever is
higher
.
Flow meters
Minimum one(1)
type/model/size and
range ,whichever is
higher
.
Any other instruments supplied
Minimum one(1)
type/model/size and
range ,whichever is
higher
. Any other Electronic module

Minimum 2nos or 10%
of total quantity of
each type & range,
whichever is higher
. I&C/ Special Cables 10%
. Process connection hardware 10% of each type
.
Valves of all types and models
5%or 2no.of each
type,class,size and
model whichever is
more
.
2way,3way,5way valve manifolds
10%or 2no.of each
type,class,size and
model whichever is

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more
.
Fittings
10%or 2no.of each
type,class,size and
model whichever is
more

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ANNEXURE - X
TRAINING REQUIREMENTS

1.00.00 General

The Contractor shall be responsible for the instruction and training of the
Owners operation and maintenance personnel identified by the
Owner/Purchaser in all aspects of plant design, construction, erection,
commissioning, etc and in such a way that operation, maintenance and if
necessary repairs of all the power plant equipment and facilities specified
can be handled competently by said personnel.

Such training of the Owner's personnel shall be performed

in Contractor's and/or sub-contractors/manufacturers' home office
and/or workshops.

in similar power plants and such power plants which are under
erection and commissioning as well as at the proposed similar Power
Plant by using the training simulator.

on the job site by the Contractor's and/or his sub-contractors,
supervisors and/or instructors deputed to the site for supervision of
erection, commissioning, testing and trial operation and/or by
specialized training instructors.

at the Power Plant by the supervisors deputed to the Plant during the
Warranty Period.

in compliance with the provisions of the Contract and the
requirements of this specification.

The personnel required for the safe and efficient plant commercial
operation and maintenance of the various types of equipment installed
will be provided by the Owner in accordance with the recommendation to
be made by the Contractor.

The training will be performed in English and/or hindi language.
Translators/interpreters will be provided by the Contractor.

The Contractor's instructors shall use modern training techniques,
procedures and aids and make available to the trainees all required
notes, manuals, drawings, etc, to supplement the Operation and
Maintenance Instruction Manuals.

The Bidder/Contractor shall provide with his tender a detailed description
about the recommended training services, including:

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Number, category, seniority, required experience, profile required etc.
of the trainees.
Preliminary training program.
Training facilities, training aids, places of training etc.
Training schedule.
Specialty and details of lectures and training.
Duration of training courses for all kind of training activities, at works,
classroom, on the job site, at the proposed Power Plant etc.

The recommended training program should be based on the
organizational and staff structures of coal fired power plants already in
operation in India, and should take into consideration not only the training
for operation and maintenance staff, such as operators, skilled workers,
foremen and technicians etc, but also for senior staff and key personnel
employed for the management and organizational duties of the various
power plant decisions.

Total instruction prices (all inclusive, taking into account the provisions
specified in the following clause) for the training of the Owner's personnel
in the Contractor's country, in similar plants, at the Contractor's works and
works of Contractor's sub-suppliers, on the job site and at the Power
Plant site shall be given by the Bidder, based on his recommended
training program.

Personnel selected by the Owner for commissioning and operation are
required to be trained at the locations convenient to the supplier so that at
the time of commissioning and operation those personnel will have
capability to handle all emergencies/normal operations.

2.00.00 Contractor's Obligations and Tasks

The Contractor shall make every effort to train the Owner's personnel so
that they can be qualified for the management, operation and
maintenance of the Contract Plant.

The Contractor shall nominate a person in charge of organization and co-
ordination activities for training.

The Contractor shall select instructors with proper experience and
skillfulness and English speaking to train the Owners personnel.

The training program will be carried out according to the requirements of
each specialty. It will consist mainly of but not limited to the following:

1. Systematic explanation in a classroom of specific subjects, such as
the equipment performance, construction, main systems, auxiliary
systems, etc.

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2. Visit to power plants.
3. Practical training on simulators.
4. Supply of all necessary training documentation (such as books,
manuals, drawings), equipment, tools and instruments etc.

3.00.00 Owner's Responsibilities

The Owner shall appoint a person as official representative for the
Owner's trainees.

The trainees shall understand the English language and shall follow the
training courses with due diligence.

4.00.00 Training schedule and program

The program for the Owner's personnel will be defined during the liaison
meetings.

Two (2) months before the arrival of the first group of the Owner's
personnel in training site the Owner shall inform the Contractor of the
date when the Owner's personnel are expected to be sent to training site.

Within Two (2) weeks after receipt of the Owner's information mentioned
above, the Contractor shall confirm its agreement or indicate difficulties.

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APPENDIX - A
APPROVED VENDOR LIST

Bidder to note that the following list of approved vendors is as per EPC tender document
of OWNER (MCCPL). Any Vendor other than mentioned in the list below will not be
acceptable Bidder shall approach IOTL for addition of any other vendors along with
complete credentials, experience of operating power plants etc and other details (IOTL
in turn will take approval from MCCPL).

MECHANICAL AND GENERAL VENDOR LIST

Components / System Preferred Vendors
Air cooled condenser, tube
bundle and main equipments
Gactel Cooling Tower Technologies.

GEA Cooling Tower Technologies.
GEI Industrial Systems Ltd.
BDT Engineering Ltd. Chennai
SPIG International.
International Coil Ltd.
Thermax SPX
Energo Engineering Projects Ltd.
Paharpur cooling towers limited.
Indus Theco PVT Ltd, Mumbai.
J ord Engineers, Baroda.
Gear Box Elecon Engineering Co. Ltd.
Fiender Macneill
NAW
New Allenbury
Premium Energy( Greaves) Transmission Ltd
Shanti Gears
Sumitumo
Vallabh Vidyanagar, Gujarat.
Vulcan
Horizontal centrifugal pump Beacon Weir Ltd,Chennai
Flowmore Private Ltd,Chennai.
J ohnson Pump (India) Ltd,Mumbai.
J yoti Pumps, Vadodara
Kirloskar Brothers , Kiroskarwadi
KSB Pumps Ltd, Pune
Mather & Platt, Pune
Microfinish, Hubli
Process Pumps (I) Pvt Ltd,Bangalore.
Sam Turbo Industries Ltd,Coimbatore
Sulzer Pumps, Mumbai
Sump Pump Aquq
Kirloskar
Kishor
KSB
SAM
SU Motor

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Components / System
Preferred Vendors
Carbon Steel Pipes
Bharat Heavy Electricals Limited, New Delhi

Dodsal Indmag Pvt. Ltd., Chennai

DSC Pipes & Tubes (P) Ltd., Delhi

Electro Steel Castings Ltd., Kolkatta

Hindustan Pipes And Fittings, Chennai

J aybee Tubes And Engineering Co., Mumbai

Kalyani Steels Limited, Pune

Madras Steels & Tubes, Chennai

Maharashtra Seamless, Chennai

Mahavir Metals (India), Chennai

Metalinox India, Mumbai

Motilal Laxichand Sanghavi, Mumbai

Navkar Fittings & Forgings Pvt. Ltd., Mumbai

Prithvi Steel & Engineering Co., Mumbai

PSI Holdings Limited, Mumbai

Rajendra Industrial Corporation, Mumbai

Sai Steel Tube Traders, Chennai

Sevantilal & Co., Mumbai

Sreevatsa Tube Corporation, Chennai

Sri Krishna Enterprises, Chennai

Steel Authority of India Ltd., Chennai

Steel Tube Company (South), Chennai

Sumit Industries, Chennai

Vinayaka Tube Syndicate, Chennai
ERW and GI Pipes DSC Pipes & Tubes (P) Ltd., Delhi
PVC pipes Finolex
J ain
J ain Irrigation Systems
Precesion
Supreme
Trubore
Pipe Fittings - Carbon Steel Alfa Laval (India) Ltd., Pune
Awaji Sangyo, Thailand
Butt-Welds (India) Pvt. Ltd., Chennai
DSC Pipes & Tubes (P) Ltd., Delhi
Fluid Controls Pvt. Ltd, Mumbai
Gujarat Infrapipes Pvt. Ltd., Baroda
Hyd-Air Engineering Works Goa, Goa
Impex Steel Corporation, Mumbai
J aybee Tubes and Engineering Co., Mumbai
Mahavir Metals (India), Chennai
Metalinox India, Mumbai
Neo Impex Stainless Pvt. Ltd., Mumbai
Pipare Tubus Fabricare, Chennai
Resistoline (India) Private Limited, Mumbai

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Sai Steel Tube Traders, Chennai
Sumit Industries, Chennai
Sungkwang Bend Co., Ltd., Korea
Tubes & Valves Manufacturing Company, Chennai
Flanges Fivebros Corporation, Mumbai
Hawa Industries Pvt Ltd, Thane
HPF Energy Services, Scotland
J ameel Trading Company, Chennai
Kunj Forgings, Ghaziabad
Mahajan Enterprises, Pune
Perfect Services (Madras), Chennai
Rajdeep Metals, Mumbai
Sanjay Forge, Mumbai
Venus Fittings & Valves Pvt. Ltd., Mumbai
Butterfly Valves
Audco India Limited, Chennai

BDK Marketing Service Pvt. Ltd., Hubli

Crescent Valves Manufacturing Company, Mumbai

CRI Pumps Private Limited

Fluidline Valves Co. (P) Ltd., Ahmedabad

Fouress Engg. (India) Limited, Mumbai

Grace Engineering Company, Gujarat

Hawa Engineers, Mumbai

Inter Valve (India) Pvt. Ltd., Pune

J ash Engineering Ltd. Indore

KSB Pumps Limited, Mumbai

Micon Engineers (Hubli) Pvt. Ltd., Hubli

Micron Valve (India) Pvt. Ltd. Mumbai

Saunders Valves (I) Ltd., Pune
Gaskets
DIP-Flow Engineering & Co., Ahmedabad

Dynamic Gaskets Pvt. Ltd. Chennai

Goodrich Gasket (P) Ltd., Chennai

Placon Agencies, Chennai

S.M.Engineers, Vadodara
Piping Supports
Pipe Supports India Pvt. Ltd., Chennai

Sarathi Engineering Enterprises., Hyderabad

Techno Industry, Howrah
Pipe Hangers
Larsen & Toubro Ltd., Chennai
Wrapping & Coating material for
Corprotex
under ground piping
IWL

Rustech

Shalimar
Underslung crane (upto 5T) Armsel Mhe Pvt. Ltd
Hark Engineeers
Hubenkraft
Morris
Unicon Technology International (P) Ltd
Semi-goliath crane Electromech Material Handling Systems (I) Pvt. Ltd.

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Grip Engineers Pvt. Ltd
Electric hoist Century Crane Engineers(P) Ltd
Electromech Material Handling Systems (I) Pvt. Ltd.
Elephant
Grip Engineers Pvt. Ltd
Reva
Chain pulley block Armsel
Elephant
Herculus Hoist Ltd, Mumbai
Indef
Morris
RD Verma
Tractel
WH Brady & Co. Ltd
Larger size expansion joints Cori Engineering, Chennai
Dwren Ltd, Calcutta.
Smaller size expansion joints B.D.K Marketing Services Private Ltd, Chennai.
BHEL
Cori Engineering, Chennai.
Dwren Ltd, Calcutta.
Flexicon Bellows & Hoses Pvt Ltd, Baroda.
GBM Manufacturing (P) Ltd, Kolkatta
Hydra India Flex, Kolkatta
Kanwal Industrial Corporation, Uttar Pradesh
KE Burgmann Flexibles India Pvt. Ltd., Chennai
Lone Star Industries, Chennai
Metallic Bellows (I) Pvt Ltd, Chennai
MIL Industries Ltd,Chennai.
Ratiswar Udyog
RM Applied Engineers, Mumbai
RRD Decors Pvt Ltd,Calcutta.
Stanfab Engineering Pvt. Ltd., Baroda
Supreme Mill Stores, Mumbai
Sur Industries Private Limited, Kolkatta
Structural Steel J INDAL
SAIL
TATA
Akzo Nobel Coatings (India) Pvt. Ltd
Ameron
Asian Paints (India) Ltd, Chennai.
Berger Paints India ltd, Calcutta.
Bombay Paints Ltd
Chugoku J enson & Nicholson Ltd, Mumbai.

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Continental Coatings Pvt. Ltd, Chennai.
Coramandel paints & Chemicals Ltd, Chennai.
Coramandel Paints & Chemicals Ltd.
Goodlass
Hempel Marine Paints
J enson & Nicholson Ltd, Chennai.
Nerolac Paints Ltd.
Rajdoot
Shalimar Paints Ltd, Chennai.
Sigma Marine Protective Coatings (India) Pvt.

Special Paints Ltd, Mumbai.

Vendor for items not indicated in the list above such as fan assembly, drive shaft etc.
shall be finalized during ordering as per Bidders vendor list.

Suggested Vendor List for C&I

Sr. No. Equipment Suggested Vendor
1. PLC GE /ALLEN BRADLY / SCHNEIDER / SIEMENS
2. SMART TRANSMITTERS
(PT/DPT)
ABB/HONEYWELL/EMERSON PROCESS
MANAGEMENT/YOKOGAWA
3. PRESSURE GAUGE
/TEPERATURE GAUGE
AN INSTRUMENTS PVT LTD/GENERAL INST
CONSORTIUM/MANOMETER INDIA PVT
LTD/WIKA INSTRUMENTS INDIA PVT. LTD/H.
GURU INDUSTRIES/WAAREE INSTRUMENTS
LIMITED
4. RTD & THERMOCOUPLE ALTOP/DETRIV INSTRUMENTS,MUMBAI
/GENERAL INST CONSORTIUM/TEMPSEN
DEVICE
5. INSTRUMENTATION
CABLES

CABLE CORPORATION OF INDIA LTD./CORDS
CABLE INDUSTRIES PVT. LTD./FINOLEX CABLES
LTD./FORT GLOSTER

6. LOCAL CONTROL PANEL ENPRO ENGINEERING/PANAM CONTROLS /
RADHA KRISHNA CONTROLS,KOLKATA/RITTAL

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VOLUME II
PART - A
SPECIFICATION: M1
AIR COOLED CONDENSER SPECIFICATION

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I N D E X


1.00.00 General


3.00.00 System Description

4.00.00 Operating conditions

5.00.00 Design Features

6.00.00 Layout

7.00.00 Construction features

8.00.00 Instrumentation and control

9.00.00 Inspection & Testing and manufacturers works

10.00.00 Test at site

Annexure-1 Heat and Mass Balance Diagram

Annexure-2 Data Specification sheet for ACC

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M1: AIR COOLED CONDENSER SPECIFICATION

1.00.00 GENERAL

This specification is intended to cover the design, manufacture,
assembly, testing, packaging for transport, transportation to site,
receiving and storage at site, erection, performance, testing and
commissioning of the Air Cooled Condenser Plant (hereinafter
referred to as ACC plant), complete with all accessories as specified
herein and as necessary for efficient and trouble-free operation.

2.00.00 CODES AND STANDARDS

The design, manufacture and testing of the equipment covered by this
specification shall, unless specifically stated otherwise, conform to the
latest editions of the standards and codes (along with all addenda)
mentioned below.

2.01.00 A.S.M.E. Boiler and Pressure Vessel Code-Sec VIII Div. 1 and Sec. IX.

2.02.00 Heat Exchanger Institute (HEI) for steam surface condenser and
performance standard - Liquid ring vacuum pumps

2.03.00 A.N.S.I. Standard Code for Pressure Piping B 31.1 - Power Piping.

2.04.00 A.N.S.I.B-16.5 Standard Code for Steel Flanges and Flanged Fittings.

2.05.00 IEC:34-12 Three Phase Induction Motors.

2.06.00 Instrument Society of American Standards for all instruments.

2.07.00 API-610 - Techical requirements for rotodynamic special purpose pumps.

2.08.00 IEC relevant standard for PVC cables.

2.09.00 ASME PTC-30.1 / VGA R-131 (German standard),

2.10.00 TEMA standards,

2.11.00 HIS standards

3.00.00 SYSTEM DESCRIPTION

3.01.00 The project envisages air cooling for the condensation of the steam
exhausting from the steam turbines. One independent air cooled
condenser (ACC) with all the auxiliaries, designed meet the requirement
of the specification, shall be provided for 300 MW unit.

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3.02.00 The air cooled condensing plant shall convert the exhaust steam from the
turbine exhaust to condensate and then deliver the condensate to the
turbine exhaust box. The exhaust steam from the steam turbine enters
the air cooled condenser steam header through steam ducts from TEB.
The steam from the steam header flows down through the inside of the
finned tubes arranged in bundles in A frame. With air from the fans
forced over the tubes and fins, the steam flowing inside the tubes is
condensed and the condensate is collected in the condensate headers
located at the bottom of the A frame. The condensate from the headers
shall be collected in the TEB. TEB act as hotwell also at the bottom. TEB
provides the suction source for two 2 x 100% capacity (one pump
operating, one on stand-by-mode) condensate extraction pumps. The
condensate flow from the pumps shall be sent through the CPU, gland
steam condenser and LP Heater to the deaerator. The non-condensables
collected in the tube bundles shall be evacuated by the vacuum pumps.

3.03.00 Refer Annexure - 1 indicating HMBD received from BTG contractor
(CWPC).

3.04.00 Condenser Connection to the TG Exhaust

3.04.01 The steam turbine exhaust box (TEB) will be provided by CWPC at the
terminal point. Further, ACC supplier will provide an expansion joint of
stainless steel construction and carbon steel piping. The condenser
connection arrangement and its internal construction shall be subject to
approval by the turbine manufacturer. A corrosion allowance 3.2 mm
minimum will be provided for carbon steel plates. The design will ensure
that the forces and moments transferred to the exhaust hood including
those arising from ducting connected to the condenser are within the
permissible limit specified by the turbine manufacturer. Refer drawing no.
11V02-201-DWG-M-FS01, indicating the system which will be provided for
the project.

3.04.02 TEB itself act as Hotwell tank and condensate tank, thereby, eliminating
the requirement of drain pumps also. Terminal point from CWPC will be
steam side and condensate side in TEB, steam piping drain in the TEB
and vacuum line connection at TEB nozzle. CWPC will provide CEP with
auxiliaries and its integral piping at turbine building ground floor, close to
the TEB hotwell.

3.05.00 Turbine exhaust box (TEB) complete with all the mountings like level
gauge, transmitter, switches, safety valve will be provided by CWPC. TEB
will collect all the drains from turbine, GSC, heaters, piping etc. In this
case, CST, Hotwell and drain pumps are not envisaged. TEB details
drawing in English language is awaited from CWPC which will be provided
after receipt of the same.

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4.00.00 OPERATING CONDITIONS

4.01.00 The equipment shall be suitable for outdoor installation.

4.02.00 Clean and oil free Compressed air for instrumentation and control will be
supplied at a pressure of 5.0 kg/cm
2
.

4.03.00 The air cooled condenser shall be designed for steam exhaust
parameters corresponding to 105% of turbine MCR (VWO) steam flow (as
indicated below), back end pressure at steam turbine flange as 0.22 bar
(a) at 40 Deg. C ambient temperature without considering the 5% heat
load margin on heat transfer area and 10% plugging margin. Additional
surface area shall be provided to meet these margins.

4.04.00 The air cooled condensers shall be compatible of working between min
and max. specified ambient air temperature. The air-cooled condenser
shall also be designed to ensure unit peak load under specified
conditions. The bidder shall submit a characteristic curve of the air cooled
condenser for above mentioned range of temperature.

4.05.00 Regulation of air flow to compensate for varying steam loading and
ambient temperatures may be achieved by the following types of control.
1. Cutting out of fans.
2. VFD drive of fans

Bidder to optimize and indicate the % of VFD fans out of total fans
required for efficient operation throughout the year meeting specification
design criteria. Accordingly, VFD % shall be finalized before ordering.

4.04.00 The design of the condenser shall avoid condensate sub-cooling under all
operating conditions including part load.

4.05.00 Following details will be provided to the Bidder at a later date after receipt
of the same from BTG supplier (CWPC).
Flash steam from drains from heater / GSC / Drain cooler
HP-LP bypass operation mode heat load details.

4.06.00 Following key parameters has been discussed with the bidders in the pre-
bid meeting.
% of fans to be provided with the VFD drive for meeting technical
requirement indicated elsewhere.
As per discussion pre-bid meeting, Vacuum pump intercooler cooling
water shall be supplied from ACW system at 33 Deg.C.
As per discussion in pre-bid meeting, Vacuum pump seal water make-
up shall be provided from DM system.

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As per discussion in pre-bid meeting, Vacuum pumps will be located
below ACC and Electrical room will be located below or close to ACC
as per standard practice followed by Bidders.

5.00.00 DESIGN FEATURES

5.01.00 The condensing system from turbine exhaust box to ACC and
condensate back to ACC shall be designed to receive and condense the
whole of the exhaust steam from the turbine, including HP-LP steam
bypass system and drains & vents under all modes of operation. Refer
Annexure-2 indicating design parameters for major equipments.

5.02.00 The air cooled condenser shall be designed for steam exhaust parameters
corresponding to 105% of turbine MCR (VWO) steam flow (as indicated
below), back end pressure at steam turbine flange as 0.22 bar (a) at 40
Deg. C ambient temperature without considering the 5% heat load margin
on heat transfer area and 10% plugging margin. Additional surface area
shall be provided to meet these margins. The heat load for various
conditions shall be as per following details:

Sr.
No.
Parameters VWO 100%
TMCR
HP Heater
Out
HP-LP
Bypass
1
TG Exhaust Flow,
TPH
713.8 679.7 722.9

(#)
490 TPH
at
0.80 MPa,
180 Deg.C
and
2791.06
kJ /kg.
2
TG Exhaust
Enthalpy, kJ /kg
2481.1 2488.6 2487.3
3
Condensate
Enthalpy, kJ /kg
260.2 260.2 260.2
4
TG Exhaust
Pressure, MPa (a)
0.022 0.022 0.022
5
TG Exhaust Temp.
Deg. C
62.17 62.17 62.17
6
CEP discharge
temp. Deg. C
62.64 62.64 62.64
7
Design Amb.
Temp. Deg.C
40 40 40
8
Gland Steam
heater
Condensate, TPH
0.78 0.78 0.78
9
LP Heater
Condensate TPH
20.5 17.8 21.2
10
Flash steam from
drain of heater/
GSC/drain
10 TPH at saturated 0.022 MPa (Normal)
15 TPH LP flash steam and 40 TPH HP flash
steam at saturated 0.022 MPa (Emergency)(#)
Note: # Assumption in absence of data from BTG supplier.

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5.03.00 Vibration and Surge

5.03.01 Vibration of the cooling system structure shall not exceed the
recommendations given in standards as applicable. Mechanical vibration
measured at gear box and motor bearing housing, shall be assessed in
accordance with relevant standards and shall not exceed the limits of the
acceptable assessment level of generally accepted technical standards
under normal operating conditions. Each fan shall be free from harmful
surge or pulse effects arising from gusts of wind or from parallel operation
with other fans.

5.03.02 Plant and equipment shall be designed and constructed to:
(a) Eliminate or reduce the impact of vibration generated by internal
components, e.g. as in control valves, by-pass valves and similar
devices.
(b) Withstand the effects of vibration induced from other sources e.g.
piping connecting to structural steel supports or rotating and / or
oscillating machinery.
(c) Withstand the effects of vibration and / or mechanical or thermal
shock induced internally, e.g as in blow down vessels, by pass
steam dumping devices, etc.
5.04.00 Noise

Refer Specification M0 of this specification.

5.05.00 Design and Operating Conditions

All components of the condenser system and the auxiliaries shall be
designed for full vacuum and the entire system shall be vacuum tight. As
higher pressures above atmospheric pressure may occur, the system
shall be equally designed for 0.2 ata internal over pressure.

5.06.00 Exhaust Steam Ducts

All steam ducting shall be designed so as to minimize vibrations, pressure
loss and noise, and to withstand full vacuum and a maximum pressure of
150 kPa abs (=1.5 bar abs).

Manholes of 600 shall be provided to allow internal inspection and
maintenance of the ducting, while the layout shall permit as far as
practicable visual inspection of the external surfaces.

5.07.00 Condensate drain pot

The condensate coming out of the steam duct / drain tank shall be carried
into the condensate drain pot. The tank shall have a sufficient capacity to
receive all condensate at the start up and all operating conditions.

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5.08.00 Condenser Tube Bundle and Fins

5.08.01 Tubes bundles shall be designed to be rigid and self contained and so
mounted that they expand independently of the supporting structure. The
standard air face velocity (FV) is the velocity of standard air passing
through tube bundle and shall be 1.5 m/s to 3.6 m/s. The tube bundle and
fins shall be as indicated elsewhere in specification.

5.08.02 Air cooled condenser bundles shall be designed in such a way that the
non condensable gases can be extracted effectively. The life of bundles
and fins shall be designed for minimum 25 years.

5.09.00 Air Seals
Air seals shall be used to minimize air leakage and mal-distribution of air
flow.

5.10.00 Automatic Air Side Control
Regulation of air flow to compensate for varying steam loading and
ambient temperatures shall be achieved by an automatic control system.

6.00.00 LAYOUT

The plant shall be located outdoor. The electrical and control equipments
shall be located outdoor below ACC unit. The location has been marked
on the plot plan drawing no. 11V02-201-DWG-M-GA01, Rev. P1 attached
herewith.

The air-cooled condensers shall be arranged on a separate steel
structure. The height of the condenser platform shall be optimised by the
bidder.

Exhaust steam shall be admitted to the condensers via exhaust steam
duct loading out from the turbine hall. The arrangement of the exhaust
steam ducts shall be optimised by the bidder and shall be approved by
the consultant. 7.5 meter road is provided for turbine building approach.
Accordingly, clearance height of 8.0 meter shall be provided above the
same from steam duct.

7.00.00 CONSTRUCTION FEATURES

7.01.00 Steam Ducts

The ducting shall be manufactured from steel according to approved
standards. The supplier shall submit to the Owner the standards which he
intends to use and the Owners approval shall be obtained before
manufacture commences.

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All items shall be free from injurious surfaces defects, laminations, cracks
and other defects and shall be cleanly finished and have the ends cleanly
cut. All sharp edges shall be removed.

The internal duct surface shall be blast cleaned to remove all mill scale,
weld spatter etc. No corrosion protection agent shall be applied to the
internal surface without the written approval of the Owner.

7.02.00 Expansion / Contraction System

Accommodation of thermal movements in the ducting and turbine system
shall be such that the resultant stresses are reduced to a minimum.
Where possible the accommodation of such movements shall be
achieved by using twin articulated expansion bellows, restrained against
axial forces resulting from the internal positive and/or negative pressure.
Bellows shall be installed and shall be suitably designed for operation
over the entire range of back pressure and ambient air temperatures.

At all positions where sliding shall occur at support footings, dry non
friction materials such as PTFE shall be used at the interfaces. The
surfaces of such interfaces shall be flat, smooth and clad with a non
rusting material.

The flexibility of the entire ducting system shall be designed so that
essentially no undue thrusts and moments will be imposed at the exhaust
flanges of the turbine casings under any conditions.

7.03.00 Air Cooled Condenser

7.03.01 The condenser together with the associated cooling air system shall be
optimized by the Bidders. Air cooled condenser shall be designed as per
latest edition of HEI standards. Air cooled exchangers shall be arranged
in banks with several exchangers side by side. The height of tube
bundle above ground must be one half of the tube length to produce an
inlet velocity equal to the face velocity. Fan tip speed as per API
standard shall be limited to 61 m/s (12000 ft/min). The air must be
distributed from the circular fan to rectangular face of tube bundle. Fan
dispersion angle shall be 45 degree maximum, the plenum-chamber
depths shall be arrived at accordingly.

7.03.02 Fouling factors for ACC heat transfer area shall be as follows,

Air side : 0.0001 Hr. m2 deg.K/kcal
Steam/condensate side : 0.00005 Hr. m2 deg.K/kcal.

7.03.03 The selected condenser together with the condenser cooling air system
shall be such that the condenser pressure, corresponding to a sustained

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HP-LP bypass operation (nearly fully open) and turbine operation at
house load at maximum ambient air inlet temperature to condenser,
does not exceed the turbine trip value for the condenser pressure.
Further, the selected condenser together with the condenser cooling air
system shall not cause STG unit capability loss at the minimum
condenser inlet cooling air temperature.

7.03.04 The location and design of steam and water dumps to the condenser
shall be in accordance with ASME Standard TDP-1, Part-1.

7.03.05 The condenser design shall provide for adequate bowing or sloping of
tubes to assure complete drainage of the tubes.

7.03.06 A vacuum grid shall be fitted to ensure that an average reading can be
obtained and the grid shall be fitted 1200 mm below the exhaust flange
of the turbine for measurement of condenser vacuum.

7.03.07 Easy access to the interior of Air cooled condenser for inspection or
maintenance shall be provided by hinged, quick opening manhole
covers. At least one manhole shall be provided in each divided section.

7.03.08 The selection of duct cross section should be such as to optimize the
size of heat exchange surface on account of pressure drop in the duct.
The smaller the size, the greater the steam pressure drop and the
greater the required heat- transfer- surface area in the condenser. The
tradeoff lies between heat-transfer-surface cost and steam-duct cost
and the same shall be optimized by the selected supplier of the ACC
plant. The corrosion allowance of 3.2 mm shall be taken for the duct
and manifold.

7.03.09 In any case, the thermal performance of the Air cooled condenser
shall be measured at the TG exhaust flange (or TEB exhaust flange TP)
and not at the condenser steam inlet manifold.

7.03.10 The design consideration of the condenser shall be such that the lowest
optimum turbine exhaust operating pressure is never crossed to the
lower side in any operating or emergency operation of the system.
Similarly, the highest permissible turbine-exhaust operating pressure
shall not be exceeded in normal operating conditions. As per TG
supplier, the lowest operating TG exhaust pressure shall be 9 kPa. and
highest operating TG exhaust pressure is 65 kPa which shall be trip level.

7.03.12 The steam manifold and header designs should not trap the non-
condensables under any operating conditions, or allow steam back flow in
case of non-operation of any of the shell fan.

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7.03.13 A balance shall be achieved in terms of cost of fan power and the capital
cost of heat transfer area while designing the system so as to freeze the
cost efficient system. Bidder to optimize and indicate % of VFD drive
required for efficient operation of ACC throughout year meeting the
design criteria as per specification without sub-cooling.

7.03.14 The connecting duct between TG exhaust and ACC test pressure shall
be at least 1.3 times the design pressure. The exhaust duct and its
supports shall be designed considering fixed/anchor support just
below turbine exhaust flange connection. In no case any movement
in the duct should reflect on the turbine position.

7.03.15 Connections shall be provided to empty the hotwell (or TEB) from the
normal operating level to the station drains in one hour or less.

7.03.16 The tubes shall be of carbon steel (SA-214). The tubes shall be provided
with aluminium extruded / brazed fins as L fin tubes are prone to galvanic
corrosion because of their bimetallic tube-to-fin interface. Tubes and fins
shall be provided in either of the following options:

Single Row Condenser (SRC) elongated flat CS tube alumunium
coated / HDG carbon steel (of minimum 50 microns) with brazed
aluminium fins / CS HDG fins.

Multi Row Condenser (MRC) round shape HDG (of minimum 50
microns) CS tubes with extruded CS HDG fins. Number of rows in
MRC shall be limited to maximum of four (4).

7.03.17 External protection by installing atmospheric relief valve(s) in the
exhaust steam duct close to the turbine shall be implemented.

7.03.18 All ACC auxiliary pumps/exhausters shall be designed to deliver its rated
capacity when under frequency operation of 47.5 Hz occurs.

7.03.19 Air cooled condenser shall be equipped with combination of normally
operated fans and VFD driven fans, semi automatic (initiation only
manual) fin cleaning system, condenser air removal system.

7.04.00 Condenser Tube Bundle and Fins

7.04.01 The arrangement of the ACC shall be a A frame structure supporting fin
tube heat exchanger bundles, comprising finned tubes, self- supporting,
with welded headers, frames, nozzles, wind & partition walls, two (2)
staircase (minimum 1250 mm), hoists for equipment handling,
maintenance walk way and doors. Provision shall be provided for heavy
rain and strong wind conditions etc.

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7.04.02 Tubes bundles shall be designed to be rigid and self contained and so
mounted that they expand independently of the supporting structure. The
standard air face velocity (FV) is the velocity of standard air passing
through tube bundle and shall be 1.5 m/s to 3.6 m/s. The tube bundle and
fins shall be as indicated elsewhere in specification.

7.04.03 Air cooled condenser bundles will be designed in such a way that the non
condensable gases can be extracted effectively. The life of bundles and
fins will be designed for minimum 25 years.

7.04.04 The shape of the tube and fin arrangement will be such that the hydraulic
resistance to flow inside the tube is low and the tendency for settlement of
dust is minimum. The fin height will be selected keeping in view the
possibility of dust accumulation and effectiveness of cleaning. The fins
will be wound on the tube in a continuous manner.

7.04.05 Provision will be made for thermal expansion and contraction of the tube
bundle, permitting free axial movement and thereby relieving the tubes of
expansion strains even under the most severe conditions. The tube
bundles will be rigid and capable of withstanding cleaning by high
pressure water jets of fin cleaning pump for effective cleaning.

7.04.06 Adequate provision shall be made for taking up differential expansion.
Tubes shall be sloped for proper drainage during shut down. Air cooled
condenser shall be designed in such a way that the non condensable
gases can be extracted effectively.

7.04.07 Some fin tube bundles are connected in a different way. These bundles
(called dephlegmator bundles) are connected at their lower ends to
collector pipes and upper ends are connected to the air evacuation lines.
These dephlegmator tube bundles serves two purposes as follows:

a) To condense certain amount of surplus steam coming from the
condenser module as a result of purposely incomplete condensation.
b) To effect the necessary sub-cooling of non condensable to be
evacuated by air evacuation system.

The design criteria of these dephlegmator tube bundles will be similar to
the main condenser tube bundle except meeting the requirement as
stated above.

7.05.00 Condenser Air Removal System

7.05.01 The condenser air removal system has a dual purpose. To remove the air
that has leaked into the condenser via flanges and glands effectively and
to remove other non-condensable gases those are present in the steam
exhausting from the turbine. The air removal system functions under two

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regimes: One during normal operation, the other when raising vacuum on
the turbine generator unit during start-up.

7.05.02 2 x 100% or 3 x 100% mechanical vacuum pumps and accessories will
be provided for creating vacuum by removing air and non-condensable
gases from steam condenser during plant start-up and operation.
Complete air removal system will be designed as per latest HEI
standards. One vacuum pum will be operating for holding condition and
all the pumps will be operating in hogging condition.

7.05.03 Capacity of each pump shall not be less than 120% of the capacity
obtained from HEI standards. During hogging pump shall be able to
maintain 0.35 kg/cm
2
(a) within 20 minutes with both pumps in operation.

7.05.04 The pumps will be two-stage liquid ring type to meet the design conditions
specified. In case of a two stage pump both the stages will be mounted
on a common shaft. The unit will require no internal lubrication and will
not be damaged by water vapour, entrained droplets or slugs or water.

7.05.05 Each pump with its accessories will be furnished as a packaged unit
mounted on a common steel base and will be complete with all
accessories including but not limited to, the integral piping, cooler, air
ejector, air flow meter, valves, wiring and controls as necessary.

7.05.06 Provision will be made in the design of the equipment to prevent loss of
vacuum by flow of atmospheric air back into the condenser upon
shutdown of the pump.

7.05.07 Not used.

7.05.08 Seal water makeup to the liquid ring pumps will be from ECW header or
DM make-up system through an isolation valve. Intercooler will be
provided with Cu- Ni tubes with SS cage baffle plates and tie rods will be
cooled by ACW water. Bidder to design the system using the ACW and
DM water for intercooler cooling water and seal make-up respectively.

7.06.00 Condenser Fin Cleaning System (initiation only manual)

7.06.01 The system shall be designed to function with the condenser in service. It
shall be designed for effective removal of scales and micro & macro
fouling on the tubes. Only automated cleaning system with manual
initiation shall be adopted. Space requirement shall be kept minimum. The
system shall be complete with all pumps (1W+1S) with integral safety
valve, piping, valves, motors and controls (for manual operation) etc. for
efficient operation of the system. The system shall be PLC based with
local control panel. However, provision for digital inputs to plant
DCS(through remote I/O) shall be kept. Nozzle beam shall be optimally

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matched to tube bundle geometry with a constant jet angle and pressure
of water to be selected to avoid fin and tube surface damage. Cleaning
system shall be provided one on each face of the ACC system.

7.06.02 The frequency of cleaning shall depend on the dirt load in the surrounding
atmosphere and deterioration of the absolute condensing pressure (loss
of vacuum by about 0.05 bar) compared to that obtained with new and
clean tubes and fins. This is a permanently installed system. The cleaning
is initiated manually and controlled from the local panel.

7.07.00 Pipe work and Valves

Piping shall be in accordance with the specification-M4.

7.08.00 Air Moving System

7.08.01 Fans

The fans shall be of low-pressure axial flow with aerodynamically
designed blade profiles. The fans shall not exert any undue vibrations on
the surrounding structure and the condenser. Vibration attenuating
equipment shall be included as necessary. Fans shall be able to operate
and support the MCR conditions even at the maximum summer
temperatures of 50 Deg.C.

Aluminium / FRP blades not requiring retensioning of attachment bolts
due to frottage of the glass resin compound at the attachment end shall
be offered.

Fan tip speed as per API standard will be limited to 61 m/s (12000
ft/min). The fan hub shall be of cast or Hot dip Galvanised Steel.

Fan speed shall be changed from the main control room or by an
automatic control system.

The fan units shall be easily accessible for maintenance and the supplier
shall provide all galleries, platforms, handrails, ladders and lifting gear
necessary for the safe and efficient maintenance and removal of the fan
and fan drive components. During maintenance procedures, there shall
be no danger to personnel from adjacent fan units.

7.08.02 Reduction Gear boxes

The gearboxes shall have sufficient oil lubrication and oil supply during
both speeds of rotation of the fans. The gearboxes shall be leak proof and
the filling connection shall be oil tight when closed. Oil level indication
shall be by easily accessible dipsticks. The gearboxes shall be equipped

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with integral anti-reverse rotation back stops. The gear casing shall be
robust and be made of high grade cast iron. The gearboxes shall be
designed in accordance with DIN 3990 or equivalent with a safety factor
for strength and wear of at least 2.0.
7.08.03 Drive motors

For detailed specification of the electric motors, refer electrical
specification.

7.08.04 At fan deck level, electric operated hoist shall be provided for equipment
handling.

7.09.00 Condensate drain pot

The drain condensate from the exhaust steam ducts shall be let into the
drain tank. The drain tank shall be able to operate safely and perfectly
under all possible conditions. The drain tank can be welded directly to the
exhaust steam duct. The drain tank shall be made of carbon steel and
shall be designed for full vacuum. The water from condensate drain point
shall be sent to Turbine exhaust box (TEB) by gravity.

7.10.00 Air leakage

All parts of the condensing system which are under vacuum will be
required to retain their vacuum tightness over the 25 year life of the power
plant. However, if leaks should occur it shall be possible to locate and
repair such leakages. The supplier shall submit details of the equipment
to locate leakages and repair the condensing parts easily.

8.00.00 INSTRUMENTATION AND CONTROL

For detailed specification of the control system, Vol.II-Part-C- Control &
Instrumentation.

9.00.00 INSPECTION & TESTING AT MANUFACTURER'S WORKS

9.01.00 General

A final inspection shall be made by the Owner's representative before the
dispatch of equipment.

9.02.00 Inspection of Welds

a) All butt welded joints used for fabrication of pressure vessels shall be
examined by spot radiography to the extent of 10% as per para. W. 52 of
ASME Sec. VIII Div.1. The dished end joints shall be fully radiographed
as per W 5.1 of ASME Section VIII, Div.1.

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b) All other welded joints except those mentioned above shall be examined
by liquid penetration examination according to the method outlined in
ASME Sec. VIII Div.1.

9.03.00 Pressure Vessels & Tanks

Inspection shall be carried out at following stages:

a) Identification of plate material to be used for fabrication against test
certificates. In absence of correlating test certificates sample testing for
physical and chemical test shall be conducted by the supplier at his own
cost to prove the quality.

b) Dimension checking for proper fit up before start of welding.

c) Checking of root pass of welding with dye penetrates method for pressure
vessels only.

d) Radiography examination and liquid penetrate inspection of the finished
welded joints to the extent desired.

e) Final dimensional check up for out of roundness, straightness, nozzle
location, etc.

f) Hydro-testing at 1.5 times the design pressure before painting or lining,
as per approval code.

g) In case of rubber lined vessels/piping, the lining shall be tested as per
provisions of AWWA / IS: 4682 STD.

9.04.00 Pumps

a) Material test certificates shall be furnished and checked for all critical
items including casing, impeller and shaft with proper correlation mark.

b) Static and dynamic balancing of the rotating parts.

c) Hydrostatic test of the casing at 1.5 times the pressure at shut off or twice
the discharge pressure under operating conditions, whichever is higher.

d) Performance test to determine head, power, efficiency and NPSH against
capacity for each pump as per approved codes.

9.05.00 Piping & Fittings

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a) All piping and plate material for flanges shall be furnished with suitable
test certificates and proper co-relation. These shall be identified before
proceeding with further fabrication.

b) All fit up shall be checked before start of welding.

c) The final pass of all welding shall be checked by dye penetrant method.

d) Spools shall be checked for dimensions including drilling for flanges.

e) Hydrostatic testing of pipe work and spools before painting or lining at 1.5
times the design pressure.

9.06.00 Field Instruments
a) Calibration test & quality assurance test procedure and test certificates.

9.07.00 Valves

a) Co-relating material test certificates for body & bonnet and compliance
certificate for internal parts shall be furnished.

b) Hydrostatic test for each valve.

9.08.00 Control Panels

The control panel shall be subjected to tests to show that the panels have
been satisfactorily designed and manufactured in accordance with the
relevant standards. Following tests shall be carried out:

a) Visual inspection including dimensional check.

b) Continuity checks for wiring errors.

c) Functional test by simulating working conditions.

d) Insulation resistance test.

e) High voltage test within following test voltage:

i) 2.5 kV for one minute for the main power circuit.

ii) 1.5 kV for one minute for all control circuits.

f) Test certificates for major components inside the panel shall be furnished.

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g) All pneumatic tubing & fittings shall be checked for leaks at 2.5 kg/cm
2

pressure of air.

10.00.00 TEST AT SITE

10.01.00 In addition to the testing indicated in the Specification M0 and other parts
of specification. Following test shall be carried out at site.

Leakage Test
A leakage test shall be performed to prove the air tightness of each
condenser bank by means of pressurized air. The test air pressure shall
be not more than 1.3 bar abs. The holding time is 24 hours. The system
shall be proved for leakages by means of soapy water applied to all
accessible field welds.
B
4.H.E.HP Exhaust
5.GSHgland steam heater
NOTE:
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2.LPHLP feedwater heater
3.DEDeaerator
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D
E F
E G
DE
generator generator generator generator
G
ANNEXURE1: HEAT AND MASS BALANCE DIAGRAM
B
99.49
3
2
1
.
9
7
2
2
.
9
433.4
2
6
.
9
2

T
=
3
.
0

T
=
3
.
0
HPH7

T
=
5
.
6
8
2
2
.
4
2
4
.
0
3
1
0
0
8
.
4
9
2
1
.
6
1
8
3
.
7
2775.4 0.00
4
1
.
4
4
1
4
9
.
8
1
7
0
.
3
1
7
.
5
0
2
5
9
1
.
0
2
5
9
.
2
4
.
2
7
2
8
3
3
6
2
.
6
0
.
4
0
15
7
.
0
9
3
1
6
6
.
9
0
.
9
8
8
1
2
6
2
.
1
7
2
2
.
9
6
2
.
6
4
0
.
0
2
2
0
6
2
.
1
7
29.37
2
4
8
8
.
3
6
7
4
.
8
98.21
79.25
GSH LPH2
26.92 418.0 18.2 332.6
LPH1
0.78
2994.2
0.5111
0
.
5
1
1
1
2
8
1
1
.
1
0
.
1
8
6
7
kW
0
.
1
9
6
5
7
6
.
4
5
2
5
2
.
4
1
1
5
.
1
4
8
4
.
1
2
1
3
.
6

T
=
0
.
0
5
6
.
6
9

T
=
-
1
.
7

T
=
1
.
0
8
2
2
.
4
1
0
0
8
.
4
G
S
H
SD
1
1
0
6
.
0
0
.
4
8
6
6
3
2
.
1
1
0
0
8
.
4
8
7
.
8
9
2
9
3
6
.
0
4.76
G
S
H
SD
540.0
887.0
540.0
3538.0
3.8455
17.75
979.0 3390.6
MCR Conditon ( Makeup 3%)
S
G
S
H
G
S
H
742.7
265.6
SG
S
H
H
.
E
.
DSG
S
H
1
7
9
.
4
8
7
.
8
9
3
3
7
.
7
1
0
0
8
.
4
1
0
0
8
.
4
7
9
0
.
0
7
6
1
.
0
temp
3
0
5
6
.
0
4
.
1
4
4
6
56.69
1
1
2
9
.
9
3054.7
4.2728
3
0
5
6
.
0
337.2
887.0 2
9
.
3
7
3.1344
1
.
0
4
0
1
4
3
.
7
8
0
.
0
4
6
3
2
8
1
1
.
1
2
4
.
0
3
kg/kW.h
2
6
.
9
2
8
0
.
7
2
0
.
0
4
8
8
0
.
1
0
5
8
3
5
3
.
9
312344
8458.1
STG output =
Heat Rate =
2
9
9
4
.
2
2
.
1
1
4
5
3
1
6
6
.
9
4
5
2
.
4
S
2
6
5
.
6
kJ/kW.h
2
7
0
5
.
2
1
1
4
.
6
411.5
6
2
.
8
5
2
6
4
.
8
7
2
2
.
9
0
.
1
0
0
5
2
5
9
8
.
2
0.71
1
8
.
2
1
2
9
1
5
.
1
0
.
0
9
5
1
0
.
7
8
6
2
.
1
7
2
6
0
.
2
7
2
3
.
1
0
.
2
8
8
2
2
.
4
2
7
0
5
.
2
4
0
7
.
0
7
2
2
.
9
9
6
.
8
4
1
0
.
2

T
=
3
.
0
HPH6
87.89 940.7
219.2
144.6
LPH4

T
=
8
.
0
104.8
516.8 805.0
189.3
72.57
123.1 99.8

T
=
8
.
0
48.54 439.1
LPH3
Steam Rate =
enthalpy kJ/kg
pressure MPa(a)

T
=
5
.
6
3
0
2
3
.
7
4
8
.
5
4
3362.6
4
1
.
4
4
flow t/h
2.0511
4.H.E.HP Exhaust
NOTE:
3.DEDeaerator
b
o
i
l
e
r
b
o
i
l
e
r
b
o
i
l
e
r
b
o
i
l
e
r
C
B
A
D B
F
A
C
D
E F
E G
DE
G
B
102.54
3
2
7
.
8
7
3
4
.
8
440.3
2
7
.
7
5

T
=
3
.
0

T
=
3
.
0
HPH7

T
=
5
.
6
8
3
7
.
3
2
4
.
7
3
1
0
3
0
.
0
9
3
3
.
8
1
8
6
.
1
2777.5 0.00
4
2
.
8
2
1
5
1
.
9
1
7
0
.
5
1
9
.
7
2
2
5
9
0
.
8
2
6
2
.
4
4
.
5
0
2
8
3
3
6
1
.
0
0
.
4
2
55
9
.
1
9
3
1
6
6
.
0
1
.
0
4
3
6
2
6
2
.
1
7
3
4
.
8
6
2
.
6
4
0
.
0
2
2
0
6
2
.
1
7
2
4
8
1
.
1
7
1
3
.
8
98.21
80.67
GSH LPH2
27.75 424.9 20.5 338.6
LPH1
0.78
2993.7
0.5405
0
.
5
4
0
5
2
8
1
0
.
9
0
.
1
9
7
6
kW
0
.
2
0
8
0
7
7
.
8
7
2
5
5
.
6
1
1
6
.
8
4
9
1
.
7
2
1
6
.
4

T
=
0
.
0
5
8
.
7
6

T
=
-
1
.
7

T
=
1
.
0
8
3
7
.
3
1
0
3
0
.
0
G
S
H
SD
1
1
2
0
.
7
0
.
5
1
3
6
4
1
.
2
1
0
3
0
.
0
9
1
.
0
8
2
9
3
9
.
7
5.03
G
S
H
SD
540.0
934.7
540.0
3535.9
4.0525
17.75
1030.0 3390.6
VWO Conditon ( Makeup 0%)
S
G
S
H
G
S
H
785.5
265.8
SG
S
H
H
.
E
.
DSG
S
H
1
8
1
.
7
9
1
.
0
8
3
4
4
.
4
1
0
3
0
.
0
1
0
3
0
.
0
8
0
0
.
5
7
7
1
.
5
temp
3
0
6
7
.
7
4
.
3
6
7
7
58.76
1
1
4
4
.
8
3066.4
4.5028
3
0
6
7
.
7
343.9
934.7
3.1480
1
.
0
9
8
5
4
5
.
0
3
0
.
0
4
9
1
2
8
1
0
.
9
2
4
.
7
3
kg/kW.h
2
7
.
7
5
8
2
.
1
4
0
.
0
5
1
6
0
.
1
1
2
1
3
5
3
.
9
327187
8411.2
STG output =
Heat Rate =
2
9
9
3
.
7
2
.
2
3
0
6
3
1
6
6
.
0
4
5
2
.
4
S
2
6
5
.
8
kJ/kW.h
2
7
0
5
.
3
1
1
5
.
0
411.5
6
2
.
8
4
2
6
4
.
8
7
3
4
.
8
0
.
1
0
6
5
2
5
9
7
.
8
0.78
2
0
.
5
0
2
9
1
8
.
0
0
.
0
9
5
1
0
.
7
8
6
2
.
1
7
2
6
0
.
2
7
3
5
.
1
0
.
2
9
8
3
7
.
3
2
7
0
5
.
3
4
1
3
.
9
7
3
4
.
8
9
8
.
4
4
1
7
.
1

T
=
3
.
0
HPH6
91.08 953.3
222.0
149.8
LPH4

T
=
8
.
0
106.4
524.4 815.8
191.7
74.80
124.8 101.4

T
=
8
.
0
50.06 446.0
LPH3
Steam Rate =
enthalpy kJ/kg
pressure MPa(a)

T
=
5
.
6
3
0
2
4
.
8
5
0
.
0
6
3361.0
4
2
.
8
2
flow t/h
2.1637
4.H.E.HP Exhaust
NOTE:
3.DEDeaerator
b
o
i
l
e
r
b
o
i
l
e
r
b
o
i
l
e
r
b
o
i
l
e
r
C
B
A
D B
F
A
C
D
E F
E G
DE
G
B
4.H.E.HP Exhaust
NOTE:
3.DEDeaerator
Steam Rate =
enthalpy kJ/kg
pressure MPa(a)

T
=
5
.
6
3
0
2
2
.
6
5
1
.
5
3
3360.6
4
4
.
1
1
flow t/h
2.1503
77.01
124.5 101.0

T
=
8
.
0
51.53 444.4
LPH3
154.5
LPH4

T
=
8
.
0
106.0
522.8 814.2
191.4
HPH6
93.91 951.9
221.7
8
6
2
.
3
2
7
0
3
.
9
4
1
2
.
3
7
5
6
.
8
9
8
.
0
4
1
5
.
6

T
=
3
.
0
2
9
1
7
.
6
0
.
0
9
5
1
0
.
7
8
6
2
.
1
7
2
6
0
.
2
7
5
7
.
1
0
.
2
9
1
1
4
.
2
411.5
6
2
.
8
2
2
6
4
.
7
7
5
6
.
8
0
.
1
0
5
1
2
5
9
6
.
4
0.76
2
0
.
6
8
S
2
6
5
.
2
kJ/kW.h
2
7
0
3
.
9
0
.
1
1
0
7
3
5
3
.
4
325626
8454.1
STG output =
Heat Rate =
2
9
9
2
.
4
2
.
2
1
6
8
3
1
6
5
.
0
4
5
2
.
1
3.1631
1
.
0
8
9
6
4
6
.
5
2
0
.
0
4
8
4
2
8
0
9
.
6
2
5
.
4
7
kg/kW.h
2
8
.
5
2
8
1
.
8
1
0
.
0
5
0
9
1
1
4
3
.
6
3065.6
4.4842
3
0
6
6
.
9
343.4
931.9 3
0
.
9
0
3
0
6
6
.
9
4
.
3
4
9
6
60.54
H
.
E
.
DSG
S
H
1
8
1
.
4
9
3
.
9
1
3
4
3
.
9
1
0
6
0
.
9
1
0
6
0
.
9
7
9
8
.
9
7
7
0
.
0
temp
VWO Conditon ( Makeup 3%)
S
G
S
H
G
S
H
778.1
265.2
SG
S
H
540.0
931.9
540.0
3536.0
4.0357
17.75
1030.0 3390.6
1
0
6
0
.
9
G
S
H
SD
1
1
1
9
.
6
0
.
5
0
8
6
3
9
.
5
1
0
6
0
.
9
9
3
.
9
1
2
9
3
9
.
6
5.01
G
S
H
SD
2
5
5
.
3
1
1
6
.
5
4
9
0
.
1
2
1
6
.
1

T
=
0
.
0
6
0
.
5
4

T
=
-
1
.
7

T
=
1
.
0
8
6
2
.
3
0.78
2992.4
0.5350
0
.
5
3
5
0
2
8
0
9
.
6
0
.
1
9
5
3
kW
0
.
2
0
5
6
7
7
.
5
3
98.21
80.33
GSH LPH2
28.52 423.3 20.7 337.2
LPH1
2
6
2
.
1
7
5
6
.
8
6
2
.
6
4
0
.
0
2
2
0
6
2
.
1
7
30.90
2
4
8
1
.
5
7
0
4
.
7
1
6
9
.
8
1
9
.
9
1
2
5
8
9
.
5
2
6
2
.
1
4
.
4
8
4
2
3
3
6
0
.
6
0
.
4
1
86
0
.
9
6
3
1
6
5
.
0
1
.
0
3
5
1
1
8
5
.
8
2777.2 0.00
4
4
.
1
1
1
5
1
.
5

T
=
3
.
0
HPH7

T
=
5
.
6
8
6
2
.
3
2
5
.
4
7
1
0
6
0
.
9
9
3
2
.
4
105.53
3
2
6
.
4
7
5
6
.
8
438.7
2
8
.
5
2

T
=
3
.
0
b
o
i
l
e
r
b
o
i
l
e
r
b
o
i
l
e
r
b
o
i
l
e
r
C
B
A
D B
F
A
C
D
E F
E G
DE
G
b
o
i
l
e
r
b
o
i
l
e
r
b
o
i
l
e
r
b
o
i
l
e
r
B
67.03
2
9
7
.
9
5
3
0
.
2
403.5
1
8
.
0
5

T
=
3
.
0

T
=
3
.
0
HPH7

T
=
5
.
6
5
9
7
.
3
1
6
.
3
1
7
1
8
.
0
8
5
9
.
8
1
7
1
.
9
2764.6 0.00
2
7
.
4
7
1
3
9
.
9
1
7
5
.
3
7
.
0
9
2
6
0
7
.
2
2
4
2
.
5
3
.
1
9
3
9
3
3
7
4
.
6
0
.
3
1
43
7
.
2
1
3
1
8
0
.
1
0
.
7
4
9
5
2
6
2
.
1
5
3
0
.
2
6
2
.
6
4
0
.
0
2
2
0
6
2
.
1
7
2
5
3
8
.
6
5
2
2
.
3
98.21
73.53
GSH LPH2
18.05 388.1 7.4 308.6
LPH1
0.79
3007.7
0.3902
0
.
3
9
0
2
2
8
2
4
.
1
0
.
1
4
3
3
kW
0
.
1
5
0
8
7
0
.
7
3
2
3
5
.
6
1
0
7
.
0
4
5
0
.
1
1
9
9
.
7

T
=
0
.
0
3
6
.
9
0

T
=
-
1
.
7

T
=
1
.
0
5
9
7
.
3
7
1
8
.
0
G
S
H
SD
1
0
2
8
.
3
0
.
3
7
1
5
8
9
.
8
7
1
8
.
0
5
6
.
3
6
2
9
1
4
.
8
3.57
G
S
H
SD
540.0
658.5
540.0
3547.7
2.8745
17.75
718.0 3390.6
75% MCR Conditon ( Makeup 0%)
S
G
S
H
G
S
H
563.2
270.5
SG
S
H
H
.
E
.
DSG
S
H
1
6
7
.
7
5
6
.
3
6
3
1
3
.
8
7
1
8
.
0
7
1
8
.
0
7
3
8
.
9
7
1
0
.
1
temp
3
0
2
3
.
6
3
.
0
9
8
1
36.90
1
0
5
1
.
9
3022.4
3.1939
3
0
2
3
.
6
313.3
658.5
3.0683
0
.
7
8
8
9
2
9
.
1
1
0
.
0
3
6
5
2
8
2
4
.
1
1
6
.
3
1
kg/kW.h
1
8
.
0
5
7
4
.
9
4
0
.
0
3
8
5
0
.
0
8
1
6
3
5
7
.
9
234007
8653.9
STG output =
Heat Rate =
3
0
0
7
.
7
1
.
5
9
2
9
3
1
8
0
.
1
4
5
4
.
8
S
2
7
0
.
5
kJ/kW.h
2
7
1
7
.
8
1
1
9
.
5
411.5
6
3
.
0
9
2
6
5
.
8
5
3
0
.
2
0
.
0
7
7
5
2
6
1
3
.
8
0.29
7
.
3
8
2
9
0
4
.
2
0
.
0
9
5
1
0
.
7
9
6
2
.
1
7
2
6
0
.
2
5
3
0
.
5
0
.
2
1
5
9
7
.
3
2
7
1
7
.
8
3
7
7
.
2
5
3
0
.
2
8
9
.
7
3
8
0
.
1

T
=
3
.
0
HPH6
56.36 876.9
205.3
93.3
LPH4

T
=
8
.
0
97.7
482.5 752.6
177.5
48.98
115.0 92.7

T
=
8
.
0
32.67 409.1
LPH3
Steam Rate =
enthalpy kJ/kg
pressure MPa(a)

T
=
5
.
6
3
0
3
6
.
8
3
2
.
6
7
3374.6
2
7
.
4
7
flow t/h
1.5451
4.H.E.HP Exhaust
NOTE:
3.DEDeaerator
b
o
i
l
e
r
b
o
i
l
e
r
b
o
i
l
e
r
b
o
i
l
e
r
C
B
A
D B
F
A
C
D
E F
E G
DE
G
B
51.73
2
8
4
.
3
4
3
8
.
5
384.2
1
3
.
6
7

T
=
3
.
0

T
=
3
.
0
HPH7

T
=
5
.
6
4
9
0
.
3
1
2
.
6
4
5
8
2
.
0
8
1
9
.
6
1
6
4
.
1
2756.5 0.15
2
1
.
3
6
1
3
3
.
3
1
7
9
.
9
3
.
3
4
2
6
2
2
.
6
2
3
1
.
5
2
.
6
1
3
8
3
3
8
2
.
1
0
.
2
6
22
8
.
4
8
3
1
8
9
.
3
0
.
6
1
7
8
2
6
2
.
1
4
3
8
.
5
6
2
.
6
4
0
.
0
2
2
0
6
2
.
1
7
2
5
7
4
.
7
4
3
4
.
4
98.21
70.28
GSH LPH2
13.67 368.8 3.3 295.0
LPH1
0.79
3017.6
0.3227
0
.
3
2
2
7
2
8
3
4
.
8
0
.
1
1
9
1
kW
0
.
1
2
5
4
6
7
.
4
8
2
2
4
.
7
1
0
1
.
6
4
2
7
.
3
1
9
0
.
5

T
=
0
.
0
2
8
.
2
2

T
=
-
1
.
7

T
=
1
.
0
4
9
0
.
3
5
8
2
.
0
G
S
H
SD
9
7
8
.
7
0
.
3
0
7
5
6
1
.
5
5
8
2
.
0
4
2
.
3
2
2
9
0
0
.
4
2.93
G
S
H
SD
540.0
537.1
540.0
3552.8
2.3525
17.75
582.0 3390.6
S
G
S
H
G
S
H
463.5
274.5
SG
S
H
H
.
E
.
DSG
S
H
1
6
0
.
0
4
2
.
3
2
3
0
7
.
3
5
8
2
.
0
5
8
2
.
0
7
0
5
.
2
6
7
6
.
4
temp
3
0
2
4
.
2
2
.
5
3
5
4
28.22
1
0
0
2
.
0
3023.1
2.6138
3
0
2
4
.
2
306.9
537.1
3.1084
0
.
6
5
0
3
2
2
.
5
0
0
.
0
3
1
8
2
8
3
4
.
8
1
2
.
6
4
kg/kW.h
1
3
.
6
7
7
1
.
6
7
0
.
0
3
3
5
0
.
0
6
8
5
3
6
1
.
2
187233
8944.1
STG output =
Heat Rate =
3
0
1
7
.
6
1
.
3
0
8
7
3
1
8
9
.
3
4
5
6
.
7
S
2
7
4
.
5
kJ/kW.h
2
7
2
9
.
6
1
2
4
.
8
411.5
6
3
.
2
7
2
6
6
.
6
4
3
8
.
5
0
.
0
6
5
1
2
6
2
2
.
6
0.00
3
.
3
4
2
8
9
9
.
3
0
.
0
9
5
1
0
.
7
9
6
2
.
1
7
2
6
0
.
2
4
3
8
.
5
0
.
0
0
4
9
0
.
3
2
7
2
9
.
6
3
5
7
.
9
4
3
8
.
5
8
5
.
1
3
6
0
.
7

T
=
3
.
0
HPH6
42.32 835.5
196.1
70.5
LPH4

T
=
8
.
0
93.1
459.6 717.9
169.7
38.06
109.6 88.1

T
=
8
.
0
25.42 389.8
LPH3
Steam Rate =
enthalpy kJ/kg
pressure MPa(a)

T
=
5
.
6
3
0
4
7
.
2
2
5
.
4
2
3382.1
2
1
.
3
6
flow t/h
1.2694
4.H.E.HP Exhaust
NOTE:
3.DEDeaerator
b
o
i
l
e
r
b
o
i
l
e
r
b
o
i
l
e
r
b
o
i
l
e
r
C
B
A
D B
F
A
C
D
E F
E G
DE
G
B
4.H.E.HP Exhaust
NOTE:
3.DEDeaerator
Steam Rate =
enthalpy kJ/kg
pressure MPa(a)

T
=
5
.
6
3
0
5
3
.
9
2
0
.
8
6
3386.7
1
7
.
6
0
flow t/h
1.0852
31.18
105.4 84.5

T
=
8
.
0
20.86 374.7
LPH3
56.6
LPH4

T
=
8
.
0
89.5
441.7 691.3
163.6
HPH6
33.77 803.9
189.1
4
1
9
.
1
2
7
3
6
.
8
3
4
2
.
9
3
7
7
.
3
8
1
.
5
3
4
5
.
5

T
=
3
.
0
2
8
9
5
.
5
0
.
0
9
5
1
0
.
7
9
6
2
.
1
7
2
6
0
.
2
3
7
7
.
3
0
.
0
0
1
2
8
.
0
411.5
6
3
.
4
5
2
6
7
.
3
3
7
7
.
3
0
.
0
5
6
6
2
6
3
5
.
6
0.00
1
.
3
7
S
2
7
6
.
8
kJ/kW.h
2
7
3
6
.
8
0
.
0
5
9
6
3
6
3
.
1
156334
9197.9
STG output =
Heat Rate =
3
0
2
3
.
4
1
.
1
1
8
8
3
1
9
4
.
7
4
5
7
.
8
3.1535
0
.
5
5
7
1
1
8
.
3
5
0
.
0
2
9
1
2
8
4
1
.
1
1
0
.
3
2
kg/kW.h
1
0
.
6
1
7
4
.
2
8
0
.
0
3
0
7
9
6
4
.
3
3027.0
2.2291
3
0
2
8
.
1
303.9
457.0
3
0
2
8
.
1
2
.
1
6
2
2
22.86
H
.
E
.
DSG
S
H
1
5
4
.
0
3
3
.
7
7
3
0
4
.
4
4
9
3
.
0
4
9
3
.
0
6
7
9
.
2
6
5
0
.
5
temp
S
G
S
H
G
S
H
396.9
276.8
SG
S
H
540.0
457.0
540.0
3556.1
2.0061
17.75
493.0 3390.6
4
9
3
.
0
G
S
H
SD
9
4
1
.
2
0
.
2
6
3
5
3
9
.
6
4
9
3
.
0
3
3
.
7
7
2
8
8
9
.
1
2.51
G
S
H
SD
2
1
6
.
3
9
7
.
4
4
0
9
.
6
1
8
3
.
5

T
=
0
.
0
2
2
.
8
6

T
=
-
1
.
7

T
=
1
.
0
4
1
9
.
1
0.79
3023.4
0.2772
0
.
2
7
7
2
2
8
4
1
.
1
0
.
1
0
2
7
kW
0
.
1
0
8
1
6
5
.
4
6
98.21
68.26
GSH LPH2
10.61 353.7 1.4 286.6
LPH1
2
6
2
.
1
3
7
7
.
3
6
2
.
6
4
0
.
0
2
2
0
6
2
.
1
7
2
6
0
2
.
0
3
7
5
.
1
1
8
2
.
7
1
.
3
7
2
6
3
5
.
6
2
2
3
.
2
2
.
2
2
9
1
3
3
8
6
.
7
0
.
2
2
72
3
.
0
9
3
1
9
4
.
7
0
.
5
2
9
2
1
5
8
.
0
2749.9 0.31
1
7
.
6
0
1
2
8
.
1

T
=
3
.
0
HPH7

T
=
5
.
6
4
1
9
.
1
1
0
.
3
2
4
9
3
.
0
7
8
8
.
9
41.79
2
7
5
.
9
3
7
7
.
3
369.3
1
0
.
6
1

T
=
3
.
0
b
o
i
l
e
r
b
o
i
l
e
r
b
o
i
l
e
r
b
o
i
l
e
r
C
B
A
D B
F
A
C
D
E F
E G
DE
G
B
104.15
3
2
9
.
3
7
4
4
.
6
442.5
2
8
.
2
7

T
=
3
.
0

T
=
3
.
0
HPH7

T
=
5
.
6
8
4
8
.
8
2
5
.
1
0
8
9
5
.
0
8
0
4
.
0
1
8
6
.
9
2778.1 0.00
4
6
.
2
3
1
5
2
.
6
1
7
5
.
1
2
0
.
4
2
2
5
9
7
.
9
1
8
6
.
9
0
.
5
4
5
0
.
5
5
3
1
7
8
.
0
1
.
0
6
2
6
2
6
2
.
1
7
4
4
.
6
6
2
.
6
4
0
.
0
2
2
0
6
2
.
1
7
2
4
8
7
.
3
7
2
2
.
9
98.21
81.03
GSH LPH2
28.27 427.1 21.2 340.1
LPH1
0.78
3004.3
0.5504
0
.
5
5
0
4
2
8
2
0
.
0
0
.
2
0
1
3
kW
0
.
2
1
1
9
7
8
.
2
3
1
8
6
.
9
1
1
7
.
4
4
9
4
.
2
1
8
6
.
9

T
=
0
.
0
0
.
0
0

T
=
-
1
.
7

T
=
1
.
0
8
4
8
.
8
8
9
5
.
0
G
S
H
SD
8
0
4
.
0
0
.
5
2
3
6
4
4
.
2
8
9
5
.
0
0
.
0
0
4.97
G
S
H
SD
540.0
890.8
540.0
3536.8
3.9617
17.75
895.0 3390.6
THO Conditon ( Makeup 0%)
S
G
S
H
G
S
H
796.1
271.1
SG
S
H
H
.
E
.
DSG
S
H
1
8
2
.
5
0
.
0
0
8
9
5
.
0
8
9
5
.
0
8
0
4
.
0
7
7
5
.
0
temp
0.00
8
0
4
.
0
3074.1
4.4019 346.0
890.8
2.8630
1
.
1
1
8
5
4
5
.
8
2
0
.
0
4
9
8
2
8
2
0
.
0
2
5
.
1
0
kg/kW.h
2
8
.
2
7
8
2
.
5
1
0
.
0
5
2
4
0
.
1
1
4
2
3
5
9
.
8
312611
8724.0
STG output =
Heat Rate =
3
0
0
4
.
3
3
1
7
8
.
0
S
2
7
1
.
1
kJ/kW.h
2
7
1
3
.
3
1
1
9
.
0
411.5
6
2
.
8
3
2
6
4
.
7
7
4
4
.
6
0
.
1
0
8
5
2
6
0
4
.
7
0.81
2
1
.
2
3
2
9
1
9
.
3
0
.
0
9
5
1
0
.
7
8
6
2
.
1
7
2
6
0
.
2
7
4
4
.
9
0
.
3
0
8
4
8
.
8
2
7
1
3
.
3
4
1
6
.
1
7
4
4
.
6
9
8
.
9
4
1
9
.
3

T
=
3
.
0
HPH6
0.00 0.0
LPH4

T
=
8
.
0
106.9
526.9 75.88
125.4 101.9

T
=
8
.
0
50.79 448.2
LPH3
Steam Rate =
enthalpy kJ/kg
pressure MPa(a)

T
=
5
.
6
3
0
3
3
.
8
5
0
.
7
9
4
6
.
2
3
flow t/h
4.H.E.HP Exhaust
NOTE:
3.DEDeaerator
b
o
i
l
e
r
b
o
i
l
e
r
b
o
i
l
e
r
b
o
i
l
e
r
C
B
A
D B
F
A
C
D
E F
E G
DE
G
APPENDIX1: HEAT AND MASS BALANCE DIAGRAM

SPECIFICATION FOR

PROJ ECT
Doc. No. 11V02-201-SPC-M-0001, REV.R0
Date: 04-11-2011
VOL-II PART-A,
ANX-II, M2
Page 1 of 4

ANNEXURE - II
DATA SPECIFICATION SHEET FOR ACC
Sr. No. Particulars Units Data / Values
1.0 AIR COOLED CONDENSER & ACCESSORIES
1.1
Number of condenser per steam
turbine generator unit
No. One
1.2 Design --
As per latest HEI Standards and
Design criteria indicated.
1.3 Installation -- Outdoor
1.4 Type
Modularized A-Frame design, for
long-term mechanical and thermal
integrity, excellent corrosion and
freeze resistance, low fan power
consumption, reliable operation and
low maintenance.
Single-Row Condenser (SRC) -
elongated flat CS tube alumunium
coated / HDG carbon steel (of
minimum 50 microns) with brazed
aluminium fins / CS HDG fins. OR
Multi-Row Galvanized (MRG) -
round shape HDG (of minimum 50
microns) CS tubes with extruded
CS HDG fins
Bidder shall limit the number of rows
in MRC to maximum Four (4).
1.5 Design Condition Refer Cl. 6.00.00
1.6 Quality of Ambient Air
As per Site data indicated
elsewhere
1.7 Design Ambient air temperature
40 Deg.C (For Electrical equipment
50 Deg C)
1.8
Design Margin on heat load at
TG VWO, 0% MU, Design
ambient temp.

5% on heat load margin for heat
transfer area.
1.9 Tube cleanliness factor 10% tube plugging margin
1.10
Oxygen in condensate at
Condensate storage tank outlet
with 3% make-up
cc/lit Not to exceed 0.015.
1.11
TG exhaust steam and
condensate parameters
Refer cl. 6.01.00, 2)
1.12
Turbine exhaust nozzle
orientation
Downwards
1.13 Steam velocity at suction m/sec <60 m/sec at 0.22 bar (a)

SPECIFICATION FOR

PROJ ECT
Doc. No. 11V02-201-SPC-M-0001, REV.R0
Date: 04-11-2011
VOL-II PART-A,
ANX-II, M2
Page 2 of 4

1.14
Fouling Factor
Steam/Condensate Side
Air Side

0.00005 Hr. m2 deg.K/kcal
0.0001 Hr. m2 deg.K/kcal
1.15
Length of steam duct from TG
terminal point
m
Approximately 43 meters. Supplier
to decide and indicate the exact
length.
1.16
No. of bends / total equivalent
length
nos/m
Supplier to decide and indicate the
exact length.
1.17
Tube bundle (Condenser)
- Design pressure and temp
- No. of bundle / module
- Bundle type

ata,
o
C
nos.

3 & 120
Supplier to indicate
A - type
1.18
No. of tubes
- Tube material
- Header material
- Tube plugging margin

CS with HDG / CS Al. coated
CS
10%

1.19
Tube bundle (dephlegmators)
- Design pressure and temp
- No. of bundle / module
- Bundle type
- Tubes per row
- Tube type

ata,
o
C
Nos.
nos.
nos.
mm

3 & 120
A - type
Elliptical

1.20
Fin
- Fin type
- Fin material
- Fin OD and thickness
- Fin pitch at different
locations
- Fin fixing details

mmxm
m
mm

Aluminium / CS with HDG
<=3.2

Extruded / Brazed
1.21
Heat transfer
- Flow type : cross flow /
parallel
- ITD
- LMTD overall
- Theoretical heat transfer
area

Deg. C
Deg.C
Sq. M

Cross flow

22.17 Deg.C
14 Deg.C
1.22
Steam side pressure Drop
- In duct
- Total system pressure drop
on tube side

kg/cm
2
kg/cm
2


1.23
Air side data
- Temperature at inlet
- Temperature at outlet
- Pressure drop across the
system
- Air velocity across the tube
bundle

Deg.C
Deg.C
kg/cm
2

m/sec

40 Deg.C

<=3.0

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Page 3 of 4

1.24
Fan data
- No. of fans
- Fan type
- Fan diameter
- No. of blades
- Blade material
- Static pressure
- Fan speed
- Motor speed

nos

mm
nos

mmwg
rpm
rpm

Axial flow
Aluminium / FRP
<140
2 - 17
1500
1.25
Gear box type
- Gar box service factor

- Motor enclosure
- BKW at fan shaft
- Fan absorbed power
- Fan sound level @ 1 m
- Gear box number

no.

kW
kW
dB (A)
no.

3 times fan absorbed power
Parellel shaft
IP- 55 (For outdoor motor IPW55)
85
Total number of fans. (Spare
required shall be provided in
mandatory spares)
1.26
Corrosion allowance on ferrous
parts
mm 3.2
1.27 Radiography Spot
1.28 J oint efficiency 0.85
1.29
Material of construction
- Expansion joint
- Exhaust steam duct
- TEB

- Structural parts
- Tube fins
- Tubes
- Tube sheet

Stainless steel
IS - 2062
Carbon steel with corrosion
protection
Carbon steel of eq. (IS-2062)
Aluminium / CS HDG as per 1.4
CS HDG or CS aluminium coated.
SA 516 Gr. 60 / 70
2.0 CONDENSER AIR EVACUATION EQUIPMENT AND ACCESSORIES
2.1 Number required per STG unit nos.
2 x 100% or 3 x 100% capacity; (1
W for holding and all working for
hogging operation)
2.2 Duty Continuous
2.3 Vapour to be handled
Mixture of air, steam and non-
condensable gases
2.4
HEI standard pressure and
temp. condition for air suction
kg/cm
2

Deg.C
0.034 kg/cm
2
(a) and 21.1 Deg.C
2.5 Design Data
2.5.1 Type
Single stage liquid ring with air
ejector or two stage liquid ring.
2.5.2 Capacity kg/hr Shall not be less that 120% of the

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ANX-II, M2
Page 4 of 4

capacity obtained from HEI
standards.
2.5.3
Capacity of pump during
hogging

Shall be able to maintain vacuum
upto 0.35 kg/sq.cm (a) within 20
minutes with both the vacuum pump
in operation
2.5.4 Source of sealing water Condensate
2.5.5 Type of coupling Flexible coupling
2.5.6
Acceptable noise level at all
operating conditions
dB (A)
85 dB (A) at a distance of 1 m from
the outline of equipment
2.5.7
Allowable vibration level at all
operating conditions
mm/se
c
7 peak , ISO: 2372
2.6 Material of Construction
2.6.1 Vacuum pumps
a) Casing Cast Iron
b) Shaft Carbon steel EN-8
c) Impeller Stainless Steel
d) Shaft Sleeves Stainless Steel
2.6.2
Seal water recirculation
pumps (if required)

a) Casing Cast Iron
b) Shaft Carbon Steel EN-8
c) Impeller Nodular Iron
2.6.3 Heat Exchanger
a) Shell Carbon steel
b) Tubes Stainless Steel
c) Tube sheet
Carbon steel with epoxy coating as
required
d) Baffle and tie rod cage
Stainless Steel

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VOL-II
PART-A, M2
Page 1 of 25

VOLUME II
PART - A
SPECIFICATION: M2
SURFACE PREPARATION AND PAINTING

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Doc. No. 11V02-201-SPC-M-0001, REV.R0
Date: 04-11-2011
VOL-II
PART-A, M2
Page 2 of 25

I N D E X


1.00.00 Cleaning, Protective Coating and Painting


3.00.00 Chemical Cleaning

4.00.00 Steam blowing

5.00.00 Mechanical Cleaning at Manufacturer's Works

6.00.00 Protection at Manufacturer's Works

7.00.00 Weather Conditions

8.00.00 Surface Preparation

9.00.00 Surface preparation methods

10.00.00 Paint Materials

11.00.00 Storage

12.00.00 Preparation of Coating Materials

13.00.00 Application

14.00.00 Safety Requirements

15.00.00 Dry Film Thickness (DFT)

16.00.00 Protective Coatings and Paint Systems

17.00.00 Inspection and Testing

18.00.00 Painting Systems

19.00.00 Cathodic Protection System

20.00.00 Coating And Wrapping Of Pipes

21.00.00 Galvanizing

22.00.00 Schedule of Primer & Finish Coats

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VOL-II
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Table-1: Recommended Painting / Coating systems for Ferrous metal surfaces

Table-2: Recommended Painting / Coating systems for Non-Ferrous metal surfaces

Table-3: Recommended Painting / Coating systems for Concrete Surfaces

Table-4: Color coding scheme

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VOL-II
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M2: SURFACE PREPARATION AND PAINTING

1.00.00 Cleaning, Protective Coating and Painting

1.01.00 General

This specification covers the general requirements related to the cleaning,
protective coating and painting of equipment, components and system.

The components and / or equipment shall be mechanically and /or
chemically cleaned during the following stages of the Contract.

Cleaning in workshop

Cleaning before painting and/or corrosion protection (application of prime
coat) Cleaning before erection and during installation.

Austenitic stainless steels, copper and Aluminium alloys, cast iron,
bimetallic and metallic/plastic items, and components fabricated by spot
welding or riveting shall not be chemically cleaned. All weld areas shall be
suitably stress relieved before chemical cleaning.

Any painting work (including surface preparation) on piping or equipment
shall be commenced only after the system tests have been completed.

Mechanical mixing shall be used for paint mixing operations in case of
two pack systems except that the Engineer may allow the hand mixing of
small quantities at his discretion


In addition to the detailed specifications of the contract, the following
codes and standards shall be followed for the work covered by this
contract:

IS: 5 : Colours for ready mixed paints and enamels.
IS: 101 : Methods of test for ready mixed paints and
enamels
IS: 161 : Heat resistant paints
IS: 2074 : Specifications for ready mixed paint, Air drying, red
oxide zinc
Chrome priming.
IS: 2339 : Aluminium paint for general purposes, in dual
container.
IS: 2379 : Colour code for identification of pipelines.
IS: 9404 : Colour code for identification of pipelines used in the
Thermal Power Plants.

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IS: 2932 : Specification for enamel, synthetic, exterior (a)
undercoating, (b) Finishing
3.00.00 Chemical Cleaning

Chemical cleaning shall be done for boiler pressure parts and turbine oil
system components at site. The detailed procedure for chemical cleaning
as well as the system for which chemical cleaning is required shall be
finalized with the Vendor.

4.00.00 Steam blowing

H.P, IP and L.P. Steam Piping and any other piping system as necessary
shall be subjected to steam blowing. The calculation, procedure and the
system for which steam blowing is required shall be finalized with the
Vendor.

5.00.00 Mechanical Cleaning at Manufacturer's Works

Mechanical cleaning shall be carried out by abrasive blasting or
alternative methods to Purchaser's approval, provided they achieve the
necessary surface condition. The Metal surfaces shall be clean and free
of mill scale, rust, dirt, grease and any other deleterious matter.

Where metal surfaces are to be painted, the surface profiles shall
conform with the painting specification requirements. Where this does not
apply surfaces shall have a surface texture not coarser than Grade 80
abrasive paper.

Abrasives containing silica, silicates or slag residues shall not be used for
water/steam side surfaces of plant except for cleaning sand castings,
where hydro blasting with sand may be used.

For austenitic materials only, abrasives containing 98% or more of
Alumina, Al2O3, shall be used. After cleaning, abrasive and debris shall
be thoroughly removed from components.

Cleaning of fabricated items shall be carried out after fabrication and final
heat treatment or welding at manufacturer's works or at site, as
appropriate. For cleaning in workshop and before painting, mechanical
cleaning as opposed to alternative chemical cleaning is the preferred
method for works cleaning except where this is precluded by design or
access considerations. Machined surfaces shall be protected during the
cleaning operations.

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6.00.00 Protection at Manufacturer's Works

As soon as all items have been cleaned and within four hours of the
subsequent drying, they shall be given suitable anti-corrosion protection.

All water, air and steam side surfaces shall be protected by the
application of approved water soluble corrosion inhibitors, or vapor phase
inhibitors that can be subsequently removed by site water washing or
steam blowing.

The rate of application of volatile corrosion inhibitors shall be at least 10
grams per square metre or 35 grams per cubic metre, whichever is the
greater, except for pipes up to 300 mm diameter for which the minimum
application rates shall be 5 grams per square metre.

Immediately after the protective treatment has been applied all vessels
and pipes shall be suitably sealed off by discs or caps or approved
alternatives to prevent ingress from the surrounds.

Cylindrical plugs shall not be driven into the ends of pipes. These
protective covers shall not be removed until immediately before final
connection is made to the associated equipment.

7.00.00 Weather Conditions

Painting shall be done only when the surface temperature is above 5C.
Surface temperature must be at least 3C above dew point to ensure that
condensation does not occur on the surface.

Precautions shall be taken against solar radiation to ensure that the
specified dry film thickness of priming or finish coats is obtained.

Any prime coat exposed to excess humidity, rain, dust etc before drying,
shall be permitted to dry and the damaged area of primer shall be
removed and the surface prepared and primed again.

8.00.00 Surface Preparation

In preparing any surface to be coated, all loose paint, dirt, grease, rust,
scale, weld slag or spatter or any other extraneous material shall be
removed and defects repaired, so as to obtain a clean, dry, even surface
to receive the priming or finishing coat (s) as called for in the painting
schedules. All surfaces should be blast cleaned whenever possible.

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9.00.00 Surface preparation methods

Bare steel surfaces should be prepared by one of the methods described
below in order of preference and in accordance with Swedish Standard
SIS 05 59 00 or Steel Structures Painting Council, SSPC, Vis 1, or DIN
55928, section-4.

(a) White metal blast cleaning: Sa 3 or SSPC - SP 5

Sa 3 Blast cleaning to bare metal. Mill scale, rust and foreign matter must
be removed completely. Subsequently, the surface is cleaned with
vacuum cleaner, clean dry compressed air or a clean brush. It must then
have a uniform metallic colour and correspond in appearance to the prints
designated Sa 3.

(b) Near white metal blast cleaning: Sa 2 1/2 or SSPC - SP 10

Sa 2 1/2. Very thorough blast cleaning. Mill scale, rust and foreign matter
shall be removed to the extent that the only traces remaining are slight
imperfections in the form of spots or stripes. Subsequently, the surface is
cleaned with a vacuum cleaner, clean dry compressed air or a clean
brush. It must then correspond in appearance to the prints designated sa
2 1/2.

Mechanical cleaning should only be used when procedures (a) and (b)
are not practicable.

(c) Commercial Blast Cleaning: Sa 2

Sa 2 Blast cleaning until at least two-thirds of each element of surface
area is free of all visible residues. This method of Blasting is suitable for
steel required to be painted with conventional paints for exposure to
mildly corrosive atmosphere for longer life of the paint systems.

(d) Near white metal blast cleaning: Sa 2 1/2 DIN 55928

Very thorough blast cleaning. Very adhesive coatings remain. From all
other surface mill scale and rust are to be removed to such an extent that
the only traces remaining are slight imperfections in the form of spots or
stripes. Further treatment sees Sub b).

The adhesivity of residual coatings in the transition zone has to be tested
even after the application of the primer.

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(e) Very thorough mechanical scraping and wire brushing St 3

St 3 very thorough scraping and wire brushing - machine brushing -
grinding - etc. are to be preferred. Surface preparation as for St 2. But
much more thoroughly. After the removal of dust, the surface must have a
pronounced metallic sheen and correspond to the prints designated St. 3.

(f) Thorough scraping and wire brushing: St 2

St 2 Thorough scraping and wire-brushing - machine brushing - grinding -
etc. The treatment shall remove loose mill scale, rust and foreign matter.
Subsequently, the surface is cleaned with a vacuum cleaner, clean dry
compressed air or a clean brush. It should then have a faint metallic
sheen. The appearance must correspond to the prints designated St 2.

Table-A (Surface Preparation Standards)

a)
Surface
preparation
method
SIS 055900 DIN 55928
Part 4
BS 4232 only
for blasting
SSPC-Vis
b)
Blasting according
to item a)
Sa 3 - First quality
White metal
SP 5
c)
Blasting according
to item b)
Sa 2 1/2 -
Second near
quality
White SP 10
d)
Blasting according.
to item c)
- - Third quality
Commercial
blast SP 6
e)
Hand or power tool
derusting
according to item
St 2 - -
Hand tool
Cleaning SP 2
f)
According to items
(e)
St 3 - -
Power tool
Cleaning SP 3
g) Flame jet cleaning - F1 -
Flame
cleaning SP 4
h) Pickling - Be - Pickling

Steel structures to be blast cleaned have to be free of pitting and other
severely corroded places in accordance with B.S. 4232 and SIS 055900.

The abrasives used for blast-cleaning shall be graded flint, grit, shot or
silica sand and shall be such that they will produce an average keying
profile on the blast cleaned surface of not more than 40 microns.

An air pressure of 7 bar g at the nozzle shall be used.

Oil, grease, soil, cement, salts, acids or other corrosive chemicals shall
be cleaned from steel surfaces, by the use of solvents, emulsions or

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cleaning compounds. The final wiping shall be with clean solvent and
clean rags or brushes. There shall be no detrimental residue left on the
surface.
Primed areas which suffer damage must be spot blasted on site to a
degree of cleanliness P Sa 2 1/2 before touching up.

Protective coating must be applied as quickly as possible after the
completion of surface preparation no matter what cleaning method has
been used.

No blast-cleaned surface shall be allowed to remain uncoated overnight.

Steel work protected by shop primer after arrival on site must be cleaned
of salt, sand, oil etc. before the first coat of paint is applied on site. Shop
primer damaged during transport must be rectified by blast-cleaning and
coating before application of the site coats.

Concrete: If a protective coating is required, concrete shall be allowed to
cure before painting.

For package units/equipment, shop primer shall be as per the paint
system given for particular environment.

The tie coat shall be applied after 7 days of curing of red oxide zinc
chromate primer. If new paint system is not suitable to upgrade existing
coating then complete paint shall be removed by mechanical or blast
cleaning before application of new coating system.

10.00.00 Paint Materials

The paints shall conform to the specifications given in Annex - 3 and
class - I quality in the products range of any of the leading manufacturers:

11.00.00 Storage

All paints and painting material shall be stored only in rooms to be
provided by the contractor and approved by Engineer for the purpose. All
necessary precautions shall be taken to prevent fire. The storage building
shall preferably be separated from adjacent buildings.

A signboard bearing the words "PAINT STORAGE - NO NAKED LIGHT
HIGHLY INFLAMMABLE - DANGER - NO SMOKING" shall be clearly
displayed outside. All paints should be stored in the safest manner so that
no container rolls down and causes accidents. The shelf life of the paints
should be ensured so that the paint materials are not in storage and use
after the date of expiry.

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12.00.00 Preparation of Coating Materials

All container shall remain un-opened until required for use.

Primers and paints which have livered, gelled or otherwise deteriorated
shall not be used.

All ingredients in any container shall be thoroughly mixed before use, and
shall be agitated frequently during application to keep the primer in
suspension.

Primer or paint mixed in the original container shall not be transferred
until all settled pigment is incorporated into the body of the liquid.

Primer or paint shall be mixed in a manner ensuring the breakdown of all
lumps, complete dispersion of pigment and uniform composition.

Two-component primers shall be mixed in accordance with the
manufacturer's instructions.

Thinners shall not be added to primers or paints unless necessary for
proper application according to the manufacturer's instructions.

When use of thinners is permitted, it must be added to the primer or paint
during mixing.

13.00.00 Application

The paint supplier has to present a written specification including at least
the flash point of the paints, ventilation requirements, handling
precautions such as inhalation, eye and skin protection, and first aid
procedure, storage requirements, spill or leak procedure, fire precaution,
waste disposal.

14.00.00 Safety Requirements

Protection of the blast cleaner operator's eyes and respiratory system
should be given prime consideration in any open blast cleaning operation.
Airfed helmets, respiratory filters, air conditioned hoods etc. should be
provided in sufficient number to the blast cleaning operators to avoid the
harmful effect of blast cleaning abrasives. Also, an automatic shut-off
device which will shut-off the air supply to the blasting machine should be
installed which will prevent the dangerous whipping of an operating blast
hose if an operator becomes disabled.

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14.01.00 Methods

Temporary corrosion protections are to be completely removed prior to
applying the definite one.

All prime coatings shall be applied by brush or airless spray or a
combination of these methods, as approved by the coating manufacturer.

All doors, windows, stairways, handrails (if painted), bolts, flanges and
equipment supports shall be finish painted by brush.

Spray guns should not be used outside in windy weather or near surfaces
of a contrasting colour unless the latter is properly protected.

All cold-spray painting shall be done using standard equipment in
accordance with accepted standards and methods.

Care has to be taken not to connect spraying devices for nitro and
backelite paints simultaneously to oil based paints.

Paint applied to items that are not be painted shall be removed at the
supplier's expense, leaving the surface clean, unstained and undamaged.

15.00.00 Dry Film Thickness (DFT)

To the maximum extent practicable the coats shall be applied as a
continuous film of uniform thickness and free of pores. Overspray, skips,
runs, sags and drips should be avoided. The different coats shall not be
of the same colour.

Each coat of paint shall be allowed to harden before the next is applied.
For epoxy paint the hardening time normally is 12-14 hours. Suppliers'
recommendations regarding hardening time of epoxy paints must be
followed.

Particular attention must be paid to full film thickness at edges.

The minimum total dry film thickness of the paint systems shall be as
recommended in the following table. The DFT is given in microns
(millionths of a metre).

16.00.00 Protective Coatings and Paint Systems

The type and number of protective coats for any item requiring painting
are to be in accordance in the attached tables "Paint Systems" (Annex-3).

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Generally, all parts shall receive the specified prime coat (s) at the
supplier's works to ensure that no corrosion occurs during transport to the
site and storage at the site.

Parts which cannot be damaged during transport shall receive the full
number of coats.

17.00.00 Inspection and Testing

All painting materials including primers and thinners brought to site by the
contractor for application shall be procured directly from manufacturer as
per specifications and shall be accompanied by manufacturer's test
certificates. Paint formulations without certificates are not acceptable.

The paints shall be tested as per IS: 101 and approved by the Owner.

Stages of inspection are as follows:

a) Surface preparation
b) Primer application
c) Each coat of paint

In addition to above, record should include type of shop primer already
applied on equipment e.g. Red oxide, zinc chromate or zinc chromate or
Red lead primer etc.

Dry film thickness (DFT) shall be checked and recorded after application
of each coat.

18.00.00 Painting Systems

Primers and finish coats for any particular paint system shall be from
same manufacturer in order to ensure compatibility.

19.00.00 Cathodic Protection System

Cathodic Protection System shall be envisaged for all buried carbon steel
pipe work, equipments / tanks etc. covering water fuel and other
miscellaneous systems. All works to be performed shall generally cover

a) The survey for topographical and cadastral features.
b) Data interpretation reports.
c) Conceptual system design & basic engineering.
d) Installation, testing and commissioning of the cathodic protection
system after the receipt of approval from the client.

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The design may be covered with temporary & permanent protection
wherever necessary and the design life shall be for a minimum period of
25 years.

Suitable holiday or defect test on all wrapped / coated pipe work and
others. Necessary specialised agency shall be deployed.

20.00.00 Coating And Wrapping Of Pipes

All oil and grease on the pipe metal surface shall be thoroughly removed
by flushing with a suitable solvent (such as xylene or 1,2,2 trichlorethane)
and wiped with clean rags. The solvent cleaning shall be as per SSPC-
SP-1. The degreased pipe metal surface shall be wire brushed / power
brushed. Preferably priming shall be done within four hours of completion
of wire brushing.

After being cleaned the pipe shall be protected from and be maintained
fee of oil, grease and dirt that might fall on the pipe before it has received
its final coat. After the surface is primed, Pypkote membrane is applied
over the pipe in spiral fashion by thermofusion process. A LPG torch or
other heat source is applied onto the lower face of the membrane till the
polymeric mix attains a shiny appearance.

The membrane is then adhered to the primer coated surface. Overlaps
are maintained as per specifications with a minimum of 15 mm. The
overlaps are doubly sealed by thermofusion on the exterior for additional
security.

The welded field joints shall be cleaned and dried in accordance with
section-3. Primer shall be applied on the clean joints in accordance with
section. Primer shall be applied on adjacent tape coating also. Over the
primed surface tapes shall be applied in accordance with sections c,d,e.
Tapes shall overlap the coating on each side of the field joint to form a
continuous external coating free of defects. Overlaps on each side of the
weld joints shall be 50 mm.

No wrinkling in the wrapper shall be allowed. If coating and wrapping is
found and satisfactory to the Engineer-in-charge the same area shall be
recoated and wrapped with approved procedures.

21.00.00 Galvanizing

Galvanizing works shall conform in all respect to IS.6158 and shall be
performed by the hot dip process, unless otherwise specified.

It is essential that details of steel members and assemblies which are to
be hot-dip galvanized should be designed in accordance with IS 6159.

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Structural steel items shall be initially grit-blasted to B.S. 4232, second
quality, (Sa 21/2) or by pickling in a bath and the minimum average
coating weight on steel sections 5 mm thick and over shall be 900 g/m2.

On removal from the galvanizing bath, the resultant coating shall be
smooth, continuous, free from gross surface imperfections such as bare
spots, lumps, blisters and inclusions of flux, ash or dross.

Galvanized contact surfaces to be joined by high-tensile friction-grip bolts
shall be roughened before assembly so that the required slip factor is
achieved. care shall be taken to ensure that the roughening is confined to
the area of the mating faces.

Small areas of the galvanized coating damaged in any way shall be
restored in accordance with relevant standards.

Cleaning the area of any weld slag rust and other inpurities and by
thorough wire brushing to give a metallic clean surface.

application of suitable number of coats of zinc-rich paint containing more
than 90% w/w of zinc in dried film. The dry film thickness shall exceed at
least 50% the thickness of the desired galvanization. In case of
application of a low melting point zinc alloy repair rod, the rods shall be in
accordance with IS 6158, the thickness of the alloy shall be at least as of
the desired galvanization.

The restored area is not to exceed 1% of the galvanized surface.

Surface restoration of parts in contact with drinking water is not allowed
and the quality of the galvanization is to be in accordance with relevant IS
standards.

After fixing, bolt heads, washers and nuts shall receive two coats of zinc-
rich paint.

Connections between galvanized surfaces and copper, copper alloy or
aluminum surfaces shall be protected by suitable preferably hydrophobe
tape wrappings to the
owner's approval.

22.00.00 Schedule of Primer & Finish Coats

PRIMERS:
P-1 REDOXIDE ZINC CHROMATE PRIMER
P-2 HIGH BUILD CHLORINATED RUBBER ZINC PHOSPHATE
PRIMER

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P-3 HIGH BUILD ZINC PHOSPHATE PRIMER
P-4 ETCH PRIMER/WASH PRIMER
P-5 EPOXY ZINC CHROMATE PRIMER
P-6 EPOXY ZINC PHOSPHATE PRIMER
P-7 EPOXY HIGH BUILD MIO PAINT
P-8 EPOXY RED OXIDE ZINC PHOSPHATE PRIMER
P-9 EPOXY BASED TIE COATFINISH COATS
P-10 HIGH BUILD CHLORINATED RUBBER PAINT
P-11 POXY ZINC RICH PRIMER

FINISH COATS
F-1 YNTHETIC ENAMEL
F-2 CRYLIC POLYURETHANE PAINT
F-3 HLORINATED RUBBER PAINT
F-4 I GH BUILD CHLORINATED RUBBER MIO PAINT
F-5 HEMICAL RESISTANT PHENOLIC BASED ENAMEL
F-6 POXY HIGH BUILD COATING
F-7 HIGH BUILD COAL TAR EPOXY
F-8 SELF PRIMING EPOXY HIGH BUILD COATING
F-9 INORGANIC ZINC SILICATE COATING
F-10 HIGH BUILD BLACK
F-11 EAT RESISTANT ALUMINIUM PAINT SUITABLE UPTO 250C
F-12 EAT RESISTANT SILICONE PAINT SUITABLE UPTO 400C
F-13 YNTHETIC RUBBER BASED ALUMINIUM PAINT SUITABLE
UPTO 150C
F-14 POXY PAINTING

22.01.00 Primer

22.01.01 Primer (P-1)
Red-oxide zinc chromate primer
Type and composition : Single pack modified phenolic alkyd medium
pigmented with red-oxide and zinc chromate
Volume solids : 30 - 35%
DFT : 25 microns / coat (min)
Covering capacity : 12-13 sq. m / Lit / coat

22.01.02 Primer (P-2)
High build chlorinated rubber zinc phosphate primer
Type and composition : Single pack Chlorinated rubber medium
plasticised with unsaponifiable plasticiser
pigmented with zinc Phosphate
Volume solids : 35-40%
DFT : 50 microns / coat (min).
Covering capacity : 7-8 sq. m / lit / coat

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22.01.03 Primer (P-3)
High build zinc phosphate primer
Type and composition : Single pack Synthetic medium, pigmented
with Zinc Phosphate
DFT : 35 - 50 microns / coat
Covering capacity : 10 - 12 sq. m / lit / coat
Heat resistant : Upto 100 C (dry)

22.01.04 Primer (P-4)
Etch primer/Wash primer
Type and composition : Two pack
Poly vinyl butyral resin medium cured with
phosphoric acid solution pigmented with zinc
tetroxy chromate
DFT : 8 - 10 microns/coat
Covering capacity : 7 - 8 sq. m/lit/coat

22.01.05 Primer (P-5)
Epoxy zinc chromate primer
Polyamide cured epoxy resin medium
pigmented with zinc chromate
Volume solids : 40% (min.)
DFT : 35 microns / coat

22.01.06 Primer (P-6)
Epoxy zinc phosphate primer
pigmented with zinc Phosphate
Volume solids : 40% (min)

22.01.07 Primer (P-7)
Epoxy high build M10 paint (Intermediate coat)
pigmented with micaceous iron oxide
Covering capacity : 5.0 sq. m /lit / coat

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22.01.08 Primer (P-8)
Epoxy red oxide zinc phosphate primer
pigmented with red oxide and zinc phosphate
Covering capacity : 13 - 14 sq. m / lit / coat

22.01.09 Primer (P-9)
Epoxy based tie coat (suitable for conventional alkyd based coating prior
toapplication of acrylic polyurethane /epoxy finishing coat).
suitably pigmented

22.01.10 Primer (P-10)
Chlorinated Rubber paint (Intermediate coat)
Type and composition : Single pack
Plasticised chlorinated rubber medium
pigmented with Titanium dioxide or equivalent
Covering capacity : 10 sq.m./lit/coat

22.01.11 Primer (P-11)
Epoxy zinc rich primer
Polyamide cured epoxy resin enriched with
metallic Zinc.

22.02.00 Finish Coats

22.02.01 Finish coat (F-1) Synthetic Enamel
Alkyd medium pigmented with superior quality
water & weather resistant pigments
DFT : 20 - 25 microns/coat (min)

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22.02.02 Finish coat (F-2)
Acrylic Polyurethane paint
Acrylic resin and isocyanate hardener suitably
pigmented.
DFT : 30-40 microns/coat
Covering capacity : 10-12 sq.m / lit / coat

22.02.03 Finish Coat (F-3)
Chlorinated Rubber paint
Plasticised chlorinated rubber medium with
chemical & weather resistant pigments.

High build chlorinated rubber MIO paint.
Chlorinated rubber based high build pigmented
with micaceous iron oxide.
Covering capacity : 6-7 sq.m./lit/coat

Chemical Resistant Phenolic based Enamel
Phenolic medium suitably pigmented.

Epoxy High Building Coating
Polyamide cured epoxy resin medium suitably
pigmented.
Covering capacity : 6.0-6.5 sq.m./lit/coat

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High build coal tar Epoxy.
Polyamine cured epoxy resin blended with coal
tar.

Self priming epoxy high build coating (complete rust control coating)
Polyamido-amine cured epoxy resin suitably
pigmented. Capable of adhering to manual
prepared surface and old coatings.

Inorganic Zinc silicate coating.
Self cured Ethyl - silicate solvent pased
Inorganic Zinc coating.

High build black.
Reinforced Bituminous composition phenolic
based resin.
DFT : 100 microns /coat (min)

Heat Resistant Aluminium Paint Suitable upto 250*C
Type and composition : Dual container (paste & medium)
Heat resistant special varnish medium
combined with Aluminium flakes.

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Heat Resistant Silicon paint suitable upto 400*C.
Silicone resin based with aluminum flakes.

Synthetic Rubber Based Aluminium Paint suitable upto 150*C.
Synthetic rubber medium combined with leafing
Aluminium.
DFT : 25 microns /coat
Covering capacity : 9.5 sq.m./lit/coat

Epoxy Coating
Polyamide cured epoxy resin suitably
pigmented

Notes
1. Covering capacity and DFT depends on method of application. Covering
capacity specified above are theoretical. Allowing the losses during
application, min specified DFT shall be maintained.

2. All primers and finish coats shall be cold cured and air dried unless
otherwise specified.

3. All paints shall conform to relevant Indian Standard and shall be applied
in accordance with manufacturer's instructions for surface preparation,
intervals, curing and application. The surface preparation, quality and
workmanship shall be ensured.

4. Technical data sheets for all paints shall be supplied at the time of
submission of quotations.

5. In case of use of epoxy tie coat, manufacturer shall demonstrate
satisfactory test for inter coat adhesion. In case of limited availability of
epoxy tie coat (P-9) alternate system may be used taking into
consideration the service requirement of the system.

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6. Contractor will submit the final colour shade for all equipments & piping
under his scope for final approval by client / consultant.

Table-1
Recommended Painting / Coating systems for Ferrous metal surfaces
Equipment/Area Surface
Preparation
Coating System Coating
Composition
DFT
(microns)
Structural Steel,
Shapes and
Plates including
Tanks
Near White
Metal Blast
Inorganic Zinc 85% zinc in dry
film
60-75
Polyamide Epoxy 77% solids by
volume
125-140
Aliphatic Polyester
Urethane*
56% solids by
volume
40-50
Hydraulic and
Waste-water
Structures
Interior Surfaces
White Metal
Blast
volume
150-200
volume
150-200
High
Temperature
Surfaces
Near White
Metal Blast
Siloxane 64% solids by
volume
50
Mechanical
Equipment -
Interior
Commercial
Blast
Polyamide Epoxy
Primer
66% solids by
volume
100-150
volume
100-150
Mechanical
Equipment -
Exterior
Near White
Metal Blast
Polyamide Epoxy
Primer
66% solids by
volume
100-150
Aliphatic Polyester
Urethane
56% solids by
volume
40-50
Electrical
Equipment
Near White
Metal Blast
Polyamide Epoxy
Primer
66% solids by
volume
100-125
Aliphatic Polyester
Urethane
56% solids by
volume
40-50
Control Panels Commercial
Blast
Polyamide Epoxy
Primer
66% solids by
volume
75-100
Low Gloss
Urethane
50% solids by
volume
35-50
Miscellaneous
Shop
Power Tool
Clean
Barrier/Universal
Primer
60% solids by
volume
50-75
Primed Surfaces Damaged Polyamide Epoxy 66% solids by 125-150

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Areas volume
Aliphatic Polyester
Urethane*
56% solids by
volume
40-50
Potable Water
Immersion (NSF
61 or National
Water Council)
White Metal
Blast
Amine-Cured
Epoxy
91% solids by
volume
75-125
Amine-Cured
Epoxy
91% solids by
volume
75-125
Demineralized
Water Immersion
White Metal
Blast
Amine-Cured
Epoxy
91% solids by
volume
75-125
Amine-Cured
Epoxy
91% solids by
volume
75-125
Water Treatment Near White
Metal Blast
Polyamide Epoxy
Primer
66% solids by
volume
100-150
Aliphatic Polyester
Urethane
56% solids by
volume
40-50
Fuel Oil
Immersion
Near White
Metal Blast
Vapor space -
Inorganic Zinc
85% zinc in dry
film
60-75
Tank bottom -
Coal Tar Epoxy
75% solids by
volume
400
* Exterior surfaces only.

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Table-2
Recommended Painting / Coating systems for Non-Ferrous Metal Surfaces
Equipment/Area Surface
Preparation
Composition
DFT
(microns)
Galvanized
Materials
Solvent
Clean
Acid Pretreatment - Varies
volume
25-150
Aliphatic Polyester
Urethane
56% solids by
volume
0-50

Table-3
Recommended Painting / Coating systems for Concrete Surfaces
Structure/Area Surface
Preparation
Composition
DFT (microns)
Plastered
Concrete or brick
block-Interior
Wet/chemical
Areas
Clean and
Dry
Epoxy Block Filler 75% solids by
volume
250-500
volume
150-200
Plastered
Concrete or brick
block-Interior Dry
Areas
Clean and
Dry
Acrylic Block Filler 55% solids by
volume
Varies
Acrylic 54% solids by
volume
50-75
Plastered
Concrete or brick
block exterior
Clean and
Dry
Epoxy Block Filler 75% solids by
volume
250-500
Aliphatic Polyester
Urethane
56% solids by
volume
40-50
Chemical Waste
Sumps
Acid Etch/
Sweep
Blast
volume
150-200
Elastomeric
Urethane
68% solids by
volume
400-500
Poured Concrete
Walls
Sweep
Blast
volume
150-200

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Table-4
Color Coding Scheme
Contents Ground Colour First Colour Band Second Band
Water
Cooling Sea green French blue
Boiler feed water Sea green Gulf red
Condensate Sea green Light brown
Drinking Sea green French blue Signal red
Treated Sea green Light orange
Fire Water Sea green Crimson red
Central heating
below
60C
Sea green Canary red
Central heating
below
60C
Sea green Dark violet
100C Sea green
Central heating
above
100C
Sea green Dark violet Signal red
Cold water down
Service from storage
tanks
Sea green Canary yellow
Domestic, hot Sea green Light grey
Hydraulic power Sea green Black
Sea, river,
untreated
Sea green White
Filtered water Sea green Light Brown
Soft water Sea green Light Brown Signal Red
Warm water Sea green Light Grey Canary Yellow
Chilled water Sea green Black Canary Yellow
Sprinkle and
hydrant water
Sea green White Signal Red
Waste water Sea green Canary Yellow Signal Red
Contents Ground colour First Colour Band Second Band
Air
Compressed upto
and including 15
kg/cm2.
Compressed to
over 15 kg/cm2
Sky blue sky blue Signal Red
Plant Air Sky blue Silver Grey
Instrument Air Sky blue French blue
Dry vacuum White
Wet vacuum White Dark violet

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Very high pressure
steam
Aluminium to IS
2339
Signal Red
High pressure
steam
Aluminium to IS
2339
French blue
Medium pressure
steam
Aluminium to IS
2339
Gulf Red
Low pressure
steam
Aluminium to IS
2339
Canary yellow
Drainage Black
Town gas Canary yellow
Oils
Light Diesel fuel Light brown Brilliant green
High speed diesel
fuel
Light brown
Paraffin Oil Light brown Signal red
Quenching oil Light brown Canary yellow
Furnace oil Light brown French blue
Lubricating oil Light brown Light grey
Hydraulic Power Light brown Dark violet
Transformer Light brown Light orange

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VOLUME II
PART - A
SPECIFICATION: M3
CRANES AND HOISTS

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I N D E X


1.00.00 General and


3.00.00 Technical Requirement

Annexure-1 Specification Data sheets

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M3: CRANES AND HOIST

1.00.00 General

This chapter covers the requirements for design, engineering,
fabrication, manufacture & assembly, inspection, erection, testing and
commissioning of cranes, hoists and associated equipment, to be
provided by the Contractor.

2.00.00 Codes & Standards

The design, manufacture, erection and testing of the cranes and hoists
shall conform to the latest edition of the following codes and
standards along with their amendments:

IS: 807 : Code of Practice for Design, Manufacture,
Erection and Testing of Cranes and Hoists
(Structural Portion).
IS: 3177 : Code of Practice for Electric Overhead
Traveling Cranes and Gantry Cranes other than
Steel Works Cranes.
IS: 1835 : Round Steel Wire for Ropes.
IS: 2266 : Steel Wire Ropes for General Engineering
Purposes.
IS: 3443 : Crane Rail Sections.
IS: 3815 : Point Hook with Shanks for General
Engineering Purpose.
IS: 5532 : Part-1: - Glossary of Terms for cranes type of
cranes.
Part-2: - Parameters
Part-3: - General Concepts
Part-4 :- Component parts
IS: 816 : Code of practice for use of metal arc welding for
general construction in mild steel.
IS: 9595 : Recommendations for metal arc welding of
carbon manganese steels.
IS: 7318 : (Part-I) Fusion welding of steel.
IS: 1323 : Code of practice for oxy-acetylene welding for
structural work in mild steel.
IS: 325 : Three Phase Induction Motors.
IS: 4029 : Guide for Testing Three Phase Induction
Motors.
IS: 2148 : Flame proof enclosures for electrical apparatus.
IS: 3938 : Specification for electric wire rope hoists.
ANSI B 30.2.0 : Safety Codes for overhead and Gantry Cranes

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Requirements of Crane Manufacturers
Association of America.

In case of contradiction between above mentioned Codes and Standards and this
technical specification, the latter will prevail.

3.00.00 Technical Requirements

Selection Criteria for Cranes and Hoists is given below. The supply shall
include necessary slings, lifting beams, handling attachments, etc.

Sr.
No.
Type of Handling
Equipments
Weight of Equipment to
be Handled
1 Double girder EOT Crane >10 T
2 Single girder EOT crane/
Under slung crane
<10 T
3 Electric Hoist >2000 kg
4 Manual hoist with trolley >500 kg and <2000 kg

Note: Electrical hoists for the equipment which has to be lifted
more than 10M, irrespective of the weight to be lifted.

3.01.00 EOT Cranes

The EOT cranes shall be designed as per Class II for
Mechanical, Electrical and Structural components (IS: 807 & IS:
3177) and shall be provided for the areas where frequent
requirement of handling of heavy loads exists. The nominal
carrying capacity of the cranes must be 10% more than heaviest
object to be lifted and aux. hoist capacity shall be in the range of 25%
of the main hoist capacity. The height of lift for EOT crane shall
be based on lifting the tallest piece from the operating floor to
grade, with sufficient clearances for lifting over other equipment on
operating floor. The span of cranes shall be derived based on the
building layout with considerations to clearances and hook approach.
Access walkway with safety handrails shall be provided.

The EOT cranes shall be designed to operate with 125% of rated load
without any permanent deformation. The EOT cranes are designed
with a maximum deflection of 1 / 900 of crane span at rated load.

The TG Building EOT crane is used for maintenance of the STG,
generator coolers, CEPs, BFPs, etc and shall be operated both from
cabin and pendant push button station.

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3.02.00 Hoists and Trolleys with Monorails

The nominal carrying capacity of the hoists and of their
attachment points shall have capacity 10% more than the heaviest
object to be lifted.

3.03.00 Electric Hoists

Pendant push button operated Electric Hoist conforming to
IS:3938 of capacity, travel and lift as per various requirements.

3.04.00 Chain Pulley Blocks

Manually operated chain pulley block conforming to IS:3832 shall be
provided as per various requirements. The chain pulley block shall
have self-braking system of holding the load at any position. The hook
provided shall conform to IS: 8610 / IS: 3815.

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ANNEXURE-I
SPECIFICATION DATA SHEET

Sr.
No.
Description Data
A) Double Girder / Single
Girder E.O.T Crane

Hook type Ramshorn Hook or Shank C. Forged steel.
Safety latch and swivel lock pin.
Material of Construction
Trolley frame Cast steel / Mild steel
Gears (Trolley) Machine cut cast steel / Forged steel / C40 /
C50
Lifting hook (Swivel) Shank C. IS 3815 Forged steel. Safety latch
and swivel lock pin.
Rope drum As per IS: 3177 with minimum 1 spare groove,
hook is at highest position.
Gears IS 3681/4460
Wire Rope Flexible plough steel with lubricated fibre core
as per IS: 2266.
Trolley wheel Forged / cast steel / C40 with minimum
300 350 BHN and single flanged to suit
standard I beam section
Type of brakes
Hoist Electro magnetic
For long travel & Cross
Travel
Electro hydraulic thruster or Electromagnetic.

No Required 2 nos. per each drive.
Limit switches
i. Cross Two way lever 2 nos
ii. Long travel Two way lever 2 nos
iii. Hoisting Two way rotary & gravity (1+1)
Electrical
Runway (DSL) Shrouded Copper conductors.
Power supply Shrouded type down shop leads shall
be provided to supply power to crane. Power
supply to Crab will be through flexible
trailing conductors.
Motors Total enclosed, fan cooled, Insulation shall
be designed for class F and temperature
limited to class B, slip ring Induction type,
degree of protection IP-55.

For Creep speed-planetary gear and motor
(sq. cage) arrangement will be provided on
hoisting drive to achieve 10% speed of the main

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speed.
Motor Duty and CDF Class S4, 40% CDF
No. of starts per hour 150 Starts/h (min) per each motor.
B) Electric Hoist
Standards IS:3938 /8610
Trolley type Electric operated
Gears (Trolley) Machine cut cast steel / Forged steel / C40/
C50.
Lifting hook (Swivel) Shank C. IS:3815 Forged steel. Safety latch
Rope drum As per IS: 3177 with minimum 1 spare
groove, hook is at highest position.
Gears IS:3681/4460
Wire Rope Flexible plough steel with lubricated fibre core
as per IS:2266
Factor of safety As per IS / Not less than 5
Trolley wheel Forged / cast steel / C40 with minimum 200-
BHN and single flanged to suit standard I beam
section.
Motor Duty and CDF Class S4, 40% CDF
Brakes 150% rated torque
- Type AC thruster break
- Hoisting One per each drive
- CT One per each drive
Limit switch
- Hoisting 1 No.
- CT 1 No.
C) Manual Hoist with
Geared Trolley

Standards CL- II IS-3832
Trolley type Hand operated
Gears (Trolley) Machine cut cast steel / Forged steel / C40 /
C50
Lifting hook (Swivel) Shank C. IS:3815 Forged steel. Safety latch
Gears IS:3681/4460
Wire Rope Flexible plough steel with lubricated fiber core
as per IS:2266
Trolley wheel Forged / cast steel / C40 with minimum 300-350
BHN and single flanged to suit standard I beam
section.

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VOLUME II
PART - A
SPECIFICATION: M4
PIPING, VALVES AND SPECIALITIES, THERMAL
INSULATION

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I N D E X


1.00.00 General and


3.00.00 Technical Requirement

Annexure-1 Specification Data sheets

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M4: PIPING, VALVES AND SPECIALITIES, THERMAL INSULATION

1.00.00 General

The Contractor is responsible for the design, supply and construction
of all piping equipment and accessories which must be in accordance
with the latest editions of the specified standards. The requirement of
Indian Boiler Regulation (IBR) shall be complied with as far as
applicable.

The basic and detailed design of all pipe work and related
components must be carried out by the Contractor in such a
way that there is good coordination and cooperation between the
Contractor, the sub contractors and the Owner/Purchaser.

The Contractor is responsible for ensuring that no mistake is made
with regard to the materials used either in the workshop or during
erection on site. This applies especially to pipes from which the
material marking put on at the pipe mill and / or workshop is removed
by such processing as bending, forging etc. In case of doubt the
Contractor is responsible for suitable quality checks.

All pipe components manufactured by the Contractor and parts
on which he has worked, are to be marked clearly with an item
number and material marking, this marking shall be permanent.

For reasons of easy availability in India for future replacement,
ANSI / ASTM materials and dimensional standards are preferred.

2.00.00 Design Criteria

The pipe work shall be designed and erected in accordance
with the American National code for Pressure Piping ANSI B31.1
Power Piping or an expressively approved equivalent standard
and Indian Boiler Regulations wherever applicable.

The present specification will prevail against that of the code
whenever the former is more restrictive.

The following approximate flow velocities should not be exceeded:

Type of Pipe work Max. Flow Velocity

Steam Lines

Vacuum lines 60 m/s

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High-pressure live steam lines 45 m/s

Low-Pressure steam lines above 5 bar 35 m/s

Low-Pressure steam lines below 5 bar 25 m/s

Saturated steam lines 20 m/s

Water and Condensate Lines

Pump suction lines (without feed water suction line) 0.8 m/s

Water discharge lines 2.0 m/s

Feed water suction lines 0.6-0.9 m/s

Feed water discharge lines 2.5-3 m/s

Air Lines

Delivery line for reciprocating compressors 20 m/s

Suction and delivery lines for rotary compressors 15 m/s

Suction line for reciprocating compressors 20 m/s

Fuel Gas and Oil Lines

Lubricating oil lines and fuel oil suction lines 1.0 m/s

Fuel oil supply lines (preheated) 1.5 m/s

Diesel fuel lines 1.5 m/s

Flue gas lines 16 m/s

The Nominal Diameters (DN) can be used for piping components are
given below:

DN (mm) (in) DN (mm) (in) DN (mm) (in)

20* 3/4 150 6 700 28
750 30

25 1 200 8 800 32
250 10 900 36

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40 1 300 12 1000 40
350 14

50 2 400 16 1200 48
450 18

80 3 500 20 1400 56
100 4 600 24

* The DN 20 and lower only for dosing pipelines and pipelines for
gaseous hydrogen, carbon dioxide and other mediums if required and
applicable.

All rules of the art considering technical and economic parameters shall
be carefully followed, namely:

For lines conveying liquids the design pressure must be equal to
maximum operating pressure including the pressure reached
during transients (water hammer).

The calculation of the pipe work shall consider also the highest
possible temperature that can occur during any mode of
operation (e.g. turbine no-load temperature) together with the
highest corresponding pressure.

Also operational defects (e.g. outage of the spray water injection to
upstream de-superheating stations) are to be considered.

For the design of safety valves installed downstream of reducing
stations, H.P. bypass valves or equivalent control valves, the
maximum throughput of the fully open reducing or bypass valve,
including injection water quantity, is to be taken as the basis for
calculation.

In addition to the required wall thickness in accordance with
calculations a corrosion allowance of 3 mm must be added for
unprotected water lines where corrosion is to be expected.

Proper care shall be taken for thermal expansion of pipe systems.

Expansion joints shall not be used in steam systems with operating
pressures above 500 kPa (g).

For all systems subject to thermal expansion of pipe size larger than
DN 100 the pipe manufacturer shall submit the necessary test
certificates.

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Doc. No. 11V02-201-SPC-M-0001, REV.R0
Date: 04-11-2011
VOL-II
PART-A, M4
Page 6 of 15

3.00.00 Guidelines for the Design and Construction of Pipe Work and
Accessories

The pipe work and its accessories shall be designed and
arranged so that all parts can be mounted and replaced without
difficulty. All important parts, such as valves must be accessible from
platforms.
The platform must be able to withstand the weight of the valve
removed as well as the weight of the appropriate number of
persons handling the valve, and must be sized adequately
providing both working space for the men and space for the valve.

The piping should be an integral system including all supporting
frame, connection parts and valves installed for safety, discharge and
fill-in system, to ensure safe and effective operation. Piping is
designed mainly in unit system, while units are interconnected, it is
necessary to make sure that the main unit can operate separately
from the reserve unit. Piping shall be assigned with supply isolation
valves in segments to turn off pipe for maintenance while the whole
system can operate continuously.

High pressure pipes and piping with thick wall that need hot bending
can only be supplied to site in the prefabricated form. The
prefabricated pipe shall be hydraulically tested before acceptance.

A pipe stress and flexibility analysis shall be made. The calculation of
pipe stress and flexibility shall be based on operating conditions of the
pipe.

The pipe-work and appurtenances shall be designed and arranged so
that no undue stresses occur during operation, transient and shut-
down conditions. All valves must be accessible. Pipes with operation
temperature above 300C shall not be pre-stressed to compensate
thermal expansion.

For piping systems with a pressure rating of PN 40 and above,
drainage and venting facilities must be fitted with double valves.

Pipelines with temperature above 400C connected to vessel and
equipment that can be inspected inside must be fitted with double
valves as well.
All steam traps shall be bypassed by means of open drainage
facilities (i.e. no direct by pass but a free drain led to a funnel).
All control valves shall be bypassed by hand operated control
valves. The control valve must be blocked for maintenance by
isolation valves.

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Doc. No. 11V02-201-SPC-M-0001, REV.R0
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VOL-II
PART-A, M4
Page 7 of 15

No tubes with nominal diameters less than 25 mm shall be
used, except for impulse measuring lines and dosing pipelines.

For all system parts subject to acceptance retests, relevant provision
shall be made so that they can be separated to allow for those retests.

None of the forces and moments transmitted by the pipes to
adjacent machines, apparatus and platforms must exceed the
maximum permissible values, given by the manufacturers of these
items.

The design of pipe work supports must not permit any
vibrations or undue stresses on the pipe, connected equipment or
structures in any operation and test conditions.

Since the steam pipes may be filled with water for a short time
(e.g. when flushing or pressure testing), supports must be
dimensioned accordingly. The pipe support structures are to be
designed to minimize heat transfer.

Overhead piping is to have a minimum vertical clearance of 3
meters above walkways and working areas and 7 meters clearance
above roadways.

To the extent that steam or hot water can remain or flow in
pipe sections isolated for repair purposes, dump pipes with hand
operated shut-off valves capable of being locked open or closed
shall be provided for the safety of personnel.

Equipment and piping systems shall be protected against excess
pressure caused by thermal expansion of locked-in fluids.

All piping shall be provided with a sufficient number of vents and
drains at its highest and lowest points. All vents, drains or dumps
points shall lead to the flash tanks or into funnels at visible points with
covers. They shall be grouped together where possible.

The Contractor shall furnish and install suitable thimbles at all
points where pipelines pass through building floors and walls.

The Contractor shall provide effective flashing rings with rain-tight
hoods for all pipes passing through the roofs or exterior walls.

All piping shall be cleaned and kept clean and free from all
foreign matter before and during erection. The Contractor shall
submit a detailed description of proposed steam blowing and other

SPECFICATION FOR

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Doc. No. 11V02-201-SPC-M-0001, REV.R0
Date: 04-11-2011
VOL-II
PART-A, M4
Page 8 of 15

cleaning procedures for all pipelines, and no part of this work shall be
started until these procedures have been approved. The Contractor
shall furnish, install and dismantle all temporary pipes, hangers,
anchors, etc required for cleaning of all piping systems.

As many welds as possible shall be carried out in the workshop.
Supports for alloyed H.P piping systems shall also be welded in the
workshop.

The supplier shall furnish and install suitable sleeves at all points
where pipes pass through building floors and walls.

Hangers and supports shall be standardized and the number of
types and component assemblies shall be reduced to the minimum.
Each pipe hanger and support component shall be of steel,
suitable for the maximum operating temperature. Spring support
assemblies shall be equipped with a means of locking the springs
against movement. Sliding surfaces shall be constructed of non-
corrodible materials that do not rely on coatings for corrosion
protection.

The use of counterweights as a substitute for support spring
assemblies will not be permitted.

After plant start-up, all supports shall be checked to confirm that
spring load indicators have assumed the proper hot load position and
that all hangers and supports which do not incorporate springs are in
the correct position. After all required adjustments have been made,
all threads shall be fully engaged and locked and all spring ties shall
be disengaged.

4.00.00 Guidelines for the Design and Construction of Valves

For reasons of plant standardization the Contractor shall
standardize the valves, to reduce number of types and manufacturers
to a minimum.

Design, construction, fabrication and testing of the valves shall
be in accordance with the applicable standards. The requirement of
this clause will apply if they are more stringent than the approved
standards. All valves shall be suitable for the media and for the
service conditions and those performing similar duties shall be
interchangeable. All valves shall conform at least with pressure class
150 according to ANSI B16.5 or equivalent. All Valves must meet the
maximum design demands for pressure and temperature of the joint
piping system. All valves must bear 1.5 times of the maximum
design pressure.

SPECFICATION FOR

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Doc. No. 11V02-201-SPC-M-0001, REV.R0
Date: 04-11-2011
VOL-II
PART-A, M4
Page 9 of 15

Basically the following types of valves shall be used:

Globe valves : Up to and including DN 50

Gate valves : DN 80 and above

Butterfly valves : DN 150 and above for auxiliary
cooling water

Lift check valves : Up to and including DN 50

Swing check valves : DN 80 and above

Ball valves : For fuel services

Diaphragm valves : Up to and including DN 150 for
chemical lines, auxiliary cooling water

If the media handled are polluted the shut off devices used in
discharge lines (e.g. drains on vessels) and possibly also in vent
lines should consist of gate valves.

The maximum permissible forces for actuation of hand wheels
are 300 N for wheels with diameter upto 400 mm and 600 N
for larger diameter wheels. Differential pressures requiring higher
forces for actuation of hand wheels will entail fitting the valve
with gears. For calculation of the gears or all other actuators the
design pressures shall be taken as differential pressures. Large
valves that are frequently operated or hard to operate manually,
shall be motorized.

Where required, valve spindles shall be lengthened so that the hand-
wheel is at a minimum height of 1 meter above the level of the floor.
Where necessary they shall be provided with headstocks and
pedestals of rigid construction. The actuation of valves by means of
chain drives is not permissible.

All valves shall be closed by rotating the hand wheel in clockwise
direction. The face of each hand wheel shall be clearly marked
open and shut, with arrows indicating the direction of rotation to
which each term refers.

Plastic or bakelite valve hand wheels will not be accepted. Valves with
solid hand wheels are not acceptable since all valves must be
capable of being locked by means of a chain and padlock in the
open and closed position.

SPECFICATION FOR

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Doc. No. 11V02-201-SPC-M-0001, REV.R0
Date: 04-11-2011
VOL-II
PART-A, M4
Page 10 of 15

Outdoor valves must be suitable for outdoor installation with due
consideration of the special climate and environmental conditions at
the site.

Unless otherwise agreed, all valves shall be fitted with the spindle in
the vertical position preferably. Eye bolts shall be provided where
necessary to facilitate handling heavy valves or parts of valves.

Materials used must conform to the applicable standards and must
comply with the pipe material and the requirements due to operating
temperature. Materials for screws, bolts and nuts must have the
operating temperature limits closely observed.

All valves of the relevant pipe-work systems must be suitable for
pickling.

In no case will grey cast iron be allowed.

Unless otherwise required by virtue of the valves function, bodies
shall have an internal cross section corresponding to the nominal
diameter of the connection.

Gate valves and swing check valves of the H.P. piping systems shall
be equipped with self-sealing lid covers. Gate valves with self-sealing
lid covers shall be equipped with a safety device at the body. If discs
are used they must be capable of being dismantled and changed
under operating conditions.

Connecting flanges shall be in accordance with the applicable
standards with regard to both the connection dimensions and the
minimum thickness of the material.

The transition from the flat rear surface of the flange (nut contact
faces) to where the welding begins must have no sharp-edged
machined grooves.

The stem must be made in one piece; the length of thread must be
such that the threaded bush is fully engaged in any position of the
moving part. The connection between the stem and the cone must be
sufficiently flexible. For H.P. globe valves and globe valves for
throttling purposes of DN 50 or less the spindle and cone must be
made in one piece. Disc must have parabolic characteristic.

In case of metallic sealing elements the difference in hardness
between the body seat and the seat of the sealing element must be

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Doc. No. 11V02-201-SPC-M-0001, REV.R0
Date: 04-11-2011
VOL-II
PART-A, M4
Page 11 of 15

equal to or more than 30 HB (Brinel hardness), the seat element
having the higher hardness values.

All globe valves shall be equipped with throttling cones
with parabolic characteristics.

Each valve shall be marked on the body with the material diameter,
the nominal pressure and an arrow showing the flow direction
whenever only one is possible.

Drain lines shall be installed at each low point or condensate
collecting point in each steam- installation shall include a
permanent strainer, upstream and downstream isolation valves and
a globe valve as free drain. Steam traps shall be of the bimetallic or
thermodynamic type, selected to suit the service conditions.

No traps which incorporates internal screens or check valves shall be
used unless specifically required by the specifications or approved by
the Owner/Purchaser.

Condensate drainers shall be of the ball-float type.

For safety valves, pressure relief valves, bursting discs and other
safety devices against excess pressure the directives of appendix
II of the code ANSI B31.1: New Mandatory Rules for the design of
Safety Valve Installations shall apply, as well as requirements of
Indian Boiler Regulations (IBR) wherever applicable.

5.00.00 Materials requirements for Piping Components and Valves

The main materials and special requirements specified under this title
shall be seen as the minimum requirement.

The following guideline represents minimum requirements. In case of
intended deviations Deviation from Enquiry Documents applies.

Piping Main Materials (ASTM Standards) Special
System Piping Components Valves Requirements
De-mineralized
water

A 312 Grade TP
316L or equivalent

A 182 Grade F316 L
or A351 Grade CF
8M or equivalent.
Sealing elements:
(disc and seat) as
body material.
-kind of connection:
flanged
- stem: rising
-bonnet connection:
flanged

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Doc. No. 11V02-201-SPC-M-0001, REV.R0
Date: 04-11-2011
VOL-II
PART-A, M4
Page 12 of 15

Service and
Instrumentation
air

DN<12 copper,
DN>12
A53 Grade
A
galvanized
Bronze or stainless
steel

Piping components
and Valves
screwed up to
max. DN 50 or
flanged.
Auxiliary
cooling water
(DMCW)

A 53 Gr. A or
equivalent.
Surface protection:
The rubber lining
protection has to be
carried out by
specialized firms
according to
appropriate
standards and as
proved
manufacturers
and the quality must
be approved GRP
pipes or cement
lined steel pipes
is also acceptable
depending on pipe
size.
A 105, A 216 Grade
WCB or equivalent.

Surface protection:
The rubber lining
protection has to be
carried out by
specialized firms
according to
appropriate standards
and as proved
manufacturers and the
quality must be
approved GRP pipes
or
cement lined steel
pipes is also
acceptable depending
on pipe size.
Piping components
and valves
flanged

Valves:In the case
of Butterfly valves
the disc must be
double eccentrically
supported.

Heavy fuel oil
and hydrazine
dosing lines.
A 53 Grade A or
equivalent.

A 105 or A216
Grade WCB or
equivalent.
Sealing elements
(disc and seat)
materials with a
minimum Cr. content
of 13%.
Hardness 250 HB in
case of auxiliary
cooling water the
sealing of rubber or
equivalent suitable for
the service.
Valves
-kind of
connection butt
welding ends for
valves with rubber
elements.

- stem: rising
- hand wheel; non
rising
-bonnet connection:
flanged.

Lines for dosing
additives such
as Trisodium
phosphate
solution, Ferrous
sulphate solution
A 312 Grade TP
304 or equivalent

A 182 Grade 304,
A 351, CF 8 or
equivalent.

Valves with
butt
welding ends.

SPECFICATION FOR

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Doc. No. 11V02-201-SPC-M-0001, REV.R0
Date: 04-11-2011
VOL-II
PART-A, M4
Page 13 of 15

6.00.00 Thermal Insulation

The insulation shall be installed in accordance with the
recommendation of the British Standard Code of Practice
CP3005, 1969 or IS: 14164 (1995) or equivalent.

Special attention shall be paid to the ease of maintenance of
each part of the plant and straightforward access to insulated
components requiring maintenance should be possible.

Insulation shall be provided for heat conservation, for personnel
protection and for the prevention of condensation.

The basis for economic calculation of thermal insulation
thickness shall be a surface temperature of 60C at an ambient
temperature of 35C and at a wind velocity of 1 m/s.

Insulation for personnel protection shall be such that surface
temperatures do not exceed 60C.

Insulation for condensation prevention shall be applied to equipment
operating at temperatures below the maximum dew point, where
condensation could form detriment to plant structures or
equipment or cause discomfort to operating personnel.

Only mineral fiber mats shall be used. Asbestos is not allowed
to be used for insulation.

The mats must be stable in shape, chemically inert, free of sulphur
and alkali, resistant to water and steam; non-flammable and
capable of withstanding continuous exposure to the pipe design
temperature. The insulating mats used for insulation of stainless
steel equipment shall have a chloride content of less than 0.15%.

The density of mineral wool mats shall be not less than 100
kg/m
3
under a loading of 100 kg/m
2
.

The nominal thickness of the mats must be mentioned on the
mats by the manufacturer.

The thermal conductivity of the material at 100C shall not exceed
0.055 W/m
2
.

All insulated equipment shall be provided with a jacket of
Aluminium sheeting outdoor, galvanized sheeting indoor, which
must have the following minimum thicknesses:

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Doc. No. 11V02-201-SPC-M-0001, REV.R0
Date: 04-11-2011
VOL-II
PART-A, M4
Page 14 of 15

o Outer insulation diameter up to 350 mm Sheet thickness 1.0 mm

o Outer insulation diameter above 350 mm Sheet thickness 1.0 mm

o Tanks and other large equipment Sheet thickness 1.2 mm

Tank tops shall be provided with insulation strong enough to
support a mans weight.

The sheets shall be secured and connected at the longitudinal
seams with stainless self tapping screws (five screws per meter).

At the longitudinal and circumferential joints the sheets shall overlap
by at least 50 mm so as to drain off the liquid and not to trap the liquid
in the insulation.

The seams and penetrations of any sheet metal insulating jacket
installed outdoor shall be sealed against penetration of water by
means of a suitable insulating tape.

The inside of the Aluminium jacket shall be protected against contact
corrosion from the wire mesh of the insulating mats by suitable means
(e.g. Kraft paper).

In case of greater insulation thicknesses (at least from 60 mm
upwards) spacers shall be provided to ensure a uniform insulating
thickness on all sides and a perfectly circular shape of the sheet
metal jacket.

All flanges and fittings shall be provided with two-piece or multi-part
caps made of Aluminium sheet of the specified thickness.

The shaped caps of the welded-in fittings shall be made longer by
approximately twice the insulation thickness so that the welding
seams will be exposed after removal of the cap, where possible,
the caps should be fitted with a clamping strip or lever hook to
facilitate assembly.

All manholes shall be provided with removable insulated covers,
secured with easily accessible clamps or screws.

Tanks and apparatus shall be insulated in the same way as pipes,
except that the insulating material must not be attached by wire but by
using strong galvanized steel bands.

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Doc. No. 11V02-201-SPC-M-0001, REV.R0
Date: 04-11-2011
VOL-II
PART-A, M4
Page 15 of 15

Spacers are only to be welded to apparatus if this is essential
for satisfactory retention of the insulation. The welding of spacers
to apparatus is subject to approval by the apparatus Owner/Purchaser
at site in writing.

Compensators are to be insulated with detachable, two-piece or
multipart caps. the sheet metal jacket shall be formed of Aluminium
sheets. The insulation mats are to be secured in the sheet metal caps
by means of hooks and clips.

In case of trace-heated pipelines, the heating pipes shall be
provided with an Aluminium radiation plate. The radiation plate shall
be attached eccentrically to the pipe axis in the area of the tracing
only.

Wherever insulation is necessary only for the protection of personnel,
it shall be applied around that portion of the pipeline length or to
that surface of the equipment that is located within 2.50 m
above the tread surface of, or within 1.20 m horizontally beyond
the side or end of any floor, platform, walkway, stair or ladder.

Where necessary drain lines and valves shall be provided with a
contact guard of min 30 mm thickness against accidental contact, and
this shall be installed in the same way as the other insulation.

To avoid the condensation of moisture on cold surfaces of plant
parts, their surface temperature must lie above the dew point of
air. Plant parts for which these conditions do not exist, must be
provided with insulation against condensation.

In the case of insulation against condensation, the outer
protection of the insulation must not only provide a mechanical
barrier but also it must be implemented so as to be vapour-tight,
to avoid the entry of moisture through water vapour diffusion into
the insulating layer.

For this purpose bitumen sealers, bitumen binders or special paint
finishes shall be used.

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