bharat heavy electricals limited · all pressure vessels shall be designed and constructed in...

BHARAT HEAVY ELECTRICALS LIMITED

PROJECT ENGINEERING MANAGEMENT, NOIDA

Date-8-Oct-18

CORRIGENDUM- 05

PROJECT : 2X660 MW UDANGUDI SUPERCRITICAL STPP ST

PACKAGE : CONDENSATE POLISHING UNIT

ENQUIRY NO

: E-6008/2018 DTD 30/07/2018

SUBJECT : TECHNICAL AMENDMENTAND PRE-BID CLARIFICATION

Type of Corrigendum

Technical Corrigendum - Commercial Corrigendum - ☐

In reference to the above mentioned tender enquiry for CONDENSATE POLISHING UNIT package Please note the following.

1. Technical amendment-1 to technical specification along with pre-bid queries are attached for your ready reference. Vendors who have already submitted their offer, kindly review their offer and resubmit accordingly if required and who have not submitted their offer, consider the attached amendment and quote accordingly.

All the other terms and conditions of the tender enquiry remain unchanged. All the bidders are

requested to quote accordingly.

Yours faithfully,

For and on behalf of BHEL

Guru Das Dy. Manager

AMENDMENT TO TECHNICAL SPECIFICATION FOR

CONDENSATE POLISING UNIT 2X660 MW UDANGUDI TPP –

STAGE-I

SPECIFICATION NO.: PE-TS-435-155-A001

AMENDMENT NO # 1

REV. NO. 00 DATE: 08-10-2018

Page 1 of 1

The following modifications with respect to TECHNICAL SPECIFICATION FOR CONDENSATE POLISING UNIT BHEL’s Technical specification no PE-TS-

435-155-A001 shall apply.

Bidder to note that existing clauses/details as appearing in the specification stands deleted / replaced and clauses/details as mentioned in “Modified to or Read as” column

shall be applicable and complied by the bidder as listed below in SCHEDULE A.

In addition, new clauses and scope are also added as listed below in SCHEDULE B and shall be a part of tender specification (PE-TS-423-155-A001). Bidder to comply

the same.

SCHEDULE- A

MODIFIED CLAUSES/PAGE NUMBERS:

Sl

no. Section

Sub-Section/

Description

Clause

no Page no Existing clause/details Modified to or Read as

1. I Sub-Section– C-1

all 11-31 SPECIFIC TECHNICAL

REQUIREMENTS

(MECHANICAL)

Revised SPECIFIC TECHNICAL REQUIREMENTS

(MECHANICAL). Refer ANNEXURE-I attached

2. I

Sub-Section– D all 386-407 GENERAL Technical

Requirements (Mech.)

Revised GENERAL Technical Requirements

(Mech.) Refer ANNEXURE-II attached

3. II Sub-Section– II Sub-section -7 - 526-527 P&ID OF CONDENSATE

POLISHING UNIT ( Rev-0) Revised P&ID OF CONDENSATE POLISHING UNIT ( Rev-1) Refer ANNEXURE-III attached

SCHEDULE- B

NEW CLAUSES / SCOPE ADDED:

Sl no. Section

No. Sub-section

Annexure

/Clause no.

Page

no. Description

4. I

Sub-Section– C-2 -- Bidder to refer customer specification for applicable piping, valves and fittings. Refer ANNEXURE-IV attached

********************

TITLE: 2x660 MW UDANGUDI SUPERCRITICAL STPP-

STAGE I

SPECIFICATION NO. PE-TS-435-155-A001

SECTION : I TECHNICAL SPECIFICATION FOR

CONDENSATE POLISHING UNIT SUB-SECTION: C-1

REV. NO. 01 DATE : 08-10-2018

SECTION –I SUB-SECTION – C1-SPECIFIC TECHNICAL REQUIREMENTS (MECHANICAL)

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TECHNICAL DETAILS OF CONDENSATE POLISHING PLANT

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1. INTRODUCTION

For maintaining the feed water purity condensate polishing plant will be provided in the feed water cycle at the downstream of condensate extraction pumps. The function of the CPU will be to purify the condensate effluent from the condenser by removing solids and dissolved salts with the intent of reducing corrosion and depositions in the steam-water cycle. The proposed Condensate Polishing Unit (CPU) shall treat the condensate of the Turbine-Generator (TG) Unit of the power station, using deep Mixed Bed Ion Exchange Polisher Vessels and an external regeneration system. Condensate polishing service vessels for each unit alongwith common external regeneration system shall be provided.

2. SYSTEM DESCRIPTION

This document gives the system description, design philosophy and control & instrumentation philosophy of CONDENSATE POLISHING UNIT (CPU) for 2x660 MW UDANGUDI TPP-STAGE I. There shall be three service vessels (3 x 50%) for each 660 MW unit, each polishing 50% of the condensate flow corresponding to 1% make up, design condenser pressure and all HP heaters out of service condition. A common external regeneration facility for both the unit shall be provided. Polisher mixed bed/ service vessels of 660 MW Unit shall be located in TG hall. However, the regeneration system shall be external. The CPU regeneration system will be located in DM Plant area.

3. SALIENT DESIGN INPUTS/ CRITERIA The design flow rate of each service vessels shall be 662.5 T/Hr. Total flow for each unit shall be 1325 T/Hr. The quality of influent (condensate at inlet of CPU), effluent (condensate at outlet of CPU) and service run length to be considered for design of the CPU shall be as below: Normal conditions: During normal conditions, the quality of influent and effluent shall be considered as below: -

Description Influent Effluent

Sodium, ppb 10 2

Iron, ppb 50 5

Silica, ppb 30 5

Chloride, ppb 10 2

Ammonia, ppb 100 -

TDS (total dissolved solids) (excluding ammonia), ppb

100 20

pH 8.5 -

Conductivity, µ mhos/cm - ≤ 0.1 at 25°C

Suspended solids (crud), ppb 50 5

Under the above operating conditions and design flow through the polisher units, the service run of the vessels shall be 15 days (360 hrs). The mode of CPU operation during this period shall be either in hydrogen cycle or a combination of hydrogen and ammonia cycle which shall be decided by the CPU supplier while maintaining the above effluent quality.

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Whenever specific conductivity starts increasing in the effluent, it shall be deemed that the ammonia cycle has commenced. Start up conditions : During unit start-up conditions, the quality of influent and effluent shall be considered as below: -

Description Influent Effluent

Sodium, ppb 50 20

Silica, ppb 150 20

TDS (total dissolved solids) (excluding ammonia), ppb

2000 20

Average Crud (mostly black oxide of iron),ppb

500 150

The useful service run between two regenerations under start-up conditions shall not be less than 50 hours.

The bed cross section shall be such that the average velocity of condensate through it shall not exceed 2 meters/min at the design flow rate. The effective depth of the mixed resin bed in the condensate polisher service vessels shall not be less than 1100 mm.

Maximum pressure drop under dirty conditions will be restricted to about 3.5 kg/cm2

including the pressure drop across effluent resin traps.

Cation resins shall be regenerated by technical grade hydrochloric acid to IS:265 (concentration 30-33% by volume) and anion resins by sodium hydroxide, rayon grade to IS:252 available as 48% lye or as flakes.

The regeneration process shall be of proven design and shall give resin separation compatible with the desired effluent quality. Bidder shall include inert resin in the system if he feels that it helps in better resin separation.

Sizing calculations for resin volume provided and capacities of various regeneration equipment and neutralizing pit shall be submitted during detailed engineering.

Design pressure of service vessels shall be equal to shut off pressure of condensate extractions pump

Design Pressure of Service vessels shall be 45 kg/cm2(g)

Design temperature of the vessel shall take care of all operating regimes including HP-LP bypass operation. Condensate temp under HP-LP bypass operation = 55 deg.C

Design temperature Service vessels shall be 55 Deg C.

All pressure vessels shall be designed and constructed in strict accordance with the ASME code Section-VIII or acceptable equivalent international standard. Adequate Mill tolerances shall be considered for determining the thickness of the shells and dished ends of pressure vessels. A minimum thinning allowance of 2 mm shall be considered for the dished ends of pressure vessels.

External Regeneration Facility

Alkali solution preparation facility

The tank capacity shall be equal to 120% of regeneration requirement of one polisher vessel.

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The rated flow of the filter shall not be less than the design capacity of the alkali transfer-cum recirculation pump, and the maximum velocity through the filter shall not exceed 12 m/hr. Depth of the filter material shall not be less than 1 m.

4.0 SCOPE OF CONDENSATE POLISHING UNIT

4.1.1 Service Vessels

3x50% capacity service vessels for each unit. Total 6 vessels shall be installed for 2x660 MW units. Service vessels shall be complete with condensate inlet and outlet connections,

connections for resin transfer to and from the vessels, bed support-cum-underdrain system, inlet water distributors, air distribution arrangement for resin mixing, all fittings and appurtenances etc. as specified and as required. External resin traps shall be provided at the outlet of each service vessel, designed for in-place manual back washing. All necessary piping, valves and fittings with actuators necessary for their remote operation. Common drain header for service vessels of each unit. All necessary drains, vents and sampling points, with valves shall be provided as required.

4.1.2 Resin Trap

Outlet of each condensate polishing vessel and waste effluent header of common regeneration system shall be provided with a resin trap whereas at the outlet of Activated carbon filter a media trap shall be provided.

4.1.3 Emergency bypass system

Each condensate polisher service unit shall be provided with an automatic bypass for the condensate polisher on the condensate inlet and outlet headers of the unit with a butterfly type control valve and wafer type butterfly isolation valves on the upstream and down stream sides of the control valve.

Complete instrumentation and controls for this system, including the differential pressure transmitters, panel mounted indicating type controller with provision for remote manual operation, actuator for the control valve with position indicator etc.

For transferring the exhausted and regenerated resins between the service units and the common external regeneration facility common piping with isolation valves shall be erected. Routing of this pipe line shall be developed by in line with his standard practice and shall be finalised during detailed engineering stage.

In the event of excessive pressure differential (0.35 MPa) between the condensate inlet and outlet headers, this control valve will open automatically to bypass requisite quantity of condensate to prevent this pressure differential from exceeding a preset limit when two vessel/one vessel /no vessel is in operation.

1X100% capacity control valve shall be provided to achieve proper control under all operating conditions.

4.1.4 External Regeneration Facility

One (1) common facility for regeneration of the ion-exchange resins from the condensate polishers of two units shall be provided. The system shall include but not limited to the following:

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Regeneration system

Two number resin separation / regeneration vessels and one number mixed resin storage vessel to hold charge of one service vessel shall be provided along with all internals, fitting and appurtenances for these vessels. Mixed resin vessel shall be supplied as per OEM standard practice.

Resin injection hopper, complete with a water ejector system shall be provided for resin make-up to the resin separation/ regeneration vessel. The system shall be sized to handle upto 150 liters of as received new resins per single injection.

All necessary piping, valves and fittings with the actuators necessary for their remote automatic operation shall be provided. These shall include all drains, vents and sampling points with valves as required.

Common waste effluent header with one resin trap designed for in-place manual backwashing shall be provided.

2x100% capacity CPU regeneration water pumps shall be provided for water supply for chemical preparation/dosing and transfer of resin from service vessel to regenerating vessels and vice versa. The pumps shall be horizontal centrifugal type and conform to IS: 1520/IS: 5120 or equivalent without any negative tolerance. All wetted parts of the pump shall be of CF-8M.

Chemical dosing system

2X100% capacity hydraulically operated ejectors or metering pumps shall be provided each for dosing of acid and alkali as per contract specification.

Alkali solution preparation facility

Complete facility for preparing alkali solution from alkali flakes shall be provided as per details given below:

One (1) no. alkali preparation tank complete with electrically driven stirrer, and dissolving basket shall be provided. The tank capacity shall be equal to 120% of regeneration requirement of one polisher vessel.

2x100% capacity horizontal centrifugal type alkali solution transfer-cum-recirculation pumps shall be provided to fill the alkali day tank in one hour.

One (1) no. activated carbon filter shall be provided for alkali preparation. The rated flow of the filter shall not be less than the design capacity of the alkali transfer-cum recirculation pump, and the maximum velocity through the filter shall not exceed 12 m/hr. Depth of the filter material shall not be less than 1 m.

The prepared alkali shall be stored in two (2) no. alkali day tanks.

Facility of bulk storage tanks to hold 48% alkali lye shall also be provided and alkali dosing system shall be designed for this also.

All interconnecting piping, valves and fittings as required for the system.

Carbon trap shall be provided at the outlet line of Activated carbon filter. This carbon trap shall have screen opening of 60 mesh.

Materials

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Valves for handling acid, alkali, ammonia, etc shall be preferably of diaphragm type (MSRL).

Air blowers

Two (2) (1W+1SB) nos. oil free type air blowers, each with electric motor drives for supplying all the process air required for cleaning of resins and their regeneration processes. Each blower shall be complete with motor, V-belt drive with belt guard, inlet filter & silencer, v-belts and discharge snubber, all mounted on a single base.

Further 2x100% capacity air blowers shall also be supplied for mixing the resins in the service vessels. . Each blower shall be complete with motor, V-belt drive with belt guard, inlet filter & silencer, v-belts and discharge snubber, all mounted on a single base.

Relief valve (s) shall be provided as required.

Bulk acid and alkali storage tanks

One (1) no. hose Station for Transfer of Hydrochloric Acid (30-33% HCl). The hose station shall consist of one (1) no. of hose pipe. Hose size shall be of 80 mm /NB @ 20 m, provided along with coupling & diaphragm type isolation valves

One (1) no. hose station for transfer of Alkali (48% NaOH). The hose station shall consist of one (1) no. of hose pipe. Hose size shall be of 80 mm /NB @ 20 m, provided along with coupling & diaphragm type isolation valves

Two nos. (2X100%) Acid unloading pumps each complete with electrical drive motor and all other accessories as required.

Two nos. (2X100%) Alkali unloading pumps each complete with electrical drive motor and all other accessories as required.

Two nos. (2X100%) Alkali transfer cum recirculation pumps each complete with electrical drive motor and all other accessories as required.

Two (2) nos. Bulk Acid storage tanks complete with integral pipe works, valves, level transmitter, level gauges, fume absorber cum overflow seal pot and all other accessories required.

Two (2) nos. Bulk Alkali storage tanks complete with integral pipe works, valves, level transmitter, level gauges, CO2 absorber, over flow seal pot and all other accessories required.

DM water for regeneration

DM water required shall be drawn from DM water storage tanks (not a part of CPU scope) by 2 x100% capacity CPU regeneration cum resin transfer pumps taking suction from the DM water storage tank.

Effluent disposal system

One (1) no. Neutralization Pit of RCC construction with two (2) compartments with acid and alkali resistant lining along with isolation gates shall be provided in the CPU regeneration area. Each section shall have capacity to hold 150% of waste water generated from CPU in one regeneration + 120% of waste generated from DM plant (SAC,SBA & MB) in one regeneration. Dosing of acid and alkali shall also be provided to neutralize effluents of CPU regeneration waste before disposal.

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One (1) no. Acid Measuring Tank( MOC-FRP-500 ltrs capacity) for Neutralization- pit complete with integral pipe works, valves & instruments all other accessories. One (1) no. Alkali Measuring Tank ( MOC-FRP-500 ltrs capacity)for neutralization-pit along with slow speed agitator driven by motor complete with integral pipe works, valves & instruments all other accessories. Two (2 x 100%) capacity Waste Recirculation / Disposal pumps, each complete with electrical drive motor. These pumps shall be of horizontal centrifugal type with priming arrangement(Priming tank-MOC:FRP ) and shall be supplied for waste recirculation and disposal to CMB of ETP. The pump shall be designed to pump the total volume of one section of the neutralization pit in 2 hours. Proven agitation system like air agitation, venture mixing etc. shall be provided in addition to recirculation from pumps. Air blowers of regeneration system shall be used for air agitation. Two (2) nos. Safety Shower with necessary accessories All interconnecting piping, valves and fittings as required for the CPU regeneration system.

5.0.0 CONSTRUCTION REQUIREMENTS

5.1.0 Service Vessels

All service vessels and regeneration area pressure vessels shall be fabricated from carbon steel plates to SA 285C or SA-516 Gr. 70 or equivalent and lined internally. Service vessels shall be of spherical shape or Cylindrical shape.

Lining used may be soft rubber having a shore durometer reading of 40-70 on the A scale, or semihard rubber having a durometer reading of 45-70 on the D scale. The lining shall be applied in three layers, resulting in a total thickness of not less than 4.5 mm anywhere on the internal surfaces of the vessels.

Inlet water and regenerant distributor of service vessels shall be of hub and diffuser splash plate or header and perforated laterals. Material of construction shall be SS-316 except for acid service which will be of haste alloy-B.

Under drains shall be provided with screened laterals with internal perforated pipes and rubber lined flat bottom. For resin separation/ regeneration/ mixed resin vessels, it may have fully screened bottom (NEVA – clog type with pora septanurese screen, fully supported by subway grid or equal).

All internal fasteners shall be of SS-316 and heavy duty locknuts shall be used throughout. 5.2.0 Exchange resins

Cation-anion resin ratio shall be 1.5 parts cation to 1.0 part anion by volume. In case the CPU supplier ’s process requires any non-ionic resin the same shall represent at least 10 percent of the bed volume, but not less than 15 cm of the bed depth in the resin separation/cation regeneration tank of the external regeneration facility. The CPU Grade resin shall be of uniform particle size quality.

Adequate resins for the condensate polisher service vessels along with one (1) spare charge of resin in the mixed resin storage tank shall be supplied. In addition, a separate charge of resin shall also be included for using the resins during commissioning of unit. Total 9 charges of resin will be supplied.

The resins shall be in the form of spherical beads. The particle sizes and densities shall be

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carefully selected to facilitate clear separation between the resins during regeneration process.

The average force required to fracture the individual bead of cation resin in hydrogen form, anion resin in hydroxide form and Inert resin shall exceed 350 grams. Not more than 5 percent of the beads tested in each batch shall get fractured by forces less than 200 grams.

Base of the ion-exchange resins shall be copolymer of styrene and divinylbenzene forming a macroporous or macrorecticular structure. The type of resins to be supplied shall as below:

Cation : Strong acid, with sulfonic acid functional group

Anion : Strong base, with quaternary ammonium (type-I) functional group

Inert (if required ) : Non-ionic, compatible with the above type resins

The resins shall be of reputed manufacturer with adequate past record of successful service for not less than 3 years in similar application.

5.3.0 Vessel freeboard requirements

The pressure vessels in the common external regeneration facility shall be provided with adequate freeboards over the top of the settled resins, to minimize resin loss during their use. Minimum permissible freeboards are as follows:

Mixed resin storage vessel – 50%

Resin separation vessel – 75%

Anion and cation regeneration vessels-100%

Activated carbon filter-75%

In case resin separation vessel is also used as regeneration vessel then the free board shall be 100%.

Adequate Mill tolerances shall be considered for determining the thickness of the shells and dished ends of pressure vessels. A minimum thinning allowance of 2 mm shall be considered for the dished ends of pressure vessels.

5.4.0 Resin traps

Outlet of each condensate polisher vessel and waste effluent header of the common regeneration shall be provided with a resin trap. Pressure drop at design flow through a clean resin trap shall not exceed 0.35 kg/cm2. Resin trap shall be of rubber lined steel construction and internals (cord and screen) shall be of Johnson Screens (Ireland) or equivalent (SS-316) construction.

Resin traps of process effluent line shall have screen opening not exceeding 120 percent of associated process vessel under drain screen Opening. Other resin traps shall have screen opening of 60 mesh. Manual back flushing shall be provided for all resin traps.

5.5.0 Emergency Bypass system

In the event of excessive pressure differential between the condensate inlet and outlet headers, this control valve will open automatically to bypass requisite quantity of condensate to prevent this pressure differential from exceeding a preset limit( 0.35 MPa). The control system shall be so designed that the control valve is able to bypass 50% of rated flow when any of the service vessel is out of service and 100% of flow when both the service vessels are

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out of service.

5.6.0 Piping

The arrangement shall avoid any sharp bends which cause segregation of the mixed resins, and pockets where the resins can get trapped. Suitable observation ports shall be provided in all critical areas to enable the operator to monitor completeness of the resin transfer operations. All necessary arrangements for venting and draining of the pipeline shall be provided.

Remotely operated valves suitably interlocked with the plant operation, shall ensure that the resins get transferred to and from only the particular service vessel which has been selected by the operator.

The resin transfer pipeline shall be of stainless steel type 304. The pipeline shall be sized for a flow velocity of between 2 and 3 m/s. The isolation valves on the resin transfer line shall be of eccentric plug type/ball valve of stainless steel construction.

6.0.0 CONTROL AND OPERATION OF PLANT

Condensate polishing unit shall be controlled and monitored from the Unit DCS in the Central control room. System shall be complete with, complete with remote I/Os, Redundant Processor, power supply, communication module, redundant communication link all hardware, software, other interfaces, cables and field sensors / instruments / erection hardware envisaged to control and monitor it.

Condensate polishing unit local control room along with remote I/O panel and monitor shall be located at SWAS dry panel room in addition to remote monitoring from the central control room in the main plant DCS. CPU local control shall be provided with one (1) no. 24” LED type & A4 laser jet printer B/W per Unit in Condensate polishing unit local control room. The power supply for control system shall be taken from station UPS.

One no additional 17” LCD TFT type inbuilt in the remote I/O panel for emergency/local operation and maintenance of CPU regenerative system. The remote operation of the CPU regenerative system shall also be from the unit DCS monitor located at SWAS dry panel room.

Operator station in the Condensate polishing unit local control room shall be provided with the access to monitor the main plant operations

Condensate polishing plant mimic panel with hard wired push buttons for back panel operation. Hardwired annunciation panel shall be provided for controlling the process.

The instruments shall be offered as per the process requirement for complete auto operation.

Various analysers namely pH, conductivity, cation conductivity, silica, sodium etc., shall be provided in the required process lines.

Necessary instruments pressure gauges, Temperature gauges, DP instruments, Pressure transmitters, Radar Level transmitters, Differential pressure transmitters, Temperature Elements Various analysers, Magnetic type level indicators, shall be provided. The junction boxes and instruments / electronics housing used shall be Non – corrosive material.

Flow transmitters for each stream of CPU are to be provided for monitoring the performance and accountability

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The Bidder shall furnish required list and type of instruments during detail engineering subject to the approval of owner.

6.1.0 Control and Operation of Plant

i) General

The regeneration system shall be external. Under normal conditions, it will hold a complete charge of freshly regenerated and mixed resin, ready for use, in its storage tank. For regeneration, resin from the exhausted exchanger vessel will be transferred hydraulically to this facility. The empty exchanger vessel will then be filled up with the already regenerated resin which was stored in the regeneration facility. This exchange vessel shall come into service soon after perquisite condition is satisfied or as and when desired by the operator. In the meantime, the exhausted resin shall be cleaned, separated, regenerated, mixed and rinsed before being stored for next use.

ii) Control and operation of the condensate polishing unit

a) The condensate polishing unit shall be controlled from either Station DCS or the condensate polishing unit Operator station.

b) It shall be possible to select each of the CPU vessels for any of the following operations:

• Service

• Resin transfer from CPU vessel to regeneration plant

• Resin transfer from regeneration plant to CPU vessel

• Isolation from service

• Rinse recycle

c) The Remote I/O Unit and control room of CPU shall be in the Dry room of SWAS panel. The dry room of SWAS panel shall comprise of Express Lab also in addition to CPU controls and SWAS Instrumentation & control panels The size and location shall be topographically selected so as to accommodate these provisions.

d) The Remote I/O Unit and control room of Regenerative system for CPU shall be in the Control room of DM/RO Plant. The DM/RO plant shall be designed topographically and the physical size of the pant shall also be selected so as to accommodate the equipments of Regenerative system for CPUs. Individual building and control room shall not be required for this system.

iii) Condensate polisher control system

From condensate polishing control system it shall be possible to initiate any of the following operating modes:

a) Rinse recycle

The rinse recycle shall be a manually initiated in full automatic sequence. This sequence shall include the rinse down step until the unit effluent quality is acceptable for boiler feed water. The effluent quality shall be determined by conductivity monitoring of the rinse water outlet. A panel mounted cation conductivity indicator shall be interlocked to prevent advancing of the automatic sequence until the rinse down is complete.

b) Service mode

Service flow rate for each polishing vessel shall be monitored by panel mounted flow

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indicators. During periods of low condensate flow the operator may select to remove one of the vessels from service by a manually initiated automatic sequence. A differential pressure switch installed between the influent and effluent headers shall on a high signal cause an annunciator alarm.

Panel mounted cation conductivity indicators shall be provided to monitor the polishing system influent and effluent streams as well as the discharge of each service vessel.

c) The sequence resin transfer from CPU vessel to regeneration plant and from regeneration plant to CPU vessel shall be initiated from the local control station of CPU as well as from Unit DCS.

iv) Regeneration control system

a) Manually initiated automatic sequences shall be provided for transferring resin from a vessel to the remote common facility for physical cleaning and chemical regeneration and for returning fresh resin to that vessel. Control for chemical dosing system and alkali preparation facility shall also be provided in it.

b) Regeneration shall include hydraulic reclassification of the resins and the transfer of the resins to the respective regeneration vessels. The separated resins shall then be backwashed, cation and anion regenerated with hydrochloric acid and sodium hydroxide solutions respectively, rinsed and then followed air scrubbing and a good backwash. The resin is then transferred back to the resin separation vessel and the resins are air mixed. The mixed resins after regeneration are given a final rinse with the discharge conductivity being monitored. If the quality is satisfactory, the mixed resin shall be transferred to the resin storage vessel otherwise regeneration sequence shall be repeated.

c) Demineralised water shall be used throughout the regeneration process for backwashing, regenerant diluents, rinsing and resin transfer. A conical bottom hopper having a water ejector will be used for resin make-up.

e) It shall be possible to operate the regeneration plant in auto/semi-auto /manual mode.

f) Following operations shall be possible from the regeneration control panel: o Complete regeneration

o Resin transfer from CPU vessel to regeneration plant.

o Resin transfer from regeneration plant to CPU vessel.

g) In 'Auto' mode, once the sequence has been initiated, it shall proceed from step to step

automatically.

h) In 'Semi-auto' mode each step shall be performed only after initiation by the operator.

i) In ‘Manual’ mode complete operation shall be by the operator by operation of the control switches on the panel.

j) On Plant DCS, it shall be possible to operate the valves by means of manual operation of

solenoid valves also.

k) It shall be possible to switch mode of operation from one to the other at any moment and the operation shall proceed on the newly selected mode from that time.

l) The system shall incorporate the necessary safety features. During automatic sequential

operation, if any pre-requisite criteria is not fulfilled or missing for a pre determined time interval, the steps should not proceed further, and Alarm shall be provided. Missing criteria, sequence which is under hold up etc. shall be displayed on the Operator station

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m) A mimic diagram of the Regeneration system shall be provided on the front of the local

panel. The status of various drives and valves shall be indicated by LED on the mimic diagram.

n) Wherever standby equipments are provided, it shall be possible to select each of the drive on ‘standby’ duty.

o) The detailed logic for the sequence and for each of the drive shall be subject to the Owner’s

approval during detail engineering

p) Start, progress and stop of each of the sequence shall be annunciated in all the control panels.

q) At any time only one of the sequence shall be in progress.

v) Interlocks

All interlocks for safe operation of the plant shall be provided. They shall specifically include the following as minimum requirement:

a) Service vessels shall be taken back in service, only after they have been pressurized.

b) Service vessels shall be taken up for resin transfer only after they have been completely

isolated from the condensate system and depressurized.

c) Resin shall be transferred to and from only one service vessel at a time.

d) Resin transfer between the service and the regeneration skids shall be permitted only when the receiving vessel is initially empty.

e) It shall be possible for the operator to extend the timing of a particular step by isolating the timer for the duration. The timer will restart once the operator puts back the system on 'auto' and the other steps will then follow as programmed.

f) The regeneration sequence shall be prevented from advancing further in the event of tripping of a running motor or other fault condition which do not permit the various desired parameter of this step to be achieved. A manual override for this shall also be provided.

g) The immersion heater in the hot water tank can be put on only when there is adequate water level in the tank.

7.00.00 DRAWINGS:

P&I DIAGRAM for Condensate polishing unit. (Dwg no. PE-DG-435-155-A001) Rev-1

8.00.00 PERFORMANCE GUARANTEE PARAMETERS

Condensate Polishing Unit (CPU)

Following shall be demonstrated at site during PG test

a) Effluent quality of outlet of each vessel at its rated design flow and design service length between two regenerations

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b) Pressure drop across the polisher service vessel, as specified, in clean and dirty condition

of resin at rated design flow.

9.00.00 PAINTING SCHEDULE

Painting shall be in compliance to sub-section 2.25 of VOL II of customer specification.

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10.00.00 DATA SHEET-A

1.0 DESCRIPTION OF TURBO GENERATOR UNIT (TG) FOR WHICH CONDENSATE POLISHING IS TO BE PROVIDED :

(i) No. of units Two (2)

(ii) Capacity of each unit 660 MW

(iii) Total maximum flow in all working service vessels of each units

1325 Tons/ hr.

2.0 CONDENSATE POLISHER SERVICE VESSELS PER UNIT :

(i) No. of condensate polisher service vessel

Three (3 x 50%) for each 660 MW unit

(ii) Capacity of each condensate polisher service vessel

50% of total condensate flow per unit

(iii) Flow through each condensate polisher service vessel per unit

662.5 Tones per hour

(iv) Operating pressure of each condensate polisher service vessel

36 kg/cm2 (a)

(v) Design pressure of each condensate polisher service vessel

45 kg/cm2 (g)

(vi) Design code of each condensate polisher service vessel

ASME Sec VIII div 1 Ed-2010

(vii) Working Temp. 42 0 C

(viii) Design temperature of service vessel, its internals and accessories

55 0 C

(ix) Type of vessels Spherical

(x) Material of construction

Shell Carbon steel plates to SA 516 Gr. 70

(xi) Inside protection

Inside lined with Natural Rubber [4.5 mm thick in (3) layers]

(xii) Resin traps at the outlet of each condensate polisher service vessel & rinse outlet

SS-316 with SS 316 Internals

(xiii) Emergency by-pass system To be provided.

2.2 AIR-BLOWERS FOR RESIN MIXING (SERVICE VESSELS AREA) PER UNIT

(i) Number per unit Two (2 x 100%)

(ii) Type Rotary, Centrifugal/ Twin Lobe, oil free, positive displacement

(iii) Duty Intermittent

(iv) Capacity and head As required

(v) Noise level 80 dB (A) Max. at one meter

(vi) Pressure gauge One per blower

(vii) Location Indoor

(viii) Material of construction Casing – Cast Iron GR FG 260 to IS 210 Lobe – Cast Iron GR FG 260 to IS 210 Shaft – Carbon Steel to EN 8

(ix) Drive motor Energy Efficiency Class IE-3 as per IS : 12615

3.0 EXTERNAL REGENERATION FACILITIES

3.1 REGENERATION VESSELS

a. RESIN SEPARATION AND CATION/ANION RESIN REGENERATION VESSEL

(i) Number One (1) no. vessel common for 2 x 660 MW Units

(ii) Design Temperature 600C

(iii) Minimum Design Pressure 10 Kg/cm2 (g)

(iv) Type Vertical Cylindrical

(v) Material of construction

Shell SA 516 Gr. 60 or 70/ SA 282 Gr. C

Dished ends SA 516 Gr. 60 or 70 / SA 282 Gr. C

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(vi) Inside protection Inside lined with Natural Rubber [min. 4.5 mm thick in (3) layers]

(vii) Design code ASME Sec VIII div 1 Ed-2010/ IS 2825 as applicable.

(viii) Resin trap at outlet of each regeneration vessel

SS316 with SS316 internals

(ix) Accessories Operating platforms, ladders, supports, lifting lugs (4 nos. minimum), handhold (1 no. of 150 mm dia.) & manhole (Minimum- 2 nos. of 500 mm dia.) and other structural work for each vessel shall be provided to facilitate accessibility for operation and other equipment etc.

b. CATION/ANION RESIN REGENERATION VESSEL







Dished ends SA 516 Gr. 60 or 70/ SA 282 Gr. C


(vii) Design code ASME Sec VIII div 1 Ed-2010/ IS 2825 as applicable.

(viii) Resin trap at outlet of each regeneration vessel

SS316 with SS316 internals


c. MIXED RESIN STORAGE VESSEL







Dished ends SA 516 Gr. 60 or 70/ SA 282 Gr. C


(vii) Design code ASME Sec VIII div 1 Ed-2010/ IS 2825 as applicable

(viii) . Resin traps at the common outlet header of regeneration vessels

SS with SS 316 Internals


3.2 CHEMICAL HANDLING, PREPARATION & DOSING SYSTEM

a) CHEMICAL TANKS ALKALI DAY TANK ACID DAY TANK

(i) Number required 2X100% 2X100%

(ii) Type Vertical Cylindrical Atmospheric with dished bottom and cover at top

(iii) Liquid to be handled NaOH HCL

(iv) Location ------------ To be designed for outdoor duty -----------

(v) Useful capacity (each tank)

Adequate to hold quantity of alkali( 48%) required for single regeneration of a condensate polisher mixed bed with 20% overall margin.

Adequate to hold quantity of acid required (30-33% HCL) for single regeneration of a condensate polisher mixed bed with 20% overall margin.

(vi) Material (Shell, Dished end & top cover)

FRP FRP

(vii) Internal protection FRP FRP

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(viii) External painting Not Applicable Not Applicable

(ix) Level indicator ---Gauge glass with overlap--

(x) Level transmitter per tank Two (2) Two (2)

(xi) Stirrer per tank 1 No., Slow speed stirrer driven by motor drive and reduction gear. Speed of stirrer = 200 RPM Max.

Not Applicable

(xii) MOC of Agitator SS – 316 Not Applicable

(xiii) Drive motor of stirrer Energy Efficiency Class IE-3 as per IS : 12615

Not Applicable

(xiv) Dissolving Basket Provide (50-60 mesh B.S.) Not Applicable

(xv) MOC of Basket SS – 316 Not Applicable

(xvi) Accessories Fume absorbers, carbon dioxide absorber, vent, overflow, drain connection, overflow seal pot, sample connection, level transmitter, operating platform, ladders, lifting lugs (4 Nos. minimum), hand hole etc.

b) DOSING PUMPS ACID DOSING PUMPS ALKALI DOSING PUMPS

(i) Number Two (2 x 100%) nos. (1 W+ 1 S) Two (2 x 100%) nos. (1W+1S

(ii) Type Simplex positive displacement hydraulically operated diaphragm type

(iii) Whether suction strainer required

--------------- Yes ----------------

(iv) Material of construction

Liquid End (Pump Head, Valves, Valve housing, valve spring etc.)

Polypropylene SS-316

Diaphragm -------PTFE-----------

Packing -------PTFE-----------

Shaft ----- Hardened steel EN 8 (BS: 970)------

Worm & worm wheel (if applicable)

--------------Manganese Bronze -------------

Connecting rod --------------Manganese Bronze -------------

Cross head guide --------------Bronze -------------

(v) Capacity & head Capable of meeting regeneration one cation/ anion unit (with 20% margin); head as required (with 20% margin).

(vi) Accessories

Pressure/ Pulsation Dampener

One per pump One per pump

External safety relief valve (in addition to inbuilt safety valve)

Two (One per pump), MOC-Polypropylene

Two (One per pump), MOC- SS-316

(vii) Pressure gauge ------------- One per pump with Teflon diaphragm seal --------------

(viii) Maximum pump stroke speed per minute

--------------------------------------- 100 --------------------------------

(ix) Accessories required for each pump

Coupling guard, drain plug, vent valve, isolation valves, Y-type strainers, pressure gauges, pulsation dampener etc.

(x) Drive motor of pump The drive motor of each pump will be Energy Efficiency Class IE-3 as per IS: 12615

c) Density Meter Acid Alkali

(i) Number One (1) at each mixing tee outlet One (1) at each mixing tee outlet

(ii) Type Density indicator (Hydrometer type) Density indicator (Hydrometer type)

(iii) Indication Local Local

(iv) Location Diluted Acid line Diluted Alkali line

d) Flow Indicator

(i) Number One in each DM water line One in each DM water line

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(ii) Type Rotameter Rotameter

e) Flow Switch or Flow Transmitter

One in each water line, vane actuated type or DP bellows type /As per P&ID

3.3 CPU REGENERATION CUM RESIN TRANSFER PUMPS

(i) Number Two (2 x 100%) nos. (1W+1S)

(ii) Type Horizontal, centrifugal

(iii) Operation Intermittent

(iv) Liquid to be handled DM Water

(v) Capacity & head As required (with 20% margin)

(vi) Suction condition Flooded

(vii) Material of construction

Casing & impeller SS 316/ ASTM A 351 CF 8M

Shaft SS 316

Wearing rings As per manufacturer’s Standard

Shaft sleeve material SS 410

(viii) Packing seal Mechanical type

(ix) Mechanical Seal Will be Provided

(x) Pump Speed Maximum 1500 rpm

(xi) Pressure gauge One for each pump with Teflon diaphragm seal

(xii) Pressure dampener One number per pump

(xiii) Recirculation line with motor actuated butterfly valve

Shall be provided

(xiv) Accessories required for each pump Coupling guard, drain plug, vent valve, isolation valves, Y-type strainers, pressure gauges, pulsation dampener.

(xv) Drive motor The drive motor of each Pump will be Energy Efficiency Class IE-3 as per IS: 12615.

3.4 AIR-BLOWERS FOR RESIN MIXING (REGENERATION AREA)

(i) Number Two (2 x 100%)

(ii) Type Centrifugal/Twin lobe type, oil free, positive displacement

(iii) Location Indoor

(iv) Duty Intermittent

(v) Capacity and head As required

(vi) Noise Level 80 dB (A) Max. at one meter

(vii) Pressure gauge One per blower

(viii) Material of construction Casing – Cast Iron GR FG 260 to IS 210 Lobe – Cast Iron GR FG 260 to IS 210 Shaft – Carbon Steel to EN 8

(ix) Drive motor The drive motor of each air blower will be Energy Efficiency Class IE-3 as per IS : 12615

3.5 BULK ACID AND ALKALI STORAGE TANKS

(i) CHEMICAL TANKS ACID STORAGE TANKS ALKALI STORAGE TANKS

(ii) Number required Two (2) Two (2)

(iii) Design code -------------------BS-2594 or equivalent---------------------

(iv) Location ---------------------------------------Outdoor----------------------------------

(v) Useful capacity 20 m3(each) 20 m3(each)

(vi) Type --Horizontal cylindrical with dished ends, atmospheric, above ground--

(vii) Material of construction FRP FRP

(viii) Protection – Inside ------- -------

(ix) Protection – Outside ------- -------

(x) Concentration 30 -33 % HCl 48 % NaOH

(xi) Vent, overflow, Drain, fume absorber and sample connection pipe M.O.C.

Required, pipe, flange & valves MSRL

(xii) Manhole, staircase, platform Provided Provided

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3.6 ACID AND ALKALI UNLOADING PUMPS

(i) PUMPS ACID UNLOADING PUMPS ALKALI UNLOADING PUMPS

(ii) Number required Two (2 x 100%) nos. (1W+1S) Two (2x 100%) nos. (1W+1S)

(iii) Type -----------------------Horizontal Centrifugal--------------------------------

(iv) Location ------------------------------------Outdoor-----------------------------------

(v) Service ------------------------------------Intermittent--------------------------------

(vi) Pressure gauge One per pump with Teflon diaphragm seal

(vii) Capacity and head ------------------------------10 m3/ hr. and head as required--------------

(viii) Liquid to be handled 30 -33 % HCL 45-48% NaOH

(ix) Material of construction

Casing Polypropylene SS 316

Impeller Polypropylene SS 316

Shaft EN9 SS 316

Shaft Sleeves Ceramic SS 316

Types of shaft sealing Mechanical seal Mechanical seal

(x) Pump speed 1450 rpm 1450 rpm

(xi) Drive motor 415V, 3Ф, 50 HZ TEFC, Energy Efficiency Class IE-3 as per IS: 12615

(xii) Accessories required Coupling guard, drain plug, vent valve ,suction hoses, isolation valves, y- type strainers etc.

(xiii) Type of coupling between motor and pump

Flexible coupling

(xiv) Reinforced rubber house with coupling and isolation valve

One (1) No. of each application size 80NB, minimum 20 meter with isolation valve, Reinforced Chemical Resistant Rubber.

(xv) MOC for piping, valves & fittings in acid/alkali handling

For valve- MSRL For piping, flanges & fittings –MSRL


a) ALKALI TRANSFER CUM RECIRCULATION PUMPS WITH MOTOR

(i) Nos. required Two (2x100%) (1 W+ 1 S)

(ii) Type Horizontal, centrifugal

(iii) Service Intermittent

(iv) Location Outdoor

(v) Pressure gauge One per pump with teflon diaphragm seal

(vi) Maximum Pump Speed 1500 rpm

(vii) Type of Coupling between pump & motor drive

As per manufacturer’s standard practice

(viii) Type of Sealing Mechanical Seal

(ix) Type of Suction Strainer Y- Type

(x) Concentration of working media.

5-48% Sodium Hydroxide (NaOH)

(xi) Capacity & head of each pump

As per system Requirement

(xii) Suction condition Flooded

(xiii) Materials of construction

a. Casing, impeller Stainless Steel – 316

b. Shaft & shaft sleeve

Stainless Steel -410

3.8 ALKALI DILLUENT WATER HEATING TANK (HOT WATER TANK)

(i) Number One (1)

(ii) Type/Capacity Vertical Cylindrical with dished end with Electric heater/ 120% of water required for regeneration.

(iii) Electric heater Qty. 2 nos. Electric heater (2 x 50%)

(iv) Temperature of alkali to be heated To obtain temp. from 15OC of 50OC at alkali mixing feed out

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let within 5 hours.

(v) Design Pressure

Design pressure shall be the maximum expected pressure to which the vessel may be subjected plus 5% extra margin. Maximum expected pressure for vessels placed in the discharge line of pumps shall be based on the shut-off head of the pumps plus static head at pump suction or 10 kg/cm2 (g) whichever is maximum.

(vi) Material of construction

Shell & dished end MSRL

(vii) Design code ASME Sec. VIII div 1 ed.2010/ IS 2825 as applicable

(viii) Temperature gauge, Temp. transmitters To be provided (as per P&ID).

(ix) Burn out protection To be provided.

(x) Accessories Manhole, vent, drain, sample connection, level transmitter, level gauges-2 nos. (minimum), operating platform, ladders, lifting lugs (4 Nos. minimum) etc.


a) CHEMICAL TANKS Number required

ALKALI PRAPARATION TANK 1X100%

(i) Type Vertical Cylindrical Atmospheric with dished bottom and cover at top

(ii) Liquid to be handled NaOH

(iii) Location ------------ To be designed for outdoor duty -----------

(iv) Useful capacity (each tank)

Adequate to hold quantity of alkali required (48% NaOH) for single regeneration of a condensate polisher mixed bed with 20% overall margin.

(v) Material (Shell, Dished end & top cover)

IS 2062 Gr A/B

(vi) Internal protection ----Inside lining with natural rubber min. 4.5 mm thick in three layers ---

(vii) External painting ----Chlorinated Rubber Paint ---

(viii) Level indicator ---Gauge glass with overlap--

(ix) Level transmitter per tank Two (2)

(x) Stirrer per tank 1 No., Slow speed stirrer driven by motor drive and reduction gear. Speed of stirrer = 200 RPM Max.

(xi) MOC of Agitator SS – 316

(xii) Drive motor of stirrer Energy Efficiency Class IE-3 as per IS : 12615

(xiii) Dissolving Basket Provide (50-60 mesh B.S.)

(xiv) MOC of Basket SS – 316

(xv) Accessories Fume absorbers, carbon dioxide absorber, vent, overflow, drain connection, overflow seal pot, sample connection, level transmitter, operating platform, ladders, lifting lugs (4 Nos. minimum), hand hole etc.

4.0 PIPING & VALVES

(i) Resin Transfer piping (full Port Ball Valves)

ASTM A 312 Gr. TP 316L Minimum pipe Size: NB80; Velocity : 2-3 m/s

(ii) DM water line ASTM A 312 Gr. TP 316L Minimum pipe Size: NB80; Velocity : 2-3 m/s

(iii) Piping-Service vessel Inlet

Piping-ASTM A 106 Gr. C, pipe thickness as per relevant Codes. Ball Valves – SS CF8M BFV– (body: WCB Disc:CF8M/SS316)

(iv) Piping-Service vessel Outlet Piping – ASTM A 106 Gr. C, pipe thickness as per relevant codes. BFV – Body & Disc both: CF8M/SS316; Ball Valves – SS CF8M

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(v) Service vessel bypass piping (Butterfly

Valves) Piping – ASTMA 106 Gr. C BFV –(body: WCB Disc:CF8M/SS316

(vi) Service vessel rinse piping CS to ASTM A 106 Gr. C, pipe thickness as per relevant codes.

(vii) Acid & Alkali Regeneration piping (Diaphragm Valves)

All piping, Valves & Fittings in regeneration area shall be CPVC Sch. 40 only & valves shall be PN 10 rating.

(viii) Acid/ Alkali Transfer piping (Diaphragm Valves)

All piping, Valves & Fittings in regeneration area shall be CPVC Sch. 40 only & valves shall be PN 10 rating.

(ix) Instrument Air piping (Full Port Ball Valves)

IS 1239 (Heavy Grade) ERW part –I Galvanized.

5.0 VALVES

(i) BUTTERFLY VALVES

Butterfly valves shall be of double flanged type of low leakage rate confirming to AWWA-C-504 class 300 (min.) or BS: 5155 PN 10 (min.). All the butterfly valves shall be provided with Hand wheel or lever as per the requirements. For larger sizes i.e. 150 NB and above. Valve provided with motorized or pneumatic actuator shall be provided with a hand wheel for manual operation. All the valves shall be equipped with adjustable mechanical stop-limiting devices to prevent over travel of the valve disc in the open and closed positions. The valve operators (Hand wheel or Gear reduction unit or Motor actuator etc.) shall be designed as per relevant International Standards. All the butterfly valves shall be provided with an indicator to show the position of the disc. Flanges shall conform to ANSI B 16.5 CL.300 (min.). Butterfly valves of the bypass line of service vessels shall be double flanged type.

(ii) ECCENTRIC PLUG VALVE / BALL VALVE

These valves shall be used for resin transfer line. These valves shall be flanged type and of SS 316 construction.

(iii) DIAPHRAGM VALVE The Diaphragm shall conform to following requirement for DM water application: i) Design standard: BS: 5156 or equivalent of required rating class. (Minimum rating of valves shall be PN 10). ii) Type: Flanged and lined body ends, sealed bonnet, weir pattern, tight shut off type. iii) Material of Construction a) Body, Bonnet: Cast iron IS 210 Gr. FG 260 or equivalent or Cast steel ASTM A-216 Gr. WCB. b) Body lining: Soft natural rubber (Neoprene), ebonite, Polypropylene. c) Hand wheel: Cast Iron d) Compressor: Stainless Steel e) Stem and Bush: Stainless Steel For Acid and Alkali services the valve shall be MSRL.

7.0 NEUTRALISING SYSTEM

7.1 NEUTRALIZATION PIT

(i) Number One (1) no. Pit with two (2) compartments ,common for 2 x 660 MW Units

(ii) Type Proven agitation system like air agitation, venture mixing etc. shall be provided in addition to recirculation from pumps. Air blowers of regeneration system shall be used for air agitation.

(iii) Material of Construction RCC with acid / alkali proof lining

(iv) No. of compartments Two compartments

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(v) Capacity of each

compartment Each section shall have capacity to hold 150% of waste water generated from CPU in one regeneration + 120% of waste generated from DM plant (SAC,SBA & MB) in one regeneration Regeneration waster in one regeneration of DM plant (SAC,SBA & MB) is to be taken 48m3/per regeneration. frequency once in a day .

7.2 NEUTRALIZATION PIT DISPOSAL PUMPS

(i) Number Two nos. (1 working + 1 Standby)

(ii) Type Horizontal, Centrifugal Single stage with priming system

(iii) Capacity & head To Dewater to total volume of one section/compartment of the neutralization pit in 2 hours. Head Suitable

(iv) Duty Intermittent

(v) Pump Speed 1450 rpm

(vi) Drive motor 415V, 3Ф, 50 HZ TEFC, Energy Efficiency Class IE-3 as per IS: 12615

(vii) Suction condition Negative, with priming chamber

(viii) Material of Construction

Casing 2.5% Ni Cast Iron IS210 Gr. FG

Impeller Stainless Steel CF 8M

Shaft SS-304/SS-316/SS-410

Shaft coupling SS-316

Shaft sleeve SS-316

ix Primng arrangement Required

Priming tank FRP

Priming tank capacity 5 - 6 times the suction pipe volume (min).

7.3 CHEMICAL TANKS FOR N PIT

ALKALI MEASURING TANK ACID MEASURING TANK

(i) Number required One (1) One (1)

(ii) Type ----------------------------Vertical Cylindrical Atmospheric--------------------

(iii) Useful capacity 500 liter 500 liter

(iv) Material (Shell, Dished end & top cover)

FRP FRP

Internal protection Not Applicable Not Applicable

External painting Not Applicable Not Applicable

(v) Level indicator Provided Provided

(vi) Level transmitter per tank One (1) One (1)

(vii) Stirrer per tank Slow speed stirrer driven by motor drive and reduction gear. Speed of stirrer = 200 RPM Max.

Not Applicable

(viii) MOC of Agitator SS – 316 Not Applicable

(ix) Drive motor of stirrer 415V, 3Ф, 50 HZ TEFC, Energy Efficiency Class IE-3 as per IS: 12615

Not Applicable

(x) Dissolving Basket Provide (50-60 mesh B.S.) Not Applicable

(xi) MOC of Basket SS – 316 Not Applicable

(xii) Accessories Fume absorbers, carbon dioxide absorber, manhole, vent, drain, sample connection, level transmitter, operating platform, ladders, lifting lugs (4 Nos. minimum) etc.

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SECTION : D

TECHNICAL SPECIFICATION FOR CONDENSATE POLISHING UNIT

SUB-SECTION : D-1

REV. NO. 01 DATE : 01-10-18

GENERAL TECHNICAL REQUIREMENTS

SUB-SECTION D-1 - GENERAL TECHNICAL REQUIREMENTS (MECH.)

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SUB-SECTION : D-1

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1.0 GENERAL

This specification is intended to cover design, engineering, manufacture, supply, fabrication, assembly, inspection / testing at vendor's & sub-vendor’s works, painting, maintenance / special tools & tackles, mandatory spares alongwith spares for erection as required, startup and commissioning spares as required, forwarding, proper packing, shipment and delivery at site, unloading, handling, transportation & storage at site, in site transportation, assembly, erection & commissioning, final painting at site, minor civil work, trial run at site, preparation and submission of drawing /documents including “As Built” drawings and O & M manuals, layout drawings in 2D & 3D ( As applicable) and carrying out performance guarantee /Functional / Demonstration tests at site (As applicable) & equipment /system guarantee/Aux. Guaranteed power consumption etc. inclusive of all prevailing taxes, duties and other levies and handover in flawless condition of the package specified above for above mentioned project to the end customer complete with all accessories for the total scope defined as per BHEL NIT & tender technical specification no. PE-TS-435-155-A001 for condensate polishing unit package of 2x660 MW UDANGUDI TPP-STAGE I. The Condensate Polishing Units with a common external regeneration system and associated accessories shall conform to the technical specification (PE-TS-435-155-A001) for CONDENSATE POLISHING UNIT of 2x660 MW UDANGUDI SUPERCRITICAL STPP-STAGE I.

2.0 DESIGN CONDITIONS FOR CONDENSATE POLISHING UNIT

There shall be three service vessels (3 x 50%) for each 660 MW unit, each polishing 50% of the condensate flow corresponding to 1% make up, design condenser pressure and all HP heaters out of service condition.

3.0 BRIEF DESCRIPTION OF THE SYSTEM

The proposed condensate plant shall treat the entire condensate of the turbine generator of power station. The proposed schematic arrangement of the condensate polishing plant and its regeneration facility shall be as per the enclosed P&I Diagram. Arrangement of piping, valves and instruments shown in the P&ID are bare minimum. The bidder shall include the complete system including regeneration facility as elaborated in this specification meeting the contractual requirements. The condensate polisher service vessels shall be located in the TG hall. The resins shall be transferred to and from the common regeneration facility by sluicing through a pipeline hydraulically. The regeneration system shall be external. The CPU regeneration system will be located as per main equipment plant layout (at EL 0.0 M) near Equipment fabrication assembly yard (BHEL DRG. No. PE-DG-435-100-M002). The regeneration process offered by the bidder shall be of proven design and shall essentially be the same process by virtue of which the bidder is qualified and shall give resin-separation compatible with the desired effluent quality.

4.0 SCOPE OF SUPPLY (MECHANICAL)

Broad scope of supply (mechanical) for this package is detailed below and as indicated in relevant portion of this specification. The same shall be in bidder’s scope of supply.

A. SERVICE VESSEL FACILITY

1) There shall be three service vessels (3X50%) for each 660 MW unit, each polishing 50 % of the condensate flow.

2) Each Condensate polisher vessels shall be complete with condensate inlet and outlet connections, connections for resin transfer to and from the vessels, bed support-cum-under drain system, inlet water distributors, air distribution arrangement for resin mixing, all fittings and appurtenances etc. as specified and as required.

3) One no External resin traps at the condensate & rinse outlet of each of the condensate polisher mixed beds each designed for in-place manual back flushing facility.

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4) Condensate inlet and outlet headers for each installation with pipe connections to the condensate polisher

vessels.

5) Resin transfer headers and pipe lines connecting the common external regeneration facilities to the condensate polisher vessels of each installation.

6) Rinse water outlet headers from condensate polisher vessels of each installation up to the condenser hot well. Rinse water outlet headers from condensate-polisher vessels shall be provided with a pressure reducing valve and orifice plate, suitably designed to enable the water entry to the condenser hot well under all operating condition of condenser.

7) All necessary valves, and fittings for the installations with actuators necessary for their remote operation. These shall include suitable fool proof arrangement to prevent accidental over pressurization of the resin transfer pipeline and regeneration facilities connected to it, which are designed for pressure much lower than that of the Condensate Polisher Service vessels.

8) A drain header for the condensate polisher service vessels. All necessary drains, vents and sampling points, with valves as required.

9) Gland sealing water piping for the Gland sealing valves in the rinse water line & other lines (as applicable).

10) Sample cooling line piping for sample cooling for all analysers.

11) Two nos. (1W + 1S) per unit oil free type air blowers with electric motor drives for each unit for supplying air required for mixing the resins in the service vessels. Each blower shall be complete with motor, V-belt drive with belt guard, inlet filter, silencer, flexible couplings and discharge snubber, relief valve etc. all mounted on a single base.

12) Complete Instrumentation and Control for automatic operation.

13) Emergency bypass between the condensate influent and effluent headers. Each Condensate polisher service unit shall be provided with an automatic bypass for the condensate polisher on the condensate inlet and outlet headers of the unit with a butterfly type control valve and butterfly type isolation valves (resilient material seated, to ensure bubble-tight shut off) on the upstream and downstream sides of the control valve. 1x100% capacity control valve shall be provided to achieve proper control under all operating conditions. Isolation valve shall be provided with geared operators for manual operation and shall be located at a height which can be easily operatable. Complete instrumentation and controls for this emergency by-pass system. Further all tubing, wiring air sets and other fittings required to complete the system shall be provided.

14) Total resin charges shall be supplied for the project is Nine (9) numbers. One resin charge shall be considered as resin required for one service vessel i.e. cation resin, anion resin and inert resin (if any) used for the project. Further one Year's topping requirements or 10 % of first fill quantity (7 charges), whichever is more shall be supplied by bidder.

15) One no. Specific Conductivity analyser at condensate inlet header & One no. specific Conductivity Analyzer at outlet & outlet of each Condensate polishing Mixed Beds / Condensate Polisher Service vessels. Hence total 5 nos. of Specific Conductivity analyser shall be supplied for each TG unit service vessel area.

16) One no. Cation Conductivity analyser at condensate inlet header & One no. cation Conductivity Analyzer at outlet and outlet of each Condensate polishing Mixed Beds / Condensate Polisher Service vessels. Hence total 5 nos. of Cation Conductivity analyser shall be supplied for each TG unit service vessel area.

17) One no. pH analyser at condensate inlet header & one no. pH analyser at outlet of each Condensate polishing Mixed Beds / Condensate Polisher Service vessels. Hence total 4 nos. of pH analysers shall be supplied for each TG unit service vessel area.

18) One no. multi stream sodium analyser to measure process value of each service vessel outlet for TG unit and 1 no. single stream sodium analyser to measure the process value of common inlet header of each TG unit. However, Sodium analyser shall be limited to a maximum of three (3) streams only.

19) One no. multistream Silica analyser to measure process value of each service vessel outlet for TG unit and 1 no. single stream silica analyser to measure the process value of common inlet header of each TG unit.

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REV. NO. 01 DATE : 01-10-18

However, silica analysers shall be limited to a maximum of three (3) streams only.

20) Complete instrumentation and controls for this system, including the differential pressure transmitters, panel mounted indicating type controller with provision for remote manual operation, actuator for the control valve with positioner etc. All tubing, wiring, airsets, and other fittings, required to complete the system.

21) All the piping, valves, fitting, accessories etc. used in service vessel area shall be 300# class minimum and this area shall be considered as high pressure side.

22) Minimum instrumentation required as per P & ID included in this tender specification.

23) On collection of water in the drains of instrument air lines, mechanical automatic drains and periodically solenoid operated drains (with electronic timer - 15m, 30m, 60m and 2 Hours & Timing adjustable) are to be provided

B. REGENERATION SYSTEM

The regeneration system shall be common for all mixed bed polishers of TG units and shall be external. The external CPU regeneration system will be located as per main equipment plant layout (at EL 0.0 M) near Equipment fabrication assembly yard (BHEL DRG. No. PE-DG-435-100-M002). Regeneration area shall be considered as low pressure area. Complete regeneration facility as mentioned below shall be in Bidder’s scope:

I. One external regeneration facility for regeneration of the resins from the condensate polisher vessels for TG unit shall be provided by the bidder and consists of following:

1) One no. Resin Separation & Cation Regeneration Vessel.

2) One no. Anion resin regeneration vessel.

3) One no Mixed resin storage vessel

4) All internals, fittings and appurtenances for these vessels.

5) Common waste effluent header with one resin trap designed for in place manual backwashing.

6) Resin Make up/injection hopper complete with water ejector system for resin make up. Resin make Up /injection hopper shall be sized to handle up to minimum 150 liters of as received new resins per Single injection.

7) Two (2) nos. (1W+1S) oil free type air blowers with electric motor drives, for supplying all the process air required for cleaning of resins and their regeneration processes. Further these blowers shall be also used for air agitation of neutralization pit (both compartments). Each blower shall be complete with motor, V-belt drive with belt guard, inlet filter, silencer, flexible couplings and discharge snubber, relief valve etc.as required and shall be mounted on a single base.

8) Two (2) nos. CPU Regeneration cum resin transfer Pumps each with electric drive motor drives, one normally operating and the other standby, for water supply for chemical preparation / dosing and transfer of resin from service vessel to regeneration vessels & vice-versa, backwash & rinse activities shall be provided. These CPU Regeneration cum Resin Transfer Pumps will take suction from DM water storage tanks (DM water storage tanks not in bidder’s scope) of DM plant. A terminal point of DM water line shall be provided by customer at 5 m distance from CPU regeneration Building.

9) All integral pipe works, valves, internals, fittings for this installation with the actuators necessary for their remote automatic operation along with hangers, supports and appurtenances etc. for these equipments. All necessary piping, valves and fittings These shall include all drains, vents and sampling points with valves as specified and as required.

10) Two (2) sets of safety equipment comprising PVC protection suits with hoods, rubber boots, face visors and thick PVC gauntlets shall also be provided by bidder. One numbers personnel water drench shower/safety shower and eye bath in regeneration area shall be provided by the bidder.

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II. BULK ACID AND ALKALI STORAGE & ACID & ACID AND ALKALI DOSING FACILITY

All equipment for dosing of acid and alkali solutions shall be rated to provide a maximum dosing rate at least 20% in excess of that required from process calculation. The Acid and alkali dosing equipment for regeneration of condensate polishing resins shall preferably be mounted on skid. All the equipment, piping etc. shall be assembled on two structural steel skids one for acid and one alkali dosing equipment. In order to facilitate erection at site chemical dosing preparation equipment shall be mounted on structural steel skids and assembled (including piping) at the manufacturer’s shop, to the maximum extent possible, prior to shipping. The number of mechanical connections shall be minimised by the use of pipe headers wherever possible. The following below mentioned items shall be in bidder’s scope of supply:

1) One (1) alkali preparation cum measuring tank and 2 nos alkali day tanks . These tanks shall consist of slow speed agitator driven by motor, carbon dioxide absorber, overflow seal pot, dissolving basket, integral pipe works, valves and all other required accessories. The tank capacity shall be equal to 120% of regeneration requirement of one regeneration.

2) Two (2) numbers acid measuring tanks for regeneration complete with fume absorbers, overflow seal pot, integral pipe works, valves, instrumentation and all other accessories required. The tank capacity shall be equal to 120% of regeneration requirement of one regeneration.

3) One (1) no. hot water tank for heating of alkali diluent water with (2X50%) electric heating coil, adequately insulated of MSRL construction shall be provided complete with integral pipe works, valves, instrumentation and all other accessories required. The capacity of tank shall be minimum 20% higher than the maximum water demand. This tank shall be provided with burn out protection, pressure relief valve, level transmitter, temperature indicator etc. The temperature transmitter provided on the tank shall control the heater. The heaters shall be sized for heating the water from a temperature of 15 to 50 deg. C in 5 hours at the outlet of ejector.

4) Two (2) nos. (1W+1S) alkali transfer cum recirculation pumps. These pumps shall be provided with a pulsation dampener at the outlet header of each pump along with necessary valves, instrumentation, piping & accessories as required.

5) One (1) no. Activated carbon filter for alkali complete with internals, integral pipe works, valves and all other accessories as required. Activated Carbon Filter for alkali rated flow of the filter shall not be less than the design capacity of the alkali transfer cum recirculation pumps, and the maximum velocity through the filter for this flow shall not exceed 12 meters/hour. Depth of the filter materials shall not be less than 1 meter.

6) One number Carbon trap shall be provided at the outlet line of Activated carbon filter. This carbon trap shall have screen opening of 60 mesh.

7) Two (02) numbers (1W+1S) simplex hydraulically operated diaphragm type metering pumps for acid dosing for regeneration with electric motor drive, pulsation dampener & safety relief valve at the outlet header of each pump along with all other required accessories.

8) Two (02) numbers (1W+1S) simplex hydraulically operated diaphragm type metering pumps for alkali dosing for regeneration with electric motor drive, pulsation dampener & safety relief valve at the outlet header of each pump along with all other required accessories.

9) Diluent water supply separately, for acid and alkali, each provided with an automatic on-off valve, a throttling valve for setting of flow, a local flow indicator with flow transmitter and a mixing tee where the chemicals get injected into the water stream.

10) To meet the regeneration and resin transfer water requirements (DM Water) BHEL will provide a 200 NB size DM water line terminal point along with isolation valve at 5 m distance from CPU regeneration Building. Further counter flanges, piping, valve, instrumentation and required fitting & accessories shall be in bidder’ scope.

11) All necessary suction and discharge piping for these pumps including all strainers, valves and fittings as required, upto the mixing tee with the diluent water.

12) All the equipment, piping etc. shall be assembled on two structural steel skids one for acid and one for alkali dosing equipment. The bidder shall supply all anchor bolts, foundation plates, sleeves, nuts, inserts etc. to be

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embedded in concrete for these equipment skids. The length of the foundation bolts shall be liberally sized to reach below the reinforcement level. Each equipment skid shall be provided with suitable lighting lugs, eye bolts etc. to facilitate erection and maintenance.

All interconnecting piping, valves and fittings & instrumentation as required to complete the CPU regeneration system shall be in bidder’s scope..

C. PIPING All the piping as listed below shall be in bidder’s scope. The below indicated pipes shall be designed, supplied, erected, laid and tested by the bidder. Elbows, tees, flanges, counter flanges, Hangers and supports, embedment plates with lugs etc. required for the below given piping shall also be provided by the bidder.

1) Service vessel inlet header shall be ASTM A 106 Gr. C (OD 457.2 X 12.7 mm thick)

2) Service vessel outlet header shall be ASTM A 106 Gr. C (OD 457.2 X 12.7 mm thick)

3) By pass line between Service vessel inlet & outlet header shall be ASTM A 106 Gr. C (OD 457.2 X 12.7 mm thick)

4) Rinse water outlet piping shall be ASTM A 106 Gr. C (OD 168.3 x 7.11 mm). The distance between CPU service vessel to condenser hot well shall be considered as 90 meter and this piping shall be in bidder’s scope.

5) Resin transfer piping shall be minimum 80 NB and of ASTM A 312 Gr. TP 316L Sch 40 (minimum). One-way distance for resin Transfer Piping between farthest service vessel and regeneration area shall be 1200 m. In addition to that complete resin transfer piping shall be in bidder’s scope which shall include the piping inside CPU regeneration area & CPU service vessel area also. (total 1200 meter piping is included in bidder’s scope)

6) Piping handling DM water shall be ASTM A 312 Gr. TP 3016L Sch 40 (minimum). One-way distance for DM water piping between farthest service vessel and regeneration area shall be 1250 m. In addition to that complete DM Water piping shall be in bidder’s scope which shall include the piping inside regeneration area also. (total 1250-meter piping is included in bidder’s scope)

7) Piping used for handling alkali (concentrated) and alkali solution shall be CPVC Sch. 40 minimum for complete CPU regeneration area.

8) Piping handling acid (concentrated) and acid solution shall be CPVC Sch. 40 for complete CPU regeneration area.

9) Piping for air service shall be hot dip galvanized (heavy grade) steel as per IS 1239.

10) All piping within each of the above skids/equipment for CPU regeneration area & CPU service vessel area shall be in bidder’s scope.

11) Similarly DM water piping from the customer/BHEL terminal point to CPU REGENERATION CUM RESIN TRANSFER PUMPS suction lines along with their isolation valves, Instruments, piping, flanges & fittings shall be in bidder’s scope.

12) Further DM water piping from each CPU REGENERATION CUM RESIN TRANSFER PUMPS to service vessel area and regeneration area all equipments shall be in bidder’s scope.

13) Service water piping (used for cooling of condensate sample & other activities in CPU service vessel area), piping for gland sealed valve cooling, instrument air piping, potable water piping for eye wash, service water piping for pump flushing & piping for other applications of CPU service vessel area & regeneration area shall also be in bidder’s scope.

14) Similarly, all piping between the external regeneration facility and the skids for chemical (acid or alkali) dosing and preparation shall also be designed, supplied, erected and tested by the bidder. These shall include demineralized water piping to the chemical dosing/preparation system , acid /alkali piping from customer terminal point to respective preparation/ dosing skids, the alkali preparation/ dosing skids from the external regeneration facility, alkali solution from its preparation facility to the alkali dosing skid, dilute chemical solution

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piping for acid and alkali from the dosing skids to the external regeneration facility, piping to the preparation/dosing facilities, Acid and alkali piping to N-pit ( both compartments), air grid piping arrangement in N-pit both compartments, piping from CPU regeneration area blower to CPU N-pit (both compartment), instrument air piping and power supply for immersion heaters of the diluent water tank from the regeneration facility, and all instrumentation and control wiring between these skids, etc.

15) Piping used for handling N.pit waste shall be CPVC Sch. 40 minimum for . Bidder to consider 200 meter pipe in the scope.

16) In addition, any additional piping and associated accessories required to complete the system shall be in bidder’s scope.

NOTE: Pipe routing shall be finalized during detailed engineering. However, system shall be designed to take care ± 10% change in length of piping. There will be no price implication to BHEL/Customer on account of the same by bidder.

D. ADDITIONAL REQUIREMENT

1) Operating platforms, ladders, supports and other structural works for each vessel to facilitate accessibility for operation and maintenance for all the condensate polisher mixed beds, regeneration vessels, storage tanks, alkali and acid measuring tanks & preparation tanks and other equipment’s etc. is also in bidder’s scope.

2) Initial charge of all lubricants & grease.

3) All special tools necessary for proper maintenance or adjustment of the equipment packaged in permanent box. Finish paints for touch-up painting of equipment after erection at site in sealed container.

4) Start-up and commissioning spares as required.

5) All required elbow, tee, pipe fittings etc. required for erection of the complete system including piping shall be in bidder’s scope. Bidder to provide the detailed BOQ shall be derived during detail engineering. Bidder to consider 10% margin over and above the BOQ requirement of all the fittings.

6) Wherever pipe racks are not available, pipes shall run on pedestals or below ground. All fixing items such as U clamps, nuts, bolts etc. required to lay the pipes on pedestals shall be in bidder’s scope of work. Coating, wrapping and protection required for buries pipes shall be in bidder’s scope of work.

7) Bidder shall consider 12 m static head + 10% margin in addition to the losses in straight pipes and bend in pipes, tees, reducer, expander and valves etc. (in yard piping) while selection of pump head during detailed engineering.

8) The Bidder’s scope includes all the first fill and one year’s topping, requirements of consumables such as oils, lubricants including grease, servo fluids, gases and essential chemicals( excluding acid/alkali) etc. Consumption of all these consumables during the initial operation or PG test of bidder’s supplied equipment (whichever is later) and final filling after the initial operation OR PG test of bidder’s supplied equipment (whichever is later) shall also be included in the scope of the Bidder. Bidder shall also supply a quantity not less than 10% of the full charge of each variety of lubricants, servo fluids, gases, chemicals etc. used which is expected to be utilised during the first year of operation. This additional quantity shall be supplied in separate Containers. As far as possible lubricants marketed by the Indian Oil Corporation shall be used. The variety of lubricants shall be kept to a minimum possible.

9) On completion of erection, a complete list of bearings/ equipment giving their location and identification marks shall be furnished to the Owner along with lubrication requirements.

10) MCC, DCS control room & battery room shall be located in CPU regeneration area building. All regeneration vessels and chemical dosing facilities shall be located in CPU regeneration building. Further N-pit shall be located in open area near CPU regeneration area. CPU regeneration cum resin transfer pumps shall be located inside CPU regeneration Building. Further Bidder to also provide the localized CANOPY arrangement on all pumps, blower & motors which are open to sky.

11) Document approval by customer under Approval category or information category shall not absolve the vendor of their contractual obligations of completing the work as per specification requirement. Any deviation from

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specified requirement shall be reported by the vendor in writing and require written approval. Unless any change in specified requirement has been brought out by the vendor during detail engineering in writing while submitting the document to customer for approval, approved document (with implicit deviation) will not be cited as a reason for not following the specification requirement.

12) In case vendor submits revised drawing after approval of the corresponding drawing, any delay in approval of revised drawing shall be to vendor’s account and shall not be used as a reason for extension in contract completion.

13) Bidders shall make Site visit in order to familiarize themselves with existing condition of site before submitting the bid in order to make their offer complete. During detail engineering also, the successful bidder shall be responsible for the correctness of details w.r.t. existing facility at site. Customer approval on any drawing having details of existing facility shall not be cited by the successful bidder a valid reason for any shortcoming in the work by them. BHEL shall also not entertain any cost implication for any lack of input data with regard to site during detail engineering.

14) Successful bidder shall furnish detailed erection manual for each of the equipment as well as complete system supplied under this contract at least 3 months before the scheduled erection of the concerned equipment / component or along with supply of concerned equipment / component whichever is earlier.

15) Final Electrical Load list will be submitted by the successful bidder as per agreed drawing/ doc submission schedule. Thereafter any change in the electrical load list shall be entertained only subject to its feasibility, and BHEL reserves the right to debit the vendor cost of any changes necessitated in the switch gear /MCC on account of changed loads.

16) Wherever CIVIL works is excluded from the bidder’s scope, successful bidder shall furnish civil assignment / scope drawings. The corresponding CIVIL drawing prepared by BHEL / CIVIL agency, based on civil assignment drawing of bidder will be furnished to the successful bidder for concurrence. In case any modification is required in the civil work already carried out based on final civil inputs given by vendor, BHEL reserves the right to debit cost of such rework to vendor”.

17) Ladder & platforms shall be provided for each tank for easy accessibility & maintenance purpose by bidder and the same shall be in bidder’s scope.

18) All necessary valves and fittings for the installations with the actuators necessary for their remote operation and the same shall be in bidder’s scope.

19) Embedment plates with lugs shall also be provided by bidder as per system requirement and the same shall be in bidder’s scope.

20) All channels & brackets, mounting plates as required for mounting of motors, pumps, stirrers, tank etc. shall be in bidder’s scope.

21) Start-up and commissioning spares as required shall be in bidder’s scope.

22) Mandatory spares as per attached Annexure-II of Sub-Section E to this technical specification and the same shall be in bidder’s scope.

23) All necessary structural steel for pipe supporting structure, platforms, walkways / pathways and access stairs, mechanical plant and equipment, mechanical services and pipe work associated with CPU Plant shall be in bidder’s scope.

24) All Motorized valves shall be provided with integral starter as per requirement and as indicated in the P&ID and shall be in bidder’s scope.

25) All handrails shall be of 32 mm nominal bore MS pipes (medium class) as per IS: 1161 galvanized using 750 gm/sq. m of zinc. Hand railing shall be a two-rail system with the top rail 1000 mm above the walkway surface and the intermediate rail 450 mm below the top rail. Handrail post spacing shall be limited to 1500 mm as far as possible but can be proportioned to the length of the opening. In such a case spacing shall not exceed 1850 mm centre to centre of posts. Hand railing shall be shop fabricated for specific locations and field welded or bolted to the erected structural steel. Railings shall be provided with 100 mm wide and 8 mm thick MS strip at bottom as toe guard all along the length of railing in horizontal plane. For RCC stairs, hand railing with 20

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mm square MS bar balustrade with suitable MS flat and Aluminium / Teakwood handrail shall be provided, unless specifically mentioned otherwise.

26) Instrument hook up material shall be in bidder’s scope.

27) Permanent ladder (not rungs) for approaching the top of tanks, valves for All steel inserts with lugs, plates, bolts, nuts, sleeves, edge angles and all other embedding components etc. as required to grout in civil works and to support/hold the equipments being supplied under this specification for opening/maintenance purpose.

28) Wrapping, coating and protection of the entire buried pipe shall be as per IS 10221 or AWWA C 203-93.

29) Any item/work either supply of equipment or erection material which have not been specifically mentioned in but are necessary to complete the woks for trouble free and efficient operation of the plant shall be deemed to be included within the scope of this specification and shall be in bidder’s scope without any commercial, technical and delivery implication to BHEL.

30) All other items are also included in scope of supply as specified in other part of the specification.

31) Bidder shall perform the guarantee parameters as per specification requirement to the satisfaction of owner. The exact modalities of verifying guarantee for the parameters indicated in the specification shall be finally as agreed with the owner during detailed engineering & mutually agreed.

5.0 ELECTRIC HOIST AND MANUAL HOIST (CHAIN PULLEY BLOCK)

Required number of electric hoist / manual hoist of adequate capacity, to meet the erection and maintenance requirements are to be provided for the various areas. Bidder to note that Manual hoists (hand operated) shall be designed to duty class 2 as per IS 3832 and electric wire rope hoist shall be designed as per IS: 3938 (latest). The stipulations of all statutory codes like Indian Electricity Act, Indian Electricity Rules, Factory Acts, Local Municipality act etc. shall however prevail over the specification requirements, in case any conflict arises between this specification and the statutory codes. Maintenance tools and tackles shall be as per data sheet attached.

5.1 DESIGN CRITERION FOR ELECTRIC HOIST AND MANUAL HOIST (CHAIN PULLEY BLOCK)

For items weighing 300 kg and above, hoists and trolleys along with monorails shall be provided throughout the plant where crane cannot be utilized. For items weighing less than 1000 kg, manual hoists shall be provided. For items weighing 1000 kg and more, electric hoists (lift & travel) shall be provided. In case the lifting height is more than 10m, electric hoist (lift & travel) shall be provided irrespective of the weight. All hoists shall be provided with trolleys.

Capacity of cranes & hoists shall be selected considering a minimum margin of 25% over the maximum weight of the heaviest equipment / component to be handled. For hand operated hoists, the hoists shall be suitable for operation from floor level. Hand chain shall be provided for long travel of trolley and the Hoisting mechanism. The operator shall be able to control the movement of the electrical/ manual hoist with the help of floor operated pendant.

5.2 SCOPE OF SUPPLIES

Equipment and services to be furnished by the bidder for the ELECTRIC HOIST/ MANUAL HOIST with accessories as per the details given in the technical specification and data sheet A. Any equipment /accessories not specified in the specification but required to make the ELECTRIC HOIST/ MANUAL HOIST complete and efficient operation shall also be under the bidder’s scope of work. Compliance with this specification shall not relieve the bidder of the responsibility of furnishing material and workmanship to meet the specified working/duty conditions.

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5.2.1 Electric hoist shall include but not be limited to the following: -

a. Hoisting and CT drive arrangement b. All electrical equipment including cables (as per electrical scope matrix) and panels. c. PVC insulated shrouded bus bar DSL d. Earthing arrangement. e. Initial fill of lubricant. f. Painting of electric hoist and accessories. g. Maintenance Tools & Tackles (as per attached list) h. Erection & Commissioning spares i. Isolating switch in enclosure at operating floor for disconnecting supply to DSL while maintaining the electric hoist.

5.2.2 Erection and Commissioning spares (ELECTRIC HOIST)

The Bidder shall also supply erection & commissioning spares along with his main equipment as per his experience, for replacement of damaged or unserviceable parts during the execution of the project at site, to avoid delay in the project schedule. This shall form part of the main equipment supply. The Purchaser shall retain the unutilized commissioning spares. The initial fill of lubricants, oil etc. shall also be supplied by the bidder.

5.2.3 Services to be provided by the bidder Packing, forwarding and transportation to site, storage and handling at site. 5.2.4 Erection and Commissioning 5.2.5 Functional test (Overload testing, load testing at rated speed, travel and hoisting motion checks as per

relevant Indian standards). 5.2.6 Obtaining clearance and acceptance certificate from the concerned competent authority after site test as

applicable. Necessary fees/expenditure as required shall be borne by the bidder.

5.3 INSPECTION AND TESTING

As per enclosed reference quality plan and as per IS 3938 (latest revision). Prime inspection agency shall be Consultant/ End Customer. Equipment supplied shall be strictly in accordance with nomenclature & technical specification. Any additional testing requirement/CHP (Customer Hold Point) at any stage of inspection deemed necessary by Consultant/ End Customer during detailed engineering shall be carried out without any commercial or technical implication.

5.4 TESTING AT VENDOR’S WORKS

Hoist along with its drives, controls and other accessories shall be demonstrated for the rated capacity against the rated speed of motions and for the service conditions specified as specified in QAP and as per IS 3938 for electric hoist and IS 3832 for manual hoist. The bidder shall have the full responsibility for the safe and efficient operation of the hoist with associated accessories as a single unit. If the shop performance tests indicate the failure of any of the components to achieve the guaranteed performance, the deficiency shall be made good at bidder’s cost. Demonstration tests shall be carried out each time after the rectification /modification is carried out.

5.5 MAKE OF SUB - VENDOR ITEMS

Makes of bought out items will be as per list specified in the specification. No other make will be acceptable, until and unless specifically got it approved by the purchaser/ end client. (Refer annexure-I)

5.6 TESTING AT SITE A) ELECTRIC HOIST: As required for statutory clearance for operating at site i.e., overload test, load test and other tests as per IS 3938. Test for Operation -After the supply has been connected, tests shall be carried out to prove the following:

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a) The satisfactory operation of each controller, switch, contactor, relay and other control devices and in particular, the correct operation of all limit switches under the most unfavourable conditions. b) The correctness of all circuits and interlocks and sequence of operation. c) The satisfactory operation of all protective devices. Overload Test -After test but before the hoist is put into service, it shall be tested with overload relays appropriately set, to lift and sustain a test load of 125 percent of the working load. During the overload test, the hoist shall sustain the load under full control. The specified speeds need not be attained but the hoist shall show itself capable of dealing with the overload without difficulty. B) MANUAL HOIST: As required for statutory clearance for operating at site with following minimum test i.e. Overload and load test.

5.7 MAINTENANCE TOOLS AND TACKLES

One (1) complete unused new set of special purpose tools, tackles and accessories along with detailed instructions and maintenance manual shall be supplied. Tools shall be of suitable sizes for maintenance of electric hoist of each type and capacity. Each tool and wrench shall be stamped so as to be identified easy for its use. The tools shall be supplied in steel toolbox and with a copy of instruction manual. The items supplied shall be of the best quality, specially protected against rusting. The following shall be provided as minimum requirement: S-No. Description Qty. 1 Complete set of ring spanners (Indicate the sizes offered) 1 Set 2 Complete set of screwdrivers (Indicate the sizes) 1 Set 3. Adjustable Spanner 1 No. 4. Insulated plier 1 No. 5. Grease gun 1 No. 6. Oil gun 1 No. 7. Line tester 1 No. Note: -The tools shall be supplied in one tool box. Bidder shall ensure that the tools & tackles mentioned in above list are sufficient to handle all sizes/capacities of hoists & in case any other /additional tool is required for handling/maintenance any size/capacity of hoist the same shall be included in this list.

5.8 ELECTRICAL REQUIREMENTS For Electrical requirement bidder to refer sub section C-3 of this technical specification.

6.0 SCOPE OF SUPPLY (ELECTRICAL)

Complete electrical scope as per specification / details indicated in Sub-Section C-3

7.0 SCOPE OF SUPPLY (C&I)

Complete C&I scope as per specification / details indicated in Sub-Section C-4 (Specific Technical Requirement C&I)

8.0 SCOPE OF SUPPLY (CIVIL)

Total Civil is in BHEL’s Scope of work, however complete grouting for equipments, fixing and any concreting inside the vessels, puddle pipe inside civil structure, nozzles, supporting plate/ structures & lining shall be in bidder’s scope. Also detailed Civil Input drawing shall be provided by bidder. Successful bidder shall furnish civil assignment drawings. The corresponding CIVIL drawing prepared by BHEL / CIVIL agency, based on civil assignment drawing of bidder.

9.0 SCOPE OF SERVICES

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The bidder’s scope also includes following services for scope under this specification:

(i) Erection and commissioning, unloading, storage and handling at site. (ii) Minor civil work like chipping of foundation, grouting below base plate for all structures, equipment, (iii) grouting of anchor bolts wherever these are not placed in the foundation during casting of foundation (iv) itself, excavation & filling of earth for buried pipes if and as required. Grouting material shall be in bidder’s

scope of supply. To the extent possible, vendor shall ensure to supply all foundation bolts timely so as to facilitate placement of these bolts while casting the foundation. Wrapping, coating and protection of all the buried pipe shall be as per IS10221.

(v) Pre-commissioning work such as flushing, hydraulic testing etc. Necessary consumables and instrumentation as required for inspection and testing at works as well as at site including pre-commissioning activities shall be arranged by the successful bidder at their own cost.

(vi) Arrangement of all instruments, equipments, lab facilities, reagents, monitoring gadgets for monitoring, pre-commissioning, carrying out trial run, commissioning, PG test & till plant hand over.

(vii) Monitoring gadgets, instruments and equipments required for maintenance. (viii) Bidder to arrange his personnel at BHEL-PEM office for preparation of control scheme of the CPU package.

Further bidder to also depute his personnel during FAT of CPU- DDCMIS for certifying correctness & completeness of implementation of Control logic at BHEL –EDN office. Bidder to also arrange his personnel at site during commissioning of DDCMIS of CPU package as and when required by customer / BHEL without any delay.

(ix) Complete grouting for equipment, fixing and any concreting inside the vessels and lining. (x) All personnel required during maintenance, Commissioning, trial run and PG test. (xi) Trial run for requisite period. (xii) Performance Guarantee testing. (xiii) Training of plant Owner’s personnel, O&M operators’ personnel on plant operation and maintenance. (xiv) All other facilities/ services as described in section on site services in specification and related to (xv) CPU Plant scope of work. (xvi) Relevant requirements as per GTR, GCC, ECC & SCC. (xvii) All the Piping, Valves and Equipment’s of this system shall be protected against external corrosion by

providing suitable painting. The surfaces of stainless steel, Gunmetal, brass, bronze and non-metallic components shall not be applied with any painting. The condensate pipelines and valves near the condensate polisher vessels shall be painted as per Sub-Section E ANNEXURE III of this Technical Specification.

(xviii) Painting shall be as specified Sub-Section E ANNEXURE III of this technical specification. However, any variation in the painting schedule as finally approved by BHEL / Customer shall be taken care by the bidder without any commercial and delivery implication to BHEL / Customer. Colour coding scheme shall be intimated to vendor during detail engineering.

(xix) Final touch up paint at site.

10.0 TERMINAL POINTS

10.1 CONDENSATE POLISHING PLANT - SERVICE VESSEL AREA

(i) Service vessel inlet – (OD 457.2 X 12.7 mm thick, ASTM A 106 Gr. C) - Single piping connection near service vessel area in BC bay for TG unit.

(ii) Service vessel outlet – (OD 457.2 X 12.7 mm thick, ASTM A 106 Gr. C) - Single piping connection near service vessel area in BC bay for TG unit.

(iii) Rinse water outlet- Rinse water outlet piping (OD 168.3 x 7.11 mm, ASTM A 106 Gr. C) from the service vessel outlet till condenser hot well is in scope of bidder.

(iv) The DM water used for resin transfer operations from the Regeneration building to the Condensate Polisher vessels shall be terminated by the bidder to the nearest drain trench through drain channel.

(v) 25 NB connection of Instrument air supply at 5 to 7 kg/cm2 (g) – at 5 meter distance from service vessel area. However instrumentation pipe line distribution and piping inside CPU service vessel area from the terminal point shall be in bidder’s scope.

(vi) Gland sealing valves cooling water supply & analysers rack cooling water supply piping – Service water

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connection (25 NB) at 5 meter distance from service vessel area for TG unit. Piping inside service vessel area for TG unit for mentioned services will be in bidder’s scope.

10.2 EXTERNAL REGENERATION AREA

(i) DM Water Supply – CPU Regeneration cum Resin Transfer Pumps will take suction from DM water storage tanks (DM water storage tanks not in bidder’s scope) of DM plant. A terminal point of DM water line shall be provided by customer at 5 m distance from CPU regeneration Building. Complete DM water piping from this terminal shall be in the scope of bidder.

(ii) 25 NB Instrument air supply at 5 to 7 kg/cm2 (g) – At 5 meter distance from the regeneration building.

However instrumentation pipe line distribution and piping inside Complete CPU regeneration area from the terminal point shall be in bidder’s scope.

(iii) Service water (40 NB) - At 5 meter distance from the CPU regeneration building. However, distribution and

piping inside Complete CPU regeneration area will be in bidder’s scope.

(iv) Drinking/Potable water (25 NB) - At 5 meter distance from the CPU regeneration building. However, distribution and piping inside Complete CPU regeneration area will be in bidder’s scope.

(v) In addition to that detailed terminal points shall be as per the P&ID for CPU plant (BHEL Drg. No.:

PE-DG-435-155-A001)

11.0 EXCLUSIONS

11.1 All civil works including foundation of equipment. However complete grouting for equipment, fixing and any concreting inside vessels and lining shall be in the scope of the bidder. Grouting mater ial shall be in bidder’s scope of supply. But civil works including operating / maintenance platforms and interconnection platforms (if any) with ladders / stairs & handrails, structural supports and hangers for pipes / cables / ducts, crane rails, all embedments and inserts with lugs including anchor fasteners, bolts etc., dressing of foundations, grouting of pockets and underpinning of base plates for equipment / structures and fixing supports, filling and finishing of openings in walls, floors, cladding, roof and trenches shall be in Bidder’s scope.

11.2 Main pipe trestles interconnecting CPU regeneration building and Service vessel Pipe trestle. However, auxiliary structure, hanger/support components for all the piping (CPU regeneration area, in acid/alkali handling area, interconnecting acid/alkali storage area, CPU service vessels, DM water piping, resin transfer piping, instrument air piping, service air piping, service water piping, potable water piping, air grid arrangement piping and blower piping etc.) are in bidder’s scope.

11.3 Instrument air up to terminal points.

11.4 All chemicals except reagents, monitoring gadgets required for pre- commissioning, commissioning, trial run and PG test.

11.5 Air conditioning, ventilation & firefighting facilities.

11.6 Other exclusions are mentioned in the electrical & C&I parts of this specification.

11.7 Service water, Drinking/ potable water & DM water up to terminal points.

11.8 Acid (30-33% HCL) & alkali (48% NaOH) up to terminal point.

11.9 Supply of ISMB monorail.

12.0 QP AND SUB VENDOR APPROVAL

12.1 Minimum QP requirements are specified as Sub-Section C-2. BHEL & customer reserves the right for inspection of imported items by BHEL/customer officials (if felt necessary). The same shall be decided during detail engineering during approval of QP’s.

12.2 However any additional comments as given by BHEL/Customer on quality plan shall be adhered by the bidder

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without any commercial & delivery implication to BHEL.

12.3 Requirement of detailed QP, inspection checklist, certificate of conformance etc. for each equipment and sub-vendor shall be finalized during detailed engineering stage; decision of BHEL/customer shall be binding on vendor in this regard. Any changes/additional tests insisted upon by Owner during approval of QAP’s shall be accepted by bidder without any commercial and delivery implication to BHEL/Customer. Bidder shall submit the quality plans in BHEL format during detailed engineering stage. Bidder to note further that during detailed engineering all the QAP’s/check lists etc. shall be submitted to Customer/BHEL for approval. All inspection & testing etc. shall be carried out accordingly.

12.4 List of make sub vendor items is enclosed as Sub-Section E ANNEXURE-I is indicative only and is subject to BHEL and Customer approval during detailed engineering stage without any commercial & delivery implication to BHEL.Any additional sub vendor shall be subject to BHEL and Customer approval during detailed engineering stage without any commercial & delivery implication to BHEL.

12.5 Bidder to propose sub vendor list with following back up documents within 4 weeks of placement of LOI/LOA. Thereafter no request for additional sub-vendor shall be entertained. The sub vendor list shall subject to BHEL and Customer approval during detailed engineering stage without any commercial & delivery implication to BHEL.

12.6 Dealers are not acceptable for any item of the package. Bidder shall procure all items including plates, structural, flanges; counter flanges etc. from approved sub vendor only.

13.0 FUNCTIONAL GUARANTEES AND LIQUIDATED DAMAGES

Functional Guarantees and liquidated damages shall be as per enclosed C-1 & Sub-Section C2-B .

14.0 DESIGN/ CONSTRUCTION

In addition to the requirements of Sub-Section A,B,C,D the following shall also be complied under scope of this specification. The P&I diagram is for bidder’s compliance. The material of construction specified in Datasheet-A are minimum requirements and material of construction for other components not specified shall be similarly selected by the bidder for intended duty which shall be subject to BHEL / Customer approval during detail engineering without any commercial & delivery implication to BHEL.

15.0 BIDDER TO FURNISH 4 SETS OF TECHNO-COMMERCIAL BID INCLUDING FOLLOWING DOCUMENTS/INFORMATION (FOR ELECTRICAL AND C&I PLEASE REFER THE RESPECTIVE SECTION OF THE SPECIFICATION).

Deviation if any in the enclosed Schedule of deviation with cost of withdrawal only with mention of specification clause for which deviation is being asked. (Stamped & Signed)

Compliance certificate. (Stamped & Signed)

Schedule of Declaration. (Stamped & Signed)

Unpriced Price Schedule duly filled as “Quoted”. (Stamped & Signed).

Any other documents submitted by bidder except as asked in the bid’s specification shall not be evaluated & considered as null & void.

16.0 DRAWING/DOCUMENTS REQUIREMENT

After award of LOI, following minimum drawing/documents shall be submitted by the bidder for BHEL/Customer approval. However any additional drawing/document if found necessary for completion of the engineering, the same shall be submitted by bidder without any commercial & delivery implication to BHEL. The number of drawing/documents to be submitted by the bidder shall be as per enclosed Sub -Section E Annexure VI. The submission of soft copy or hard copy of the document whichever is later will be considered

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as final date of submission of the document. The bidder has to submit the revised drawing /document along with the compliance sheet indicating enumerate reply to all BHEL and customer comments or observations. Without compliance sheet the submission of the drawings/documents will not be considered and the delay on this account will be solely on bidder’s side only. Bidder to comply with the observations of the BHEL and CUSTOMER without price & delivery implication. For the Drawings/Documents distribution Procedure, please refer attached Section E Annexure VI Bidder has to submit the revised drawing/document along with the compliance sheet indicating enumerate reply to all BHEL and customer comments or observations. Without compliance sheet the submission of the drawings/documents will not be considered and the delay on this account will be solely on bidder’s side only. The numbers of soft copies & hard copies of drawing/documents to be submitted by the bidder shall be as per enclosed Annexure-VI. After award of LOI/LOA, drawing/documents to be submitted by the bidder for BHEL/Customer approval has been indicated in Section E Annexure VI. However any additional drawing /document if found necessary for completion of the engineering, the same shall be submitted by bidder without any commercial & delivery implication to BHEL. Bidder to note that the successful bidder, during detail engineering, will submit the drg/doc through web based Document Management System in addition to hard copies to be submitted as per the Sub- Section E Annexure VI of this specification. Bidder would be provided access to the DMS for drg/doc approval and adequate training for the same. Detailed methodology would be finalized during the kick-off meeting. Bidder to ensure following at their end

Internet explorer version – Minimum Internet Explorer 7

Internet speed – 2 mbps (Minimum preferred)

1. Pop ups from our external DMS IP (124.124.36.198) should not be blocked

Vendor’s Internal proxy setting should not block DMS application’s link (http://124.124.36.198/wrenchwebaccess/login.aspx)”

DMS user manuals to be used by BHEL PEM vendors for uploading, viewing, revising, commenting and tracking documents on PEM’s DMS have been uploaded on PEM internet website (www.bhelpem.com) under the Vendor session.

For quick access bidder may refer the link http://bhelpem.com/DMSManuals/DMSManuals.html

17.0 SPARES

The Bidder shall include in his scope of supply all the necessary Mandatory spares, start up and commissioning spares as indicated in the relevant sections of specifications. The general requirements pertaining to the supply of these spares is given below: -

16.1 RECOMMENDED SPARES: The bidder shall also furnish list of recommended spares parts for three (3) years normal operation with unit prices. These recommended spares shall be those considered necessary by the bidder on a stand-alone basis. The BHEL reserves the right to buy any of the recommended spare parts as considered necessary by him. The recommended spares shall be delivered at project site at least two months before the scheduled date of initial operation of first unit. However, the spares shall not be dispatched before the dispatch of the main equipment. The price of these spars will remain valid upto 6 months after placement of Notification of Award for the main equipment. However, the Bidder shall be liable to provide necessary justification for the quoted prices for these spares as desired by the BHEL/Customer.

16.2 MANDATORY SPARES:

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All Mandatory spares listed in Sub -Section E Annexure II of this specification are in bidder’s scope of supply. All the Mandatory spares for the equipment under the contract provided by the vendor will strictly conform to the specifications and documents and will be identical to the corresponding main Equipment/components supplied under the contract. Whenever the quantity is mentioned in "sets" the bidder has to give the item details and prices of each item. The Employer reserves the right to buy any or all the mandatory spares parts. All mandatory spares shall be delivered at site at least two months before scheduled date of initial Operation of the first unit. However, spares shall not be dispatched before dispatch of corresponding main equipments. Wherever quantity is specified both as a percentage and a value, the Bidder has to supply the higher quantity until and unless specified otherwise. Inspection of mandatory spares shall be in line with the approved quality plans for the respective Items/equipments. The inspection categorisation of mandatory spares shall also be in line with the approved categorisation plan for the respective items/equipment.

16.3 START-UP & COMMISSIONING SPARES

Start-up and commissioning spares are those spares which are required during the start-up and commissioning of the equipment/system. All spares used till the plant is handed over to the BHEL/Customer shall come under this category. The Bidder shall provide for an adequate stock of such start up and commissioning spares to be brought by him to the site for the plant erection and commissioning. They must be available at site before the equipments are energized. The unused spares, if any, should be removed from there only after the issue of Taking Over certificate. All start up spares which remain unused at the time shall remain the property of the Bidder. Notes: 1) The Bidder shall indicate the service expectancy period for the spares parts (mandatory) under normal operating conditions before replacement is necessary. 2) All spares supplied under this contract shall be strictly interchangeable with the parts for which they are intended for replacements. The spares shall be treated and packed for long storage under the climatic conditions prevailing at the site e.g. small items shall be packed in sealed transparent plastic with desecrator packs as necessary. 3) All the spares (mandatory) shall be manufactured along with the main equipment components as a continuous operation as per same specification and quality plan. 4) Each spares part shall be clearly marked or labelled on the outside of the packing with its description. When more than one spares part is packed in a single case, a general description of the content shall be shown on the outside of such case and a detailed list enclosed. All cases, containers and other packages must be suitably marked and numbered for the purposes of identification. 5) All cases, containers or other packages are to be opened for such examination as may be considered necessary by BHEL / Customer. 6) The Bidder will provide the BHEL/Customer with all the addresses and particulars of his sub suppliers while placing the order on vendors for items/components/equipments covered under the contract and will further ensure with his vendors that the BHEL/Customer, if so desires, will have the right to place order for spares directly on them on mutually agreed terms based on offers of such vendors. 7) The Bidder shall warrant that all spares supplied will be new and in accordance with the contract Documents and will be free from defects in design, material and workmanship.

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8) The bidder to provide datasheets/assembly drawings of the manufacturer/ any other relevant document showing Bill of Material(s), Make, Model Number, Part Number etc. through which the mandatory spares to be supplied can be uniquely identified. 9) The bidder shall guarantee the long term availability of spares to the BHEL/Customer for the full life of the equipment covered under the contract. The Bidder shall guarantee that before going out of production of spares parts of the equipment covered under the Contract, He shall give the BHEL/Customer at least 2 years advance notice so that the latter may order his bulk requirement of spares, if he so desires. The same provision will also be applicable to sub-vendors. Further, in case of discontinuance of manufacture of any spares by the Bidder and/or his sub-vendors, bidder will provide the BHEL/Customer, two years in advance, with full manufacturing drawings, material specifications and technical information including information on alternative equivalent makes required by BHEL /Customer for the purpose of procurement of such items. 10) Wherever quantity has been specified as percentage (%), it shall mean percentage (%) of the total population of the item in the station (project), unless specified otherwise and the fraction will be rounded off to the next higher whole number. 11) Wherever the quantities have been indicated for each type, size, thickness, material, radius, range etc. these shall cover all the items supplied and installed and the break up for these shall be furnished. 12) In case spares indicated in the list are not applicable to the particular design offered by the bidder, the bidder should offer spares applicable to offered design with quantities. 13) Each spare shall be clearly marked and labelled on the outside of the packing with its description. When more than one spare part is packed in single case, a general description of the contents shall be shown on the outside of such case and a detailed list enclosed. All cases, containers and other packages must be suitably marked and numbered for the purpose of identification.

18.0 MISCELLENEOUS REQUIREMENT

I. Bidders is advised to visit the site in order to familiarize themselves with existing condition of site before submitting the bid in order to make their offer complete. During detail engineering also, the successful bidder shall be responsible for the correctness of details wrt existing facility at site. Customer approval on any drawing having details of existing facility shall not be cited by the successful bidder a valid reason for any shortcoming in the work by them. BHEL shall also not entertain any cost implication for any lack of input data with regard to site during detail engineering.

II. The complete system shall be proven and necessary design documentation in support of proveness shall

be submitted by the successful bidder in support of the systems, if asked by the customer without any price and delivery implication to BHEL and customer.

III. System to be designed to meet all the statutory requirements. Preparation of all necessary drawings/data/

documents for obtaining necessary Approval of statutory authorities like CCOE, IBR, Weight & Measures Department and any other agency/ competent authority, on behalf of the customer, related to installation of CPU plant (if required) is included in bidder’s scope. All expenses required to obtain the approval shall also be borne by the successful bidder. Successful bidder shall inform customer well in advance requirement of authority letter along with format for the same. After issuance of authority letter by customer, it will be vendor’s responsibility to regularly follow up with the concerned authorities to obtain timely approval from these authorities. Any delay on account of the same, unless any specific information related to above approval to be furnished by customer is delayed by customer, shall be to vendor’s account and shall not be used as a reason for extension in contract completion.

IV. Vendor to attend regular engineering meeting with BHEL and customer fortnightly in BHEL or customer

office as decided during detail engineering. Vendor will depute all his concerned engineering representative along with the project manager for discussion and approval. Meeting can be held at site also.

V. In case of any conflict and repetition of clauses in the specification, the more stringent requirements among

them are to be complied with.

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VI. Latest version of all codes and standards to be followed.

VII. CPU regeneration facilities (Neutralisation pit which area kept in open) shall be housed in RCC Building. Control room, battery room & MCC room for CPU plant shall be shall be housed shall be located in RCC building. RCC building shall have toilet blocks for ladies and gents.

VIII. Bidder to submit BBU during detailed engineering after approval of Basic documents. BBU shall be equal

to BOQ for the package and there shall be no price and delivery implication is applicable to BHEL / customer for the same. None of the items supplied for the project as non-billable. Incomplete BBU shall not be review by BHEL. Further during detail engineering breakup of supply prices of condensate polishing unit package in the Billing break up schedule shall be prepared as per below mentioned details:

1.0 THE BREAK UP (%) OF SUPPLY PRICES OF CONDENSATE POLISHING UNIT PACKAGE IN THE BBU SHALL BE IN LINE WITH THE BELOW PROVIDED DETAILS:

1.1 Lump sum firm price for supply of Atmospheric tanks inclusive of all taxes, duties and other levies as applicable.

5 % of Total Supply Price.

1.2 Lump sum firm price for supply of Pressure Vessels inclusive of all taxes, duties and other levies as applicable.

20% of Total Supply Price.

1.3 Lump sum firm price for supply of Valves inclusive of all taxes, duties and other levies as applicable.


1.4 Lump sum firm price for supply of Instruments & analysers inclusive of all taxes, duties and other levies as applicable.


1.5 Lump sum firm price for supply of Pumps & Blowers with motor inclusive of all taxes, duties and other levies as applicable.


1.6 Lump sum firm price for supply of Piping & Fittings inclusive of all taxes, duties and other levies as applicable.


1.7 Lump sum firm price for supply of Resin media inclusive of all taxes, duties and other levies as applicable.


1.8 Lump sum firm price for supply of agitators, heater, strainers, resin trap, filter nozzle inclusive of all taxes, duties and other levies as applicable.


1.9 Lump sum firm price for supply of Balance items inclusive of all taxes, duties and other levies as applicable.


IX. Any statutory requirement / clearance required for the package from government / local body shall be in

bidder’s scope.

X. All interconnecting piping, valves, fittings including dosing piping, drain piping from tanks to nearby drain, flushing lines from nearest available water source, valves, fittings and accessories is also in bidder’s scope.

XI. All the vertical pumps shall be self-lubricating type.

XII. Document approval by customer under Approval category or information category shall not absolve the

vendor of their contractual obligations of completing the work as per specification requirement. Any deviation from specified requirement shall be reported by the vendor in writing and require written approval shall be taken from BHEL. Unless any change in specified requirement has been brought out by the vendor during detail engineering in writing while submitting the document to customer for approval, approved document (with implicit deviation) will not be cited as a reason for not following the specification requirement.

XIII. KKS numbering if required, as per BHEL/Customer requirement shall be provided by the Bidder during

detailed engineering stage without any commercial/delivery implication to BHEL.

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XIV. Any item/work either supply of equipment or erection material which have not been specifically mentioned but are necessary to complete the works for trouble free and efficient operation of the plant shall be deemed to be included within the scope of this specification. The bidder without any extra charge shall provide the same.

XV. Buried piping shall be protected as under (as per IS-10221).

Surface cleaning by wire brush, power tool cleaning etc. Apply one coat of coaltar/primer/enamel. Apply one layer of tape comprising of coaltar. Application of tape shall conform to AWWA C- 203/IS 10221 (Appendix-B) with Minimum thickness of tape as 4MM +10%

XVI. All drawings/documents shall be approved by BHEL/Customer during detailed engineering stage.

Successful Bidder shall comply with the comment of the customer/BHEL without price & delivery implication.

XVII. Successful bidder shall furnish detailed erection manual for each of the equipment as well as complete

system supplied under this contract at least 3 months before the scheduled erection of the concerned equipment / component or along with supply of concerned equipment / component whichever is earlier.

XVIII. Final Electrical Load list will be submitted by the successful bidder as per agreed drawing/ doc submission

schedule. Thereafter any change in the electrical load list shall be entertained only subject to its feasibility, and BHEL reserves the right to debit the vendor cost of any changes necessitated in the switch gear /MCC on account of changed loads.

XIX. Wherever CIVIL works is excluded from the bidder’s scope, successful bidder shall furnish civil assignment

/ scope drawings. The corresponding CIVIL drawing prepared by BHEL / CIVIL agency, based on civil assignment drawing of bidder will be furnished to the successful bidder for concurrence. In case any modification is required in the civil work already carried out based on final civil inputs given by bidder, BHEL reserves the right to debit cost of such rework to bidder.

XX. In case vendor submits revised drawing after approval of the corresponding drawing, any delay in approval

of revised drawing shall be to vendor’s account and shall not be used as a reason for extension in contract completion.

XXI. While all efforts have been made to make the specification requirement complete & unambiguous, it shall

be bidders’ responsibility to ask for missing information, ensure completeness of specification, to bring out any contradictory / conflicting requirement in different sections of the specification and within a section/Sub-section itself to the notice of BHEL and to seek any clarification on specification requirement in the format enclosed under SECTION -II of the specification. In absence of any such clarifications, in case of any contradictory requirement, the more stringent requirement as per interpretation of Purchaser / Customer shall prevail and shall be complied by the bidder without any commercial implication on account of the same. Further in case of any missing information in the specification not brought out by the prospective bidders as part of pre-bid clarification, the same shall be furnished by Purchaser/ Customer as and when brought to their notice either by the bidder or by purchaser/ customer themselves. However, such requirements shall be binding on the successful bidder without any commercial & delivery implication to BHEL / Customer.

XXII. The bidder shall be responsible for providing all material, equipment & services, which are required to fulfil the intent of ensuring operability, maintainability, reliability and complete safety of the complete work covered under this specification, irrespective of whether it has been specifically listed herein or not. Items though not specifically mentioned but needed to make the system complete as stipulated under these specifications are also to be furnished unless otherwise specifically excluded. Omission of specific reference to any component / accessory necessary for proper performance of the equipment shall not relieve the vendor from the responsibility of providing such facilities to complete the supply and erection & commissioning of condensate polishing unit.

XXIII. It is not the intent to specify herein all the details of design and manufacture. However, the equipment shall conform in all respects to high standards of design, engineering and workmanship and shall be capable of

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performing the required duties in a manner acceptable to purchaser who will interpret the meaning of drawings and specifications and shall be entitled to reject any work or material which in his judgment is not in full accordance herewith.

XXIV. The extent of supply under the contract includes all items shown in the drawings, notwithstanding the fact that such items may have been omitted from the specification or schedules. Similarly, the extent of supply also includes all items mentioned in the specification and /or schedules, notwithstanding the fact that such items may have been omitted in the drawing.

XXV. The general term and conditions, instructions to tenderer and other attachment referred to elsewhere are made part of the tender specification. The equipment materials and works covered by this specification are subject to compliance to all attachments referred in the specification. The bidder shall be responsible for and governed by all requirements stipulated herein.

XXVI. Deviations along with cost of withdrawal (positive or negative), if any, should be very clearly brought out

clause by clause in the enclosed schedule; otherwise, it will be presumed that the vendor's offer is strictly in line with tender specification & there is no deviation. (Price to be given in sealed envelope only.)

XXVII. In case all above requirements are not complied with, the offer may be considered as incomplete and would become liable for rejection.

XXVIII. Unless specified otherwise, all through the specification, the word contractor shall have same meaning as successful bidder / vendor and Customer / Purchaser / Employer will mean BHEL and /or TAMILNADU GENERATION AND DISTRIBUTION CORPORATION LIMITED (TANGEDCO), and /or FITCHNER CHENNAI (customer’s assigned consultant).

XXIX. The equipment covered under this specification shall not dispatch unless the same have been finally inspected, accepted and shipping release issue by BHEL/Customer.

XXX. BHEL’s/Customer’s representative shall be given full access to the shop in which the equipments are being manufactured or tested and all test records shall be made available to him.

19.0 MINIMUM IMPORTED ITEMS

i) Resins.

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Vol-II Section 2-20 Piping and vlv and ftgs_R0 2.20 Piping, Valves and Fittings

VOLUME II

SECTION 2.20

PIPING, VALVES AND FITTINGS

1.0.0 GENERAL

This section is intended to provide the scope, design, constructional and functional

requirements for all power plant piping, valves and fittings.

2.0.0 SCOPE OF SUPPLY

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

High pressure/ power cycle piping

• High pressure piping covering complete main steam, hot reheat and cold reheat Piping between boiler and turbine nozzles, HP & LP bypass piping.

• Complete auxiliary PRDS and auxiliary steam piping system.

• All extraction steam piping.

• Complete feed water piping including booster pumps suction, interconnection between booster pumps and main pumps, boiler feed discharge piping upto economiser, recirculation, BFP warm up and leak off.

• Spray piping system for reheater/ superheater attemperation, HP & LP bypass system and auxiliary PRDS system.

• Condensate piping system.

• Condenser make up water system.

• Heater drains and vents piping including necessary flash tanks.

• Steam drains including necessary flash tanks.

• Valve gland sealing piping system.

• Miscellaneous line drains and vents including necessary flash tanks.

• Complete safety valve exhaust piping for safety valves on steam generator, HP piping, Aux. PRDS, heaters and deaerator etc.

• Start up vents, safety valves, pneumatic relief valves (PRVs), flash tanks and all vents from the respective equipments and pipes upto a level of one meter above the boiler house/ TG building roof. Silencers shall be provided for start up vents, lowest safety valve and PRV’S. All drains from respective equipments and pipelines shall be connected to the drain manifold of the flash tanks.

• Complete chemical dosing system piping.

• Any other piping system to make the power cycle piping complete.

• Complete steam blowing and chemical cleaning of piping including provision of temporary piping as required.

• Piping systems shall be complete with fittings/accessories, specialities, blow-down valves, vent valves, drain valves and safety valves along with their escape piping, drain piping and steam traps, expansion joints, insulation, hangers, supports, restraints/guides, snubbers and auxiliary steel etc. The drain system shall be complete along with drain pipes, unit flash tank, drain valves, root valves, relief/safety valves, control valves, motorised valves, gate/ globe valves, non return valves, break-down orifices, steam traps etc.

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Low pressure piping and valves etc.

The scope of low pressure piping including miscellaneous piping shall cover piping systems for the following services from the terminal points within the main plant area as specified elsewhere:-

• Condenser cooling water system, Auxiliary cooling water system, closed cooling water system

• Condenser make up, boiler fill and deaerator fill systems

• DM water supply and distribution system

• Condensate polishing system

• Condenser on load tube cleaning system

• Condenser air evacuation system

• Drain water system

• Chemical dosing system

• Service water systems, Potable/ drinking water system

• Air preheater wash system

• Sea water intake and outfall system

• Cooling tower blow down and make up system

• Fire water piping system

• Fuel oil unloading, storage and forwarding piping systems

• Effluent system

• Ash slurry system

• Instrument air and Service air piping system

• Sludge system

All interconnection piping within and between the equipments and any other piping system

Piping systems shall be complete with fittings/ accessories and specialities, expansion joints, all isolating and regulating/ control valves, hand operated and/or motorized/pneumatic/ hydraulic actuators, surface painting/ protection, hangers, supports, trestles, restraints/ guides, snubbers and auxiliary steel etc as required.

Power cycle control valves

All the control valves as required complete with pneumatic actuators and accessories, which shall include but not be limited to the following:

• Desuperheating spray water control valves for superheater, reheater and auxiliary steam supply

• HP and LP heaters normal and emergency level control valves

• BFP recirculation control valves

• Deaerator level control valves

• Deaerator pressure control valves

• Condensate recirculation flow control valves

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• Condenser normal make up control valves

• Condenser emergency make up control valves

• Feed water control valves (low load)

• Condensate recirculation control valve

• Excess condensate dump control valve

• Deaerator overflow control valve

• Boiler drain control valves The power cycle control valves shall be complete along with suitable type of bypass valves. Each control valve shall be provided with arrangement of upstream and downstream isolation valves (hand/ pneumatically/ electrically operated). All other control valves not specifically included above but required for completeness of the system shall also be in the scope of the

Contractor. All other valves with in the system / Equipment / package.

3.0.0 DESIGN CRITERIA

The pipe work shall be designed and erected in accordance with ANSI / ASME B31.1 'Power

piping', and the relevant codes and standards of ASTM & AWWA or an expressively approved equivalent standard and Indian Boiler Regulations wherever applicable.

All the piping system including main steam piping system, cold reheat steam piping system, hot reheat steam piping system and HP & LP bypass steam piping system shall after erection be subjected to hydrostatic test pressure as per IBR no:374. In view of the above, piping support system / selection of spring hangers for the above piping shall also be designed for hydrostatic pressure of the respective piping system without any requirement of additional / temporary supports during hydraulic testing of piping system. All the power cycle pipe thickness shall be calculated as per ASME B31.1 and IBR-350 and maximum of thickness values calculated as per ASME B31.1 and IBR-350 shall be considered. Corrosion allowance as per IBR-350 shall be considered in power cycle pipe thickness calculation.

The present specification shall prevail against that of the code whenever the former is more

restrictive. The supply must be in accordance with the latest editions of the approved Standards as

agreed by the Owner / Owner’s Representative, incorporating any other features as required by this Specification and in accordance with the Piping Materials Specification. The requirement of Indian Boiler Regulation (IBR) shall be complied with as far as applicable.

All pipe components manufactured by the Contractor and parts on which he has worked, are

to be marked clearly with an item number, specification number and material. This marking shall be permanent.

Sizes of pipelines shall be selected such that the velocity of fluid in pipes does not exceed the

following limits under conditions of maximum possible volumetric flow : Steam : Superheated steam 75 m/s

Saturated Steam 40 m/s

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Wet steam / Exhaust steam 30 m/s Water and Condensate lines: Pump suction lines (without feed water suction line) 1.5 m/s

Pump discharge lines 2.5 m/s

Feed water discharge lines 6.0 m/s

Feed water suction lines 1.0 m/s Air lines:

Delivery line for reciprocating compressors 20 m/s

Suction line for reciprocating compressors 20 m/s

Suction and delivery lines for rotary compressors 20 m/s Oil lines: Lube and Control oil lines 1.0 m/s

Pump suction line for HSD/HFO 0.8 m/s

Pump discharge line for HSD/HFO 1.8 m/s

Pipe line under gravity flow shall be restricted to a flow velocity of 1 m/sec generally. Channels under gravity flow shall be sized for a maximum flow velocity of 1.2 m/sec. The following " C" Value shall be used in HAZEN William’s formula for calculating the friction loss in piping systems. i) Carbon Steel pipe : 100 ii) C.I Pipe / Ductile Iron : 100 iii) Rubber lined steel pipe : 120 iv) PVC I HDPE pipes : 140

v) GRP pipes : 150 vi) RCC Conduits : 100

All rules of the art considering technical and economic parameters shall be carefully followed, namely:

• Lower values of velocities that those stated above shall be used to determine line size if dictated by considerations of pressure drop, NPSH, surges, water hammer, etc.

• The design flows considered in line sizing shall not be less than the rated capacities of equipment to which the piping is connected such as pumps, blowers, compressors, valves, flow limiting orifices, etc., or the system heat and/or mass balance diagrams.

• 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 together with the highest corresponding pressure.

• 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.

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• Sizes of Boiler feed pump suction piping shall be selected to meet the NPSH requirements of the pumps under transient conditions prevailing on loss of steam supply to feed water tank. Similarly for all pumps, NPSH requirements shall be satisfied in line sizing.

• The calculation of wall thickness required for pipelines subject to internal and / or external pressure shall be based on the formulae and recommendations as given in the applicable codes. Adequate allowances shall be made towards thinning due to bending, weakening at branch connections, threading, commercial tolerances on pipe wall thickness, corrosion and erosion, etc. and the same shall be subject to approval by Owner / Owner’s representative.

• The pipe thickness for CW pipe shall be arrived for full vacuum conditions.

• In case of carbon steel materials, the nominal wall thickness of pipeline shall be not less than the minimum acceptable values given below, Contractor to furnish calculation justifying thickness selection :

NB mm (inch) 15

(1/2) 20

(3/4) 25 (1)

- 40 (1.5)

50 (2)

- 80 (3)

100 (4)

Min. thickness mm

3.73 3.91 4.55 - 5.08 5.54 - 5.54 6.02

NB mm (inch) 150 (6)

200 (8)

250 (10)

300 (12)

350 (14)

400 (16)

450 (18)

500 (20)

-

Min. thickness mm

7.11 8.18 9.27 9.53 9.53 9.53 9.53 9.53 -

> NB 600 mm to NB 950 mm – 10.00 mm > NB 950 mm to NB 1200 mm – 12.00 mm

Sizes of NB 32 (11/4”), NB 65 (21/2”), and NB 125(5”) shall not be used in the piping system. Minimum thickness for stainless steel pipes shall be Sch 40S as per ANSI B36.19.

• In addition to the required wall thickness in accordance with calculations, a corrosion allowance of 1.6 mm must be added for unprotected water lines where corrosion is to be expected.

4.0.0 DESIGN AND CONSTRUCTION OF PIPEWORK 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 the floors / 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.

For piping systems with a nominal pressure of more than 40 bar (g), drainage and venting

facilities must be fitted with double valves. The pipes with nominal diameter upto and including 40 mm can be arranged at site according

to lengths and specification. The pipes with nominal diameter more than 40 mm can be installed according to the erection drawing designed. Pipe can be pre-fabricated or manufactured according to pipe length and specifications.

No tubes with nominal diameters less than 25 mm shall be used, except for impulse

measuring lines, dosing pipelines and instrument piping.

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The nominal size of the takeoff connections for instruments shall not be less than 15 mm for

service conditions not exceeding either 62 bar(g) or 425°C and 25 mm for service conditions which exceed either of these limits.

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.

Trench piping shall not be used unless found unavoidable. 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.

Piping systems shall be protected against excess pressure caused by thermal expansion of

locked-in fluids. Valve sizes for vents and drains shall be 25 NB minimum. Vent lines, which are normally

operated, shall be terminated at a minimum height of 3.0 M above the highest service platform.

For vents, pipes and any upward facing atmospheric exhaust, weather hoods and silencers as

necessary shall be provided. Manholes/Inspection chamber of adequate size shall be provided at approx. 100M interval for

large diameter CW piping. For tanks and pressure vessels, piping material for drains and vents shall be the same as that

of the vessel. Suitable drains shall be provided upstream and downstream of valves to facilitate maintenance in the circuit safely.

In addition, plugged drain and air release bosses shall be welded at appropriate places in the

piping to facilitate hydrostatic testing. Steam traps should be avoided as far as possible. If provided, steam trap 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.

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 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 H.P piping

systems shall also be welded in the workshop.

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Pipes from water drains, air vents and safety valves shall be grouped together where possible and routed to easily observed points equipped with covered funnels or to flash tanks.

So far as practicable, 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 temperature that it shall attain during plant operation. Spring support assemblies shall be equipped with a means of locking the springs against movement. Rigid supports, clamps and restraints shall be used as far as possible.

The use of counterweights as a substitute for support spring assemblies shall not be

permitted. Sliding surfaces shall be constructed of non corrodible materials that do not rely on coatings

such as paint, galvanizing, etc. for corrosion protection. Excessive friction shall be prevented. Before plant start-up, all supports shall be checked to confirm that spring load indicators have

assumed the proper cold load position and that all hangers and supports which do not incorporate springs are in the correct position. For springs which do not assume the proper cold load position, length of hanger tie rods to be adjusted in such a way that springs assume the correct cold position. After all required adjustments have been made, all threads shall be fully engaged and locked and all spring ties shall be disengaged

Seawater intake, Outfall and ACW Piping The complete seawater piping for seawater intake, outfall piping, CT make-up water system,

Auxiliary cooling water piping and the feedwater system to desalination plant shall be of HDPE/GRP. Actual piping MOC shall be referred from the respective section. Accordingly Bidder shall consider.

Pipeline shall be mainly underground with concrete encasement of 250 mm. Top of the buried

pipe shall be atleast 1.5 meters below the ground level, Buoyancy effect shall be considered while selecting the depth. Suitable air release valves shall be provided. Transient analysis shall be conducted for piping from the Intake Pump house to the Cooling Tower & Desalination Plant.

Design Requirements for GRP pipe and fittings

Sl.No. Design parameters Sea water

1. Stiffness Class 5000

2. Vacuum 760mmHg

3. Inner liner thickness 1 mm

4. Resin type for inner Liner Vinylester

5. Glass type ECR

6. Resin type for Exterior Liner Isopthalic

7. Aggregate type Silica Sand

8. Exterior Layer thickness 0.5 mm

9. Minimum initial specific stiffeners STIS

5000 N/m2

10. Ring bending strain 1.3

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The size of the manhole shall of the minimum 600mm. Design requirements for HDPE: The Intake & outfall pipe shall be buried below the sea bed and shall be covered with rip-rap to

prevent movement by currents and waves. The pipes shall be designed considering scour protection, hydrodynamic forces and buoyancy forces.

The HDPE pipes shall be of suitable diameter with rating of SDR 26 or better, PE 100 material.

The intake pipes shall be provided with man holes at every 100 m distance. The size of the manhole shall of the minimum 600 mm. The HDPE pipe shall be conformed with IS 4984/ ISO 4427/ ISO 4437./ASTM D 3350.

Materials used for the manufacture of high-density polyethylene pipe and fittings shall comply

with all requirements of ASTM D3350. The high-density polyethylene material shall be cell class of PE345664C or ASTM D3350 and shall be assigned a Plastics Pipe Institute (PPI) recommended designation of PE3408. Pipe Manufacturer shall be a member in good standing of the Plastics pipe institute.

The Flanges, fasteners, supporting structures, clamps, etc for the pipes shall be duplex

stainless steel of PREN > 38. The fasteners for connecting concrete anchor blocks shall be of suitable material for sea water.

The minimum design pressure of sea water intake and outfall pipe shall be 6 kg/cm² (g).

However higher value shall be considered based on the system requirement. Pipe shall also be designed for full vacuum conditions.

Actual piping MOC shall be referred from the respective section. Accordingly Bidder shall consider.

5.0.0 PIPING LAYOUT CONSIDERATIONS

A minimum 2.5 meter headroom shall be maintained to the lowest point of all piping components or insulation in walking areas and 8.0 meter above roadways unless otherwise approved by the Owner / Owner’s Representative. A minimum passageway of 1.5 m shall be considered for access between and around all equipments and a 150 mm minimum clearance shall be provided between piping, including insulation if applied, and any point of adjacent equipment or piping including flanges and/or pipe supports. Suitable Walkways of 750mm width for maintaining pipes and cables shall be provided on the pipe rack along with access ladders at suitable intervals.

50% extra space for the routing of future pipes for stage –II shall be provided in the pedestals

and pipe rack. While designing the pipe rack / pedestal, extra 50 % load shall be taken in order to meet the future pipes. Number of the future pipes will be finalized during detailed engineering.

Additional clearance shall be provided, where required, for pipe movement due to thermal expansion. All valves, instruments, strainers, orifices, valve motor drives and other piping accessories shall be provided with adequate space for access and removal of parts for maintenance. Bracket supports and other protruding attachments which constitute a hazard to operating personnel shall be elevated to a minimum of 2.5 m from the operator's access elevation.

All horizontal runs of outdoor piping shall be supported by pipe racks with a slope of 1:500

applicable for steam lines only and a minimum ground clearance of 8.0 m shall be considered

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for road crossing. Steam lines inside building shall be laid with a slope of 1:100. These drain valves shall be lockable.

The instruments shall be positioned to allow easy observation. A 250 mm minimum clear space shall be provided from the bottom surface of pipe to trench bottom or finished grade.

All lines shall be provided with vent and drain connections at all high and low points, respectively, as per layout constraints with suitability for operation .All piping shall be arranged to permit complete drainage when a particular unit or system is shutdown. Condensate & water lines shall also be provided with vent & drain lines for hydro test conditions. Drain points shall have a suitable isolating valve. All such drain connections shall be piped to a suitable collection point

5.1.0 Piping Flexibility Analysis

Steam piping systems shall be designed and analysed using CAESAR II software (latest version) in such a way that no excessive stresses, forces, moments or deflections can take place. This static analysis shall be done for plant operating, shut down, hydro test and occasional loading (e.g. Wind, Seismic, Safety valves popping up & Water / steam hammer conditions). As a general guidance a line shall be subjected to comprehensive stress analysis if it is fall under any of the following categories. 1. All lines at design temperature above 100 Deg.C 2. All lines 100 NB and larger connected to sensitive rotating equipments. 3. All piping subjected to vibration 4. All relief lines connected to pressure relief valves and rupture discs 5. CW Supply and Return Line near pump and condenser. 6. Sea water intake, outfall and CT Makeup pipes. 7. Other lines which in the option of Owner or Owner’s Representative requires a formal

analysis.

Pipe sagging shall be restricted to 2.5mm and piping rotation to less than 1degree.The calculations shall be based on design pressures, temperatures and weights of valves. In addition, the water weight for hydrostatic testing and the insulation weight shall also be taken into account. The calculations shall determine the maximum combined pipe stresses and the forces, moments, and deflections at all points of support, anchors and restraints. In all calculations, the manufacturing tolerance (12.5% for OD pipes) shall be taken into account. The design shall take into account possible maximum values, e.g. the maximum head of the pumps in the system as well as exceptional operating conditions, such as over pressures, vibrations and water hammer. There shall be sufficient allowance for thermal expansion and displacement without excessive stresses. The thermal expansion of the pipe work shall be carefully analyzed and appropriate pipe routing and location of the supporting equipment to be decided to prevent the piping from causing excessive forces & moments at the anchoring points.

5.2.0 Pipe Supports and Hangers

Pipe supports shall be designed according to the layout requirements. Spring shall be used

for pipe supports where restriction of vertical movement of pipe creates excessive stress in the piping system. Otherwise rigid supports like rod hangers, clamps, saddle supports etc. shall be used.

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The supporting devices shall ensure that the finished system shall provide an uniform continuous slope for draining. Loads imposed on the building structure shall, in all instances, be subject to the approval of the Engineer.

All supports for piping, cables and fitting supplied under this Contract are to be clamped to

building steelwork in preference to bolting, screwing or welding. Under no circumstances shall any part of the building steel work be drilled, cut welded without prior permission of the Owner / Owner’s Representative in writing. No point of passage of pipes through or walls is to be used as a point of support except with the approval of the Engineer.

Sling supports shall not be dependent for flexibility on the flexure of supporting rods or straps. All outdoor installation supports and hangers shall be suitably coated to withstand the local

environmental conditions. All spring supports shall be designed and fabricated to forestall the complete release of the

piping load in the case of spring failure. Supports for horizontal piping shall be spaced to prevent excessive sag, bending and shear

stress in the piping, with special consideration given where components, such as flanges and valves, impose concentrated loads.

For standard and heavier wall thickness piping, the maximum spacing between supports on

straight run of the piping shall be in accordance with ANSI B 31.1. Vertical supports shall be spaced in such a way that no pipe load is transferred to attached

equipment under cold position and also to prevent the pipe from being over stressed from the combination of all loading effects.

5.3.0 Fabrication & Erection of Piping Systems

The plant piping systems shall be fabricated, erected and tested in accordance with the requirements of ASME, ANSI, and API Standards.

All piping to be adequately supported during construction so that excessive moments or loads are not placed on equipment or other piping. The piping is to be installed to permit free expansion and contraction without damage to joints or supports. Piping bending, wherever required, is to be fabricated with a minimum of five (5) diameter radius. The joint spacing between bevelled ends of pipe shall be maintained between 1.5 and 2.5 mm. Butt welding & end preparation for pipe connections with pipe and flanges shall be as per ANSI B 16.25. All joints in high pressure and low pressure piping shall be of the fully butt welded type except at points where flanged connections are essential to permit dismantling of pipework for maintenance purposes or for matching flanged item of plants.

Interconnecting joints in all pipes shall be made by butt-welding. Such joints shall be made

without the use of backing rings. The welds shall be performed entirely in Gas Tungsten Arc. Welding (GTAW) process but where this is not practicable, a combination of GTAW for the root run, and Shielded Metal Arc Welding (SMAW) for the subsequent runs, is acceptable. Consumable insert rings may be used where considered necessary.

All flanged joints shall meet the requirements of ANSI B 16.5 or the equivalent Approved

Standard. All flanges shall be machined on the edge and spot faced at the back to receive bolts, washers and nuts. For high pressure services flange faces must be of serrated finish. Blank flanges are to be solid steel and machined all over. Flanges having pressure ratings

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less than 10 bar shall not be used. All flange jointing material unless specified, shall be subjected to the approval of the Owner / Owner’s Representative.

Socket welded connections shall be used on oil piping services less than 50 mm nominal

size. The use of socket welded connections on other piping services shall be subjected to the approval of the Owner / Owner’s Representative and restricted to the areas where the temperature or pressure cycling or severe vibration is not expected to occur or where the service may not accelerate crevice corrosion.

Screwed connections shall only be used on galvanised pipes for air services and only when

the pipe is less than 50 mm nominal size. In case of threaded joints in piping, all screw threads shall be of the ISO metric form and the diameter and pitch of thread for all bolts, studs and nuts shall conform to the ISO standards. Threaded joints are used in galvanized steel pipes only. Threaded joints, which are to be seal- welded shall be made up without the use of any joint compound or sealing tape. Threaded joints, which are not to be seal- welded shall be made leak-tight by use of suitable joint compound. Backing off of the make-up threaded joints to facilitate fit-up to alignment is not permitted.

At all points where pipes pass through concrete floors or brick or other walls, suitable floor collars or wall boxes are to be provided and fixed. The floor collars shall have raised curbs of suitable height, which shall not be less than 75 mm. The wall boxes shall be flush fitting and be of neat design and approved finish.

The Contract shall include fixing of all necessary components for the protection against

weather of such holes in an approved manner. Where pipes pass through roofs, the pipe collar shall up stand less than 200 mm above the top of the roof and hood shall shroud it to within 25 mm of the finished roof level. After the collars, boxes or other fittings been fixed in position, the floors, walls and structures shall be made good by the Contractor.

If service pipes run adjacent to each other, they are, wherever possible, to pass through a

box. Where pipes of varying bore pass through a common box, a neat plate cover shall be provided between the pipes and the box. In the case of flanged pipework, boxes shall be large enough to permit the passage of the flange.

Where pipes are laid in covered trenches this Contract shall include for the supply and fixing of all the necessary pipe supports, clamps, packing and fixings, etc.

During erection the Contractor shall be responsible for providing temporary trench covers for the protection of the pipes in the trench and for the safety and convenience of his employees and those of other contractors working or having normal access in the vicinity of trench areas.

The Contractor shall be responsible for maintaining the trenches clean and dry, and shall hand

over same to the Owner in clean and dry condition at the time of taking over of plant. 5.4.0 Cleaning, Packing and Handling of Piping Systems

The Contractor shall take all necessary precautions to ensure that the interior of all piping is kept clean during erection and free from any injurious matter.

All piping except water and air piping shall be chemically cleaned, pickled and purged with an

air blast to clean the pipe inner surface. The outside of all pipes shall also be cleaned similarly. Carbon steel and ferritic alloys piping shall be cleaned after hot working or heat treatment. Cleaning shall be accomplished by either of the following methods.

a) Degreasing making use of alkalis b) Pickling in hot sulphuric acid along with suitable inhibitor, followed by washing in cold and

hot water.

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c) Cleaning by means of power driven wire brushes. The brushes shall be of the same material as the metal being cleaned. Both inside and outside surfaces shall be cleaned.

d) Grit-blasting the inner and outer surfaces using silicon carbide or steel shots. All grit shall

be subsequently removed. After cleaning (by any of the above methods), the pipes shall be protected by means of an

outdoor preservative. All pipes shall be capped using plugs or plastic caps. All bevels, threads, flange faces and other sealing surfaces shall be suitably protected with wood or plastic to prevent damage to these surfaces.

Suitable connections shall be made, where necessary, on all pipe runs to facilitate the removal

of dirt and debris and the cleaning of each pipe run in accordance with the requirements

specified elsewhere. All steam piping to turbines shall be blown through with steam in accordance with the

Inspection and Testing Requirements. The Contractor shall install and subsequently remove any temporary piping, fittings, supports or instrumentation required to carry out the blowing through operation. The terminals of piping being blown through shall be adequately fixed in order to take the resultant thrusts. The anchor, whether temporary or permanent, shall be designed to take the thrust and any loads imposed on the building steelwork and shall receive the prior approval of the Owner / owner’s Representative. Target plates shall be used to ascertain that the system is rid of impurities.

5.5.0 Testing of Piping Systems

The following tests shall be conducted in the piping systems to check for cracks and the welding joint quality.

5.5.1 Hydrostatic Test All pipework shall be tested hydraulically to at least 1.5 times the design pressure for at least 2 hours. After the hydraulic test, a leak test with air to 1.1 time the design pressure for at least 24 hours shall be performed.

The hydrostatic test of the pipe work shall be carried out with skids isolated from the pipe work. Skids shall be tested separately before installation and connection to pipe work. The hydrostatic test pressure shall not be applied until the piping system and the testing medium have reached thermal equilibrium. During the tests, hydrostatic pressure shall be monitored and corrections shall be made to compensate for thermal expansion or contraction. By this procedure, the test pressure shall be kept within specified test pressure. All joints are visually examined for leakage during the test. Tested systems shall be vented and drained immediately upon successful completion of the test. All stainless steel lines are emptied and dried immediately after hydrostatic tests are completed. To avoid the possibility of pitting due to chlorine contents in water, demineralised or otherwise suitably treated water shall be used as the testing medium.

5.5.2 Pneumatic Test Pneumatic testing of a piping system is done

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i) When the piping system is so designed that it cannot be filled with water or other liquid testing medium.

ii) When the piping system is to be used in services where traces of the testing medium cannot be tolerated.

iii) When the piping system cannot be completely drained and dried out.

iv) When hydrostatic testing would contaminate, or adversely affect chemical handled during the process.

v) When the testing fluid would affect or damage internal lining. Pneumatic tests shall meet the following requirements:

• Air test shall be performed with clean, dry air. The source shall be equipped with appropriate pressure relief valves and gauges. The pneumatic test pressure shall not be less than 1.2 or more than 1.5 times the design pressure of the piping system.

• No repair welding shall be performed on a pressurised system.

5.5.3 Radiographic Test Radiographic inspection shall be carried out in accordance with the requirements of ANSI B31.1 and ASME V for checking piping weld quality. Random radiography shall be carried out in accordance with ASME V Article 2 for all full penetration butt welds. Weld repairs made a s a result of radiographic examination shall be radiographed after welding. Repairing a particular area more than two times is not permitted and the component shall be rejected. Prior approval shall be obtained from the Owner / Owner’s Representative before taking up major weld repairs (When depth of repair exceeds 20% of thickness or 25 mm whichever is smaller). Mapping of major weld repairs is also required. All welds shall be subject to 100% non destructive testing. Radiography shall be carried out as follows:

i) For piping 2½ inch NB or smaller, a single elliptical exposure which encompasses the

entire weld circumference.

ii) For piping 3 inch NB or larger, the double-wall-single-image technique shall be used with at least three exposures at 120o to each other.

The radiographic film recording shall be performed in accordance with the ASTM E94-77. The Radiographic Procedures and Standards of Acceptability shall be in accordance with ASME V and as specified in the appropriate design requirements:

• Gamma isotope double wall IR-192.

• Film used shall be fine-grained, a high contrast, direct type.

• Intensifying screen shall be `lead'.

• Image quality indicators shall be of the wire type (DIN 54109) selected to give the required level of sensitivity.

6.0.0 GUIDELINES FOR SELECTION AND ERECTION OF VALVES

6.1.0 Scope of Specification

This specification covers the guidelines for selection of valves and technical requirements for materials, installation and tests of general and special purpose valves, valve drives and related accessories. General-purpose valves include gate, globe, piston lift check, swing

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check, butterfly, plug, Ball and Diaphragm valves. Valve drives include pneumatic (diaphragm and cylinder), electric (motor and solenoid) actuators and hydraulic.

6.2.0 Valve Selection Criteria

Valve selection criteria based on mode of flow regulation is given below.

Type of valve On-Off Throttling Diverting

(Directional Change)

Globe – Straight/Angle/Oblique pattern

Yes Yes No

Globe – Multiport pattern No No Yes

Piston Yes Yes No

Parallel Gate – Conventional/Conduit/Knife

Yes No No

Wedge gate – with bottom cavity Yes No No

Wedge gate – without bottom cavity (rubber seated)

Yes Moderate No

Plug – Non lubricated/Eccentric plug

Yes Moderate Yes

Plug – Lubricated/Lift plug

Yes No Yes

Ball Yes Moderate Yes

Butterfly Yes Yes No

Pinch Yes Yes No

Diaphragm – weir type Yes Yes No

Diaphragm – straight through Yes Moderate No

Following is the valve selection criteria based on the fluid properties.

Type

Liquid

Special Applications

Neutral (water, oil

etc)

Corrosive (Acid,

alkaline etc) Slurry

Globe – Straight pattern

Yes

No No

Globe – Angle pattern &Oblique pattern

Yes No No

Globe – Multiport pattern

Yes No No

Piston Yes No No

Parallel Gate - Conventional

Yes No No

Less pressure drop

Parallel Gate – Conduit gate

Yes No No Water with sludge or

debris

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Type

Liquid

Special Applications

Neutral (water, oil

etc)

Corrosive (Acid,

alkaline etc) Slurry

Parallel Gate – Knife gate

Yes No No

Wedge gate – with bottom cavity

Yes No

No

Wedge gate – without bottom cavity (rubber seated)

Yes Yes No

Plug – Lubricated & Non lubricated

Yes Yes No

Plug – Eccentric/Lift plug

Yes Yes Yes

Ball Yes Yes No

Butterfly Yes Yes No

Pinch Yes Yes Yes Powder as the nature

of fluid Diaphragm – weir type/ Straight through

Yes Yes Yes No

For reasons of plant standardization the Contractor shall standardize the valves, to reduce

number of types and manufacturers to a minimum. Installation and testing of the valves shall be in accordance with the applicable standards. The requirement of this clause shall 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 must meet maximum design demands for pressure and temperature of the piping system.

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 handwheels are 300 N for wheels with

diameter up to 400 mm and 600 N for larger diameters. Differential pressures requiring higher forces for actuation of handwheels shall 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.

Valves that are required to be motor operated shall be provided with hand operated equipment

for closing and opening of the valves during power failure and shall have a suitable arrangement for de-coupling when the valves are being motor operated.

Gear operator shall be of totally enclosed. Bevel gear in grease case with grease nipples for

gate and globe valves and totally enclosed helical worm gear in grease case with grease nipples for ball, plug and butterfly valves.

Where required, valve spindles shall be lengthened so that the hand-wheel is at a minimum

height of one metre above the level of the floor. Where necessary they shall be provided with

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headstocks and pedestals of rigid construction. The actuation of valves by means of chain drives is not permissible.

On all valves where the hand wheels are liable to be dangerously hot to touch thermal

insulation shall be provided on the ring and spokes. All valves shall be closed by rotating the handwheel in clock wise direction when looking at the

face of the hand wheel. The face of each handwheel shall be clearly marked 'open and 'shut', with arrows indicating the direction of rotation to which each term refers.

Plastic or bakelite valve handwheels shall not be accepted. Valves with solid handwheels 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.

All 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. Eye

bolts shall be provided where necessary to facilitate handling heavy valves or parts of valves. Valves of sizes NB 50 and above shall be provided with position indications. Fire safe valves shall be supplied with antistatic devices. Materials used must confirm to the applicable standards. 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. For cold water lines ductile iron shall be allowed. In no case shall grey cast iron be allowed. Unless otherwise required by virtue of the valve's function, bodies shall have an internal cross

section corresponding to the nominal diameter of the connection. Integral bypass arrangement for gate valves shall be provided wherever necessary. In that

case, bypass valve shall be a globe valve and bypass attachment to main valve body shall not be screwed. The integral bypass valve shall also be motorized if the connected main valve is provided with motor actuator.

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 spindle 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 spindle and the cone must be sufficiently flexible. For H.P. globe valves and globe valves for throttling purposes of NB 50 or less the spindle and cone must be made in one piece.

In case of metallic sealing elements there must be difference in hardness between the body

seat and the sealing element, the sealing element having the higher hardness values. All globe valves shall be equipped with throttling cones with parabolic characteristics.

ANNEXURE-IV

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Each valve shall be marked on the body with the material diameter, the nominal pressure,

type of valve and an arrow showing the flow direction whenever only one is possible. No traps which incorporates internal screens or check valves shall be used unless specifically

required by the specifications or approved by the Owner. 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.

6.3.0 Requirements of General Purpose Valves a) Gate and Globe Valves All gate and globe valves, except bronze body valves, shall be screwed outside and yoke

designed with rising stems. Bronze body valves shall have union type bonnets and rising stems.

Bonnets joints shall be of the bolted, flanged type for class rating upto 600#. Pressure

seal bonnets shall be provided for class rating above 600#. The bypass shall be integral with the main valve and shall be of welded connection.

Valves shall be provided with back-seating construction and shall be suitable for re-

packing at full pressure with the valve in the open position. Gate valves for pressure above 40 bar shall have double wedge type discs. Globe valves shall have plug type discs. All valves shall have replaceable seat rings.

b) Check valve Check valves shall be designed for mounting in horizontal or vertical piping runs.

Check valve shall be of a non slam type with a swing disc and, in special cases, of the tilting disc type or guided piston lift type used upto 2”. Check valves are placed in line with a gate valve or a globe valve where guaranteed tightness is required. As far as possible, mounting check valves in vertical position to be avoided.

c) Butterfly valves Butterfly Valves shall be used in place of gate or globe valves for low-pressure liquid or

gas service upto 300# class rating. Valves are to be designed for minimum pressure loss when open and capable to withstand the full pressure of the line when closed and cause minimum vibration when used for throttling of flow.

• Butterfly valve Up to 100NB shall be without gear, above 100NB to 500NB shall be gear operated and above 500NB shall be motor (electrically) operated.

d) Ball Valves Ball valves may be used for low pressure liquid / air service. Each ball valve shall be

provided with an operating lever. e) Instrument Root Valves Instrument shut-off valves shall be Globe type construction, no bonnet, outside screw,

rising stem, with vent plugs and flanged or socket weld ends.

ANNEXURE-IV

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6.4.0 Requirements of Special Purpose Valves

Special purpose valves include valves operated with motor, pneumatic and solenoid actuators. These valves are mainly meant for remote operation in critical controls of fluid pressure, flow and temperature. The special valves shall have provision for hand operating gear.

a) Motor operated valves:

Electrically operated valves are preferred for non-safeguarding service. Local operation shall be provided on all valves. Every selector switch shall be lockable in "local" or "remote" or "hand" positions and each shall be provided with a padlock and two keys. Valve motors shall be supplied from the 400 V, 3-phase system.

Electric actuators shall have torque-limiting devices effective throughout full travel, the torque at which these operate being readily adjusted, and travel limit switches for controls and also for the operation of remote indicating lights.

The speed of operation of all power-operated valves is to be selected to suit the operating

conditions of the system and to minimise pressure surges. Actuators shall have adequate power and control systems to operate the valves accurately under all system operating conditions.

All motorized valves shall be equipped with four limit switches, for automatic control and

position indication purposes. Two torque switches are equipped, one for acting in the opening direction and the other in the closing direction. Limit switches shall not be used as mechanical stops. The materials of the limit switches shall be corrosion resistant to chemicals present in the plant environment by hermetically sealed snap acting single pole double throw type, able to switch faultlessly 125 V DC/24V DC/ 230V AC.

b) Pneumatic actuated valves:

Pneumatic actuators may be of the following types: - Spring opposed diaphragm motor type - Spring less opposed diaphragm motor type - Piston operated type Air actuators shall be designed to produce the required stem forces with supply air

pressures of 5.5 - 7 bar (g). Piston actuators shall be used where stem forces dictate their use.

Diaphragms shall be of moulded rubber, neoprene or other suitable materials and

diaphragm housings shall be of pressed steel construction. Piston actuators use cast pistons and cylinders with O-ring seals. Air cylinders are

manufactured in accordance with BS 4862 or approved equivalent. The cylinders, unless otherwise specified, shall be required to be supplied with protective

gaiters - bellows type to protect the piston rod seals. Cylinder seal materials are to be selected by considering higher ambient temperatures.

c) Solenoid actuated valves:

Solenoid coils are rated at 125 V DC for continuous energizing and designed to operate satisfactorily within 0.80 to 1.1 of rated DC voltage and in 55°C ambient temperature. Solenoid valves shall operate on the "ON-OFF" principle. The use of economy resistors is not allowed. Solenoids shall be installed in a vertical orientation.

ANNEXURE-IV

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d) Safety and relief valves: Safety & safety relief valves are provided to relieve the pressure in excess of the design

pressure building up in the system. All relief valves are direct spring loaded, angle body types of a design suitable for their

respective operating conditions. Relief valves for compressed air, steam services shall be of the "safety" type. Relief valves for water or oil shall be of the liquid relief type having a slow opening and closing action. All relief valves shall be arranged for field adjustment of the set pressure and provided with lifting levers.

e) Control valves:

Control valves are meant for regulating pressure, temperature & flow parameters in the

system. Control valve stations are generally designed with a gate valve at its upstream and downstream with a globe vent valve and a globe type bypass valve. Manual bypass valve is provided where manipulation can provide satisfactory control or where it is required for the safe plant shutdown following failure of the control valve. Bypass valves are not provided in cases where manual control cannot sensibly be achieved.

Trim of control valves shall be designed to avoid erosion, excessive noise and vibration

while handling flashing condensate. Control valves shall have stainless steel stems, guide bushing, inner valves, seat rings,

stem lock pins and stuffing box parts hardened with stellite or other equivalent seating surfaces.

Flow control valves shall be especially designed to meet high pressure drop applications

with stainless steel stems, stellited, or other equivalent hardening, seats and discs. Control valves shall be fitted with approved indicators, showing accurately the amount of

valve opening, and shall have electric position transmitters with 4-20 mA output equivalents to 0-100% opening. All valve seats and faces shall be renewable and be made from materials that are corrosion and wear resistant. Noise levels for control valves shall be restricted to 85 dBA at 1 m.

f) Pressure reducing valves:

Pressure reducing valves shall be designed for perfectly stable, quiet and non-vibratory

operation over its full range and shall be suitable for continuous duty at the operating temperature.

Incase of electrical or hydraulic valve operator is provided, on failure of the operating

mechanism, the valve shall not close automatically and the valve opening shall be readily adjustable by hand. A pressure relief valve shall be provided at the discharge of each reducing valve, capable of discharging the maximum flow of the reducing valve without build-up of pressure.

Pressure & Temperature gauges shall be provided upstream and downstream of each

reducing valve and this valve is operated by sensing the downstream pressure with the set pressure.

6.5.0 General requirements of installation of valves All regularly operated isolation valves and control valves shall be accessible from a permanent

floor or access platform. For operator convenience, valves shall have 1.0 m clear approach space. The stems of all valves for outdoor service shall have weatherproof protection covers of approved construction.

ANNEXURE-IV

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Sufficient overhead access and clearance shall be provided to enable the valve internals to be

withdrawn and also for the complete valve to be removed by means of lifting tackle if necessary. Pipe work systems shall be designed and supported so that valves can be isolated for maintenance purposes without shut down of the system whenever feasible and practical.

Unless otherwise specified, manually operated gate, globe, or butterfly valves shall be hand wheel operated and plug valves or ball valves shall be wrench-operated. Manual gear operators shall be provided, as required, depending on the size and pressure rating of the valve. All gear operators shall be of the totally enclosed type, self-locking, with position indicators. All valves shall be equipped with a locking facility, which permits locking in the open or closed position.

All valves shall be fitted with indicators such that it may be readily seen whether the valves are

open or shut, and the extent of opening. In case, the valves fitted with extended stems, indicators shall be provided both on the valve and at the extended stem hand wheel. Where remote indication is required, the valves shall be equipped with limit switches mounted on the valves for electrical signal of valve positions "open" and "shut" or position 0 to 100% as required.

Valves and related accessories shall be subjected to hydrostatic testing and seat leak testing

as per the requirement of the applicable codes and valve pressure classes as per B16.34 / API 598 / BS 5146. All motor actuators shall be supplied with type and routine test reports.

The shut off valves in the vent line from the safety valves shall be locked open by a approved

master key system. All isolation valves shall be designed to withstand the differential pressure across them when

closed. The drains from each filter separator and other liquid drainage points shall be fitted with a non-

return valve and manual isolating valve. The drains shall be grouped and connected to a common drain header leading to the condensate tank.

Vents and thermal reliefs shall discharge to the vent system. The capacity and the design of

the vent system shall be as per the recommendations of API standards. Whenever there is a risk of pressure above design point safety valves shall be provided.

7.0.0 MATERIAL 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.

7.1.0 Piping Material Specifications

SL NO

SERVICE SIZE PIPE FITTING

S FLANGES GASKETS

END JOINT

1 HP steam system – HP Steam to steam turbine, HP steam upto

<= 50 NB

ASTM A335 P91

ASTM A182 F91

ASTM A182 F91-

Spiral wound

Socket welded

> 50 NB ASTM ASTM A234

ASTM Spiral Butt

ANNEXURE-IV

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SL NO


S FLANGES GASKETS

END JOINT

PRDS A335 P91

WP91 A182 F91- wound welded

2 Steam Temperature above 550º C & upto 605 º C

<= 50 NB

ASTM A335 P91

ASTM A182 F91

ASTM A182 F91-

Spiral wound

Socket welded

> 50 NB ASTM A335 P91

ASTM A234 WP91

ASTM A182 F91-

Spiral wound

Butt welded

3 Steam Temperature above 500 and upto 550º C

<= 50 NB

ASTM A335 P22

ASTM A182 F22

ASTM A182 F22

Spiral wound

Socket welded

> 50 NB ASTM A335 P22

ASTM A234 WP22

ASTM A182 F22

Spiral wound

Butt welded

4 Steam Temperature above 400 and upto 499º C

<= 50 NB

ASTM A335 P11

ASTM A182 F11

ASTM A182 F11

Spiral Wound SS316

Socket Welded

> 50 NB ASTM A335 P11

ASTM A234 WP11

ASTM A182 F11

Spiral Wound SS316

Butt welded

5 Temperature below 400º C (LP steam system, Auxiliary steam system, Fuel oil, Feed water, Condensate CEP suction, Nitrogen Filling

<= 50 NB

ASTM A106 Gr B

ASTM A105

ASTM A105 Spiral Wound SS316

Socket Welded

> 50 NB ASTM A106 Gr B

ASTM A234 WPB

ASTM A105 Spiral Wound SS316

Butt welded

6 DM water distribution system/ Portable water system & LP chemical dosing system

<= 50 NB

ASTM A312 TP 316L

ASTM A182 Gr F3316L

ASTM A182 Gr F316L

EPDM/ Teflon

Socket Welded

> 50 NB ASTM

A312 TP 316L

A 403 Gr WP316L

ASTM A182 Gr F316L

EPDM/ Teflon

Butt welded

7 Closed cycle cooling water system

<= 50 NB

ASTM A53 Gr B

ERW / IS1239 part I Heavy ERW

ASTM A105/IS1239 Part

II

ASTM A105

EPDM/ Teflon

Socket Welded

Above 50 NB

and upto 450 NB

ASTM A 53 Gr B ERW /

IS1239 part I

Heavy ERW upto 150NB

& IS3589

ASTM A234

WPB/IS1239 Part II up to 150NB

ASTM A105 EPDM/ Teflon

Butt welded

ANNEXURE-IV

21 OF 31





SL NO


S FLANGES GASKETS

END JOINT

ERW above 150NB

Above 450 NB

ASTM A134-A283 Gr C ERW / IS

3589

Same as parent pipe

ASTM A105 / IS2062

Plate fabricated

EPDM/ Teflon

Butt welded

8 Instrument Air system

<= 50 NB

ASTM A53 Gr. B (ERW)/ IS1239 Part I Heavy ERW Galvanized


II Galvaniz

ed

ASTM A105

Galvanized

EPDM/ Teflon

Threaded

> 50 NB ASTM A53 Gr. B/IS1239 ERW Part I Heavy up to

150NB Galvanized

ASTM A234

WPB / IS 1239

Part II up to 150NB Galvaniz

ed

ASTM A105

Galvanized

EPDM/ Teflon

Threaded

9 Service air / service water

<= 50 NB

ASTM A53 Gr B ERW/

IS1239 Part I Heavy ERW


II

ASTM A105

EPDM/ Teflon

Socket Welded

> 50 NB & Upto 450 NB

ASTM A53 Gr B

ERW/IS1239 ERW Part I

up to 150NB.

ASTM A234

WPB/ IS 1239

Part II up to 150NB

ASTM A105

EPDM/ Teflon

Butt welded

450 NB & Above

ASTM A134-A283 Gr C

ERW

ASTM A234 WPB

Plate fabricated

from MS IS 2062 Plate

EPDM/ Teflon

Butt welded

10 Lube Oil, Waste oil and Control / Hydraulic Oil (Upstream of Filter) / LDO & HFO

<= 50 NB

ASTM A106 Gr B

ASTM A105

ASTM A105

Spiral Wound SS316

Socket Welded

> 50 NB ASTM A106 Gr B

ASTM A234 WPB

ASTM A105

Spiral Wound SS316

Butt welded

11 Lube Oil, Waste oil and Control / Hydraulic Oil (Downstream of Filter)

<= 50 NB

ASTM A312 TP316

ASTM A182 Gr F316L

ASTM A182 Gr F316L

Spiral Wound SS316

Socket Welded

> 50 NB ASTM A312 TP316

ASTM A403

GRWP316

ASTM A182 Gr F316L

Spiral Wound SS316

Butt welded

12 Sea water intake and outfall / CT

All HDPE HDPE HDPE With Backing

Ring

EPDM Fusion welded

ANNEXURE-IV

22 OF 31





SL NO


S FLANGES GASKETS

END JOINT

Makeup and Desal plant

feed water/ ash recovery water

Actual piping MOC shall be referred from the respective

section. Accordingly Bidder shall

consider.

13

Sea water intake and outfall / CT

Makeup and Desalplant

feed water/Auxiliary cooling water system/ Low

and High Pressure Sea

water

Actual piping MOC shall be referred from the respective

section. Accordingly Bidder shall

consider.

All

GRP

GRP

GRP

-

Butt and Wrap for Aboveground / Bell

and Spigot for Below ground.

14 Condenser

cooling water system

<= 50 NB

ASTM A312 TP 316

L

ASTM A182 Gr F316L

ASTM A182 Gr F316L

EPDM/ Teflon

Socket Welded

Above 50 NB

(including Above ground

CW pipe)

IS1239 part I, ERW,

Heavy, glass flake coating

(1 mm) / ASTM

A312 TP 316 L upto

150NB & IS3589

fabricated from IS 2062

,with Polyurethane

ASTM A234 WPB glass flake

coating

(1 mm) up to

350NB and

fabricated from parent

pipe with

ASTM A105 up to 150

glass flake coating

(1 mm) up to up to

350NB and fabricated

from IS2062 Plate with

Polyurethane lined

400NB and

EPDM/ Teflon

Butt welded

ANNEXURE-IV

23 OF 31





SL NO


S FLANGES GASKETS

END JOINT

lined inside 150NB and

Above

Polyurethane lined

inside 400NB

and Above

Above

Above 900 NB

(below ground)

IS3589 fabricated

from IS 2062 with

corrocoat or polyurea coating of

1500 microns DFT and

Outside of pipes shall be provided with 250 mm

thick RCC encasement

-

-

-

-

-

15 Chemical lines in Desalination plant.

ALL CPVC - - - -

Note: At the welding joints, corrocoat coating shall be applied after welding.

7.2.0 Valve Material Specifications

SL.

NO.

SERVICE SIZE BODY/

BONNET

DISC STEM HAND

WHEEL

VALVE

ENDS

1 HP steam system – HP Steam to steam turbine, HP steam upto PRDS

>65NB < 50 NB

ASTM A182 Gr.

F91 ASTM A182

Gr.F91

ASTM A182 Gr.

F91 ASTM

A182 Gr F91

ASTM A182 Gr. F6a

ASTM A182 Gr.F6a

ASTM A47 Gr. 32510 ASTM A47 Gr.32510

BUTT WELDED. SOCKET WELDED

2 Steam Temperature above 550º C & upto 605 º C

>65NB < 50 NB

ASTM A217 C12A/ ASTM A182

Gr.F91

ASTM A182 Gr.

F91 ASTM

A182 Gr F91

ASTM A182 Gr. F6a

ASTM A182 Gr.F6a

ASTM A47 Gr. 32510 ASTM A47 Gr.32510


3 STEAM LINES (TEMP >500°C

AND <550°C)

>65NB < 50 NB

ASTM A217 WC9/ ASTM A217 C12A ASTM A182

Gr.F22

ASTM A217 WC9/

ASTM A217 C-

12A ASTM

A182 Gr F22

ASTM A182 Gr. F6a

ASTM A182 Gr.F6a

ASTM A47 Gr. 32510

ASTM A47 Gr.32510


4 STEAM LINES (TEMP>400°C

AND <499°C)

>65NB < 50 NB

ASTM A217 WC6 ASTM

ASTM A217 WC6

ASTM

ASTM A182 Gr. F6a

ASTM A182

ASTM A47 Gr. 32510

ASTM A47

BUTT WELDED. SOCKET

ANNEXURE-IV

24 OF 31





SL.

NO.

SERVICE SIZE BODY/

BONNET

DISC STEM HAND

WHEEL

VALVE

ENDS

A182 Gr.F11

A182 Gr F11

Gr.F6a Gr.32510 WELDED

5 LP steam system,

Auxiliary steam system, Fuel

oil, Feed water, Condensate CEP suction,

Nitrogen Filling

>65NB < 50 NB

ASTM A216 Gr

WCB ASTM

105

ASTM A216 Gr

WCB ASTM

A182 Gr F6a

ASTM A182 Gr F6a

ASTM A182

Gr F6a

ASTM A47 Gr 32510

ASTM A47 Gr 32510

BUTT WELDED SOCKET WELDED

6. Lube Oil, Waste oil and

Control / Hydraulic Oil (Upstream of

Filter) / LDO & HFO

>65NB < 50 NB

ASTM A216 Gr

WCB

ASTM A105

ASTM A216 Gr

WCB

ASTM A 182 Gr.

F6a

ASTM A479 Type 410-2


ASTM A47 Gr 32510

ASTM A47 Gr 32510


7. Lube Oil, Waste oil and

Control / Hydraulic Oil (Downstream

of Filter)

>65NB <50NB

ASTM A 351

CF3M

ASTM A 182 F 316 L

ASTM A 351 CF3M

ASTM A 182 F 316

L



ASTM A47 GR. 32510

ASTM A47 GR. 32510


8. INSTRUMENT AIR

>65NB < 50 NB

A216 Gr. WCB

GALV. A105

GALV.

A351 Gr. CF 8M

SS316



ASTM A47 GR. 32510

ASTM A47 GR. 32510

FLANGED RAISED FACE

SCREWED

9 SERVICE AIR SERVICE WATER

>65NB < 50 NB

A216 Gr. WCB

A105.

ASTM A216 Gr

WCB ASTM A 182 Gr.

F6a



ASTM A47 GR. 32510

ASTM A47 GR. 32510

FLANGED RAISED FACE

SOCKET WELDED

10 SEA WATER >65NB < 50 NB

A 439 Gr.D2 -

NI RESIST

A182 F316L

A 439 Gr.D2 - NI RESIST

A182 F316L

DUPLEX SS

DUPLEX SS

ASTM A47 GR. 32510

ASTM A47 GR. 32510

FLANGED RAISED FACE

SOCKET WELDED

11 Condenser cooling water system

>600NB

CI-IS 210 FG-260 or ASTM A-216 CLB or Fabricated steel as

per ASTM

A-515 Gr. 60/80 / IS:2062 Gr. B or

CI-IS 210 FG-260 or ASTM A-216 CLB or Fabricated steel as per ASTM A-515 Gr. 60/80 / IS:2062 Gr.or

DUPLEX SS

ANNEXURE-IV

25 OF 31





SL.

NO.

SERVICE SIZE BODY/

BONNET

DISC STEM HAND

WHEEL

VALVE

ENDS

>65NB UP TO 600NB < 50 NB

equivalent. Fully ebonite

lined

A 439 Gr.D2 -

NI RESIST

A182 F316L

equivalent. Fully

ebonite lined

A 439 Gr.D2 - NI RESIST

A182 F316L

DUPLEX SS

DUPLEX SS

ASTM A47 GR. 32510

ASTM A47 GR. 32510

FLANGED RAISED FACE

SOCKET WELDED

12 DM Water / DMCW/ CCCW / Potable water /LP chemical dosing system

>65NB < 50 NB

ASTM A 351

CF3M

ASTM A 182

F316L

ASTM A 351 CF3M

ASTM A182 F316L

ASTM A479 Type 410-2 ASTM A479 Type 410-2

ASTM A47 Gr 32510

ASTM A47 Gr 32510

FLANGED RAISED FACE

SOCKET WELDED

Piping and valve specification also given in the respective package section. In case of contradiction between the respective package section and the piping section, superior of the respective package section and the piping section shall be provided.

8.0.0 BURIED PIPING

8.1.0 Excavation for Pipe Trenches The trench shall be cut true to the line leveled with the help of sight rails provided at every

30 m, at change of direction, gradient and at any suitable distance as directed by the Owner. If the trench is excavated below the required level indicated in the drawing, the extra depth

shall be filled with concrete or approved equivalent material as directed by the Owner. The trench shall be excavated so as to provide an average cover of 1500 mm or equal to the

diameter of the largest pipe to be laid in the trench unless otherwise shown in drawings. The average cover shall be reckoned from top of the pipe of the largest diameter to be laid in the trench, to the finished grade. The width of the trench, shall be sufficient to give free working space on each side of the pipe. The free working space shall conform to IS:783. Generally it shall not be less than 150 mm on either side or 1/3 of dia of pipe whichever is greater.

No excavated material shall be deposited within 1.5 meters from the excavated trench.

The dredged material shall be disposed off shore as per the regulations for sea water intake

piping In case of road cutting, all material i.e. metal, bricks, etc. shall be taken out carefully and kept

separately for reuse and road work shall be redone up to the original level prior to cutting the road with the excavated road materials after laying & testing of the pipeline. The Contractor shall provide suitable signs and barricades to prevent accidents. Contractor shall also provide reasonable bypass when a road is cut for laying pipeline. The dykes affected due to laying of the pipes, shall be redone conforming to the original specifications by the Contractor.

ANNEXURE-IV

26 OF 31





During excavation if some obstacle is met with, same shall be reported to the Owner and dealt with as instructed by him.

The Contractor shall dewater, shore or do whatever might be required to excavate the trench,

install the pipe in it and backfill the trench, in accordance with the specifications. Dewatering shall be done in advance of the laying of the pipe to allow adequate inspection of padding of the bottom if required and dewatering shall be continued throughout during laying of the pipe and backfilling of the trench.

In muddy/slushy ground, the bed shall be provided with a layer of a sand or lean concrete as

directed by the Owner. The trench shall follow the gradient of pipeline as specified in the drawing. The Contractor

shall keep the trench in good condition, until the pipe is laid and tested. All materials to shore the trench in order to prevent caving are to be furnished and removed by the Contractor.

In case pipe is lowered in caved trench and back-filled before being inspected by the Owner,

the Contractor shall re-excavate the trench for inspection and backfill it. 8.2.0 Sand bedding:-

Sand bedding of adequate thickness with fine sand to be provided as per AWWA M11

8.3.0 Corrosion Protection Tape coating Materials All underground steel pipes shall be protected with external corrosion Protection Tape. Coating shall be coal tar based tape coating materials confirming to AWWA C203. Tape shall

be coal tar component supported on fabric of organic / inorganic fibres. The fibre shall be thoroughly coated and completely covered on both sides with coal tar component. The tape shall be supplied in standard width and rolls shall be wound on hollow cores of standard diameter. The material shall have enough mechanical strength and dimension stability. As far as possible the fabric shall be thin, flexible, uniform and composed of glass fibres in an open structure bonded with a suitable inert material compatible with coal tar.

The primer shall be a coal-tar or suitable resin product. The primer shall consist of chlorinated

rubber synthetic plasticizer and solvents. These primers shall be suitably compounded to produce a liquid coating which may be applied by brushing or spraying and which shall produce effective bond between the metal and subsequent coating of coal tar tape. Primer should not contain benzol or other toxic and/or highly volatile solvents, added pigments or inert fillers or other substances and shall show no tendency to settle out in containers.

Where the soil is corrosive in nature, Cathodic protection shall be given. If soil resistivity is greater than 5000 ohm-cm, cathodic protection is generally not required

Application Procedure Cleaning, blasting and protection after blasting Before the metal is blast cleaned, all oil and grease on the surfaces shall be thoroughly

removed by flushing with a suitable solvent (such as xylene or 1,1,1 trichloroethane) and wiping with clean rags. The use of dirty or oily rags or dirty solvent shall not be permitted. All foreign matter not removable by blast cleaning shall be removed by suitable means. Blast cleaning operations shall remove all rust, scale and other impurities from the surface, exposing base material, presenting a greyish matte appearance. Slight shadows, strata or discoloration caused by rust stains or mill scale oxides need not be removed. Blasted

ANNEXURE-IV

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surfaces that rust before a priming coat has been applied shall be cleaned of all rust by buffing or wire brushing, or shall be reblasted. Adequate air separators shall be used to effectively remove all oil and free moisture from the air supply to the blaster.

After being cleaned, the pipe shall be protected from and be maintained free of oil, grease and

dirt that might fall on the pipe before it has received its coal tar tape. During blast cleaning, any pipe found to show pits shall be set aside immediately, pending examination by the Owner for acceptance, reconditioning or rejection.

Priming and Application of coal tar tape All blasted surfaces shall be primed immediately following blasting and cleaning. The

surfaces be dry at the time the primer is applied and no primer shall be applied during rain unless the pipe to be primed is protected from the weather by suitable housing.

The use of coal tar primer that has become fouled with foreign substance or has thickened

through evaporation of the solvent oil shall not be permitted. The application of primer shall be hand brushing, spraying or other suitable means and shall be in accordance with instructions for application, as supplied by the manufacturer. The apparatus to be used for application of the primer shall be acceptable to the Owner. Spray gun apparatus to be used shall include a mechanically agitated pressure pot and an air separator that shall remove all oil and free moisture from the air supply.

After application, the primer coat shall be uniform and free from floods, runs, sags, drips,

holidays or bare spots. Any bare spots or holidays shall be recoated with an additional application of primer. All runs, sags, floods or drips shall be removed by scraping and cleaning, and the cleaned area shall be retouched or remedied by reblasting and repriming. Suitable measures shall be taken to protect the wet primer from contact with rain, fog, mist, spray, dust or other foreign matter until completely hardened and tape applied.

The minimum and maximum drying times of the primer or the period between application of

primer and application of coal tar tape, shall be in accordance with instructions issued by the manufacturer.

If the coal tar tape is not applied within the allowed maximum time after priming, the pipe shall

be reprimed with an additional light coat of primer or the entire prime coat shall be removed by reblasting and the pipe reprimed.

The cleaning and priming operation may be carried out in the Contractor's workshop or on

site. The entire pipe length shall be cleaned but the ends of the pipes shall be left without coating for a distance of 230 mm for joints, which shall be coated and wrapped manually on site after laying, welding and testing the pipes.

Tape application should fallow as soon as the primed surface is tacky. Tape shall be wraped

in accordance with the manufacturer's recommendation in a manner that shall meet the adhesion and holiday detection requirement. In no case the overlap per single wrap is less than 12.5 mm. Two coats of coal tar tape coating shall be applied. A suitable primer as per manufacturer's recommendation shall be applied between the wraps. Air pockets or bubbles between the pipe and tapes or between tapes are to be avoided and tape shall be in perfect contact with the primed steel.

8.4.0 Laying of Underground Piping General After prefabrication, coating and trenching, the Contractor shall lay the underground piping in

accordance with the following clauses and as per the approved piping arrangement drawings.

ANNEXURE-IV

28 OF 31





The Contractor shall be responsible for correct layout and gradient of the line.

Lowering & Laying

The pipes shall be lowered either by mechanical methods or by hand when the trench is ready and bottom of the trench is graded as per required pipe laying conditions and specifications.

By machine The shop coated pipe, already transported to the pipe laying site/convenient length of pipe

assembly coated and wrapped near the trench after hydrostatic testing shall be placed on clean square cut skids suitably spaced so as to keep the pipe away from touching the ground. The pipe may be lowered down in the trench by the launcher cranes, with sufficient care to protect the coating of the pipeline. Bare cables, chains hooks etc. shall not be permitted to come in contact with the coating.

At tie in welds and other places, the Contractor shall clean, prime, coat and wrap manually.

Also short sections of pipelines which are impracticable to shop treat may be hand treated but only on the prior written approval of the Owner.

By Hand The pipe may be lowered with the help of tripods and chain pulleys blocks into the trench

immediately after the coating. However if in the opinion of the Owner that the temperature condition do not allow direct lowering, then the pipe shall be set down on clean square cut skids. The skids shall be so spaced as to keep the pipe away from touching the ground.

Method & Time of lowering pipe Under favourable temperature, conditions and using methods which shall not damage coating,

the pipe may be lowered into the trench. Pipe previously set on skids, because of unfavourable temperature conditions shall be

lowered into the trench normally in the cool of the morning and only when the temperature of the pipe is below the softening point of the coating materials.

All skid marks and other places of damages shall be thoroughly examined to ensure proper

patching where necessary, before the pipe is finally lowered into the trench. Handling of Coated Pipes Coated pipes shall not be placed in trench until cave in plugs, hard clods, stones, skids,

welding rods etc. have been removed there from. Where the trench has a hard or jagged bottom, sufficient fine dirt or sand shall be placed therein, before the pipe is lowered.

Coated pipe shall not be handled or moved by means of cable or chains or by prying with

skids or bars. It shall be tied and lowered by using lowering belts of a standard width and designs for the size of pipe being handled.

Coated pipe shall not be dragged along the ground or otherwise handled in a manner that

shall be detrimental to the coating. Lining up & Welding The ends of the pipe line shall be kept securely closed to prevent entry of any foreign material/

moisture after lowering into the trench. Before making joints the pipe shall be carefully laid so as to be perfectly aligned in both plan

and profile and the end closures provided shall be removed.

ANNEXURE-IV

29 OF 31





Tie-in shall be made in the coolness of the morning or when the ambient temperature is not

exceeding 29°C or softening temperature of the coating material whichever is less. All bevelling, aligning and welding shall be in accordance with the welding specifications.

Free access shall be provided for the welding of the circumferential joints by increasing the

width and depth of the trench at these points. There should be no obstruction to the welder from any side so that a good welded joint is obtained.

8.5.0 Draining All lines and equipment shall be completely drained after the hydrostatic test of a system has

been completed. High point vents shall be open to prevent excessive vacuum and permit complete draining.

If it becomes necessary to leave a system filled with the testing medium for any abnormal

length of time, suitable arrangement such as venting shall be made to provide for possible liquid expansion with change in ambient temperature.

8.6.0 Backfilling After testing and inspection of the pipeline to the entire satisfaction of the Owner, the trench

shall be backfilled with the same material as the pipe bed above the top of the pipe. No trench shall be backfilled without the approval of Owner.

Backfilling with the excavated material shall be done in layers of 200 mm, well watered and

rammed to avoid any settling afterwards. The Contractor shall place soil over the trench to such a height as to provide adequately for

future settlement of the trench backfill. If due to exigencies of the work, some portion of the pipeline is backfilled without approval of

the Owner, the Owner shall have the right to order uncovering of the pipe for examination . The backfill material shall be free from stone pieces. Surplus excavated soil or rubbish material shall be removed by the Contractor to a place

designated by the Owner. When the trench has been dug through roads all backfill shall be thoroughly compacted. In

certain cases, special compaction methods may be required by the Owner. This shall be done by the Contractor and part of the EPC work.

When the trench has been dug through unlined ditches the backfill shall be thoroughly

compacted in 150 mm layers for a distance of 1.50 m beyond the outside banks of the ditch on either side. The banks of the ditch shall also be compacted in 150 mm layers .

After the roads have been already graded, if they are trenched or otherwise disturbed by the

Contractor during laying of the pipelines. The Contractor shall restore the road to its original level and condition. In the event, the Contractor is required to place extra fill, gravel, or other special material it shall be borne by him and shall part of the EPC work.

8.7.0 Clean up of Surroundings As soon as the backfill is completed, the Contractor shall immediately clean up the adjoining

area by removing all surplus and defective material and dispose of all refuse such as spurs, sheet iron, and broken skids etc. to the complete satisfaction of the Owner.

ANNEXURE-IV

30 OF 31





8.8.0 Thrust blocks should be provided at all direction changes for GRP/HDPE Buried pipes .

9.0.0 DOCUMENTATION

9.1.0 Drawings, Data / Documents To Be Submitted Along With Offer 9.1.1 Completely filled up technical schedules and data sheets of tender documents 9.1.2 Details of similar job executed in last five years 9.1.3 Mandatory spares 9.1.4 Start up and commissioning spares 9.1.5 3 years Operation and maintenance spares 9.1.6 Special Tools and tackles for erection & maintenance 9.2.0 Drawings, Data / Documents to be furnished by the successful Bidder 9.2.1 Piping specification for Supply and erection 9.2.2 QAP for shop and field works 9.2.3 Piping general arrangement drawings 9.2.4 Stress analysis report 9.2.5 Isometric drawings 9.2.6 Datasheets and GA drawings for valves and piping specialties 9.2.7 Specification for Pipe supports and stress analysis. 9.2.8 Specification for insulation 9.2.9 Pipe Thickness calculation 9.3.0 Any other drawings required for review during the detailed engineering stage, same shall also

be submitted by contractor.

ANNEXURE-IV

31 OF 31

Project: Condensate Polishing Unit as per Tech Spec. No. PE/PG/PA1/E-6008/2018 for TENDER

FOR CPU OF 2X660 MW UDANGUDI SUPERCRITICAL STPP STAGE-1

Tender No.: PE/PG/UDN/E-6008/2018

Doc. Title: Pre-Bid Queries (Technical)

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Sr. No.

Volume Section Clause No. Page No.

Specification Requirement Clarification BHEL reply

Mechanical Clarification

1. Tender P & ID

Sec-D, D1

Drawing no. PE-DG-435-155-A001, SHEET 1 OF 2

4.0 A

526 of

529

389 of

529

As per Tender P & ID, by pass emergency line of CPU Service vessel condensate inlet and outlet headers of the unit with a butterfly type control valve and & butterfly type isolation valve in the upstream and downstream sides of the control valve are shown but as clause no. 4.0.A sr. no. 13, by pass emergency line of CPU Service vessel condensate inlet and outlet headers of the unit with a butterfly type control valve and globe type isolation valves in the upstream and downstream sides of the control valve.

Please clarify which type of valves to be used for isolation of control valve in by pass emergency line.

Refer Amendment 1

2. Tender P & ID

Sec-D, D1


4.0 C

526 of

529

392 of 529

In Tender P & ID, MOC of inlet pipe to Acid Storage tank is shown polypropylene lined MS however as per 29 clause no. 4.0.C serial no. 8 Piping used for handling acid (concentrated) and acid solution shall be CPVC Sch. 40.

Please clarify MOC of Piping for Acid application.

Piping for Acid application shall be CPVC. .Refer Amendment 1





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3. Tender P & ID

399 of 529


10.2

526 of

529

399 of

529

As per Tender P & ID 2 Nos. Bulk alkali Storage tank in the scope of Bidder but as per technical specification clause no. 10.2 serial no. ii, DM Plant Bulk alkali storage tanks (not in bidder’ scope) shall be used for regeneration of CPU Reins.

Please confirm the scope of Bulk alkali Storage tank.

Refer Amendment 1

4. Tender P & ID

Sec-D, D1


10.2

526 of

529

399 of

529

As per Tender P & ID 2 Nos. Bulk acid Storage tank in the scope of Bidder but as per technical specification clause no. 10.2 serial no. iii, DM Plant Bulk acid storage tanks (not in bidder’ scope) shall be used for regeneration of CPU Reins.

Please confirm the scope of Bulk acid Storage tank.

Refer Amendment 1

5. Section-I,

Subsection C-1

3.5 28 & 30 of 529

As per clause no. 3.5 serial no. vii, MOC of Bulk alkali Storage tank is shown FRP but all others atmospheric tanks like alkali day tank and alkali preparation tank which is use for alkali application is shown IS:2062 Gr. A/B inside rubber lined.

Please confirm the MOC of Bulk alkali Storage tank.

Refer Amendment 1

C & I Clarification





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1. Vol II 4 5.0.0 224 of

529

Various analysers namely pH, conductivity, cation conductivity, silica, dissolved oxygen, sodium etc., shall be provided in the required process lines.

In scope of supply clause 4.0 (Page 388 of 529) as well as Tender P&IDs, pH, conductivity, cation conductivity, silica and sodium analyzer are applicable and quantified too. But, about dissolved oxygen analyzer, no where is written & shown in the respective portion of scope of supply and Tender P&IDs.

As per our past experience, dissolved oxygen analyzer does not play any role in CPU package. Please confirm whether we have to consider the same or not.

In case it is applicable then please inform the its location and quantity.

Dissolved Oxygen Analyser is excluded from scope of supply.

Tender.N

Project:

S.No Volume Section Clause Page No Clarification BHEL Reply

1

Spec.No-PE-TS-

435-155-A001,

REV 0

Spec.No-PE-TS-

435-155-A001,

REV 0

Section-I,

SUBSECTION-C-1

Section-D,

SUBSECTION-D-1

4.0, Piping & Valves,

Point No-(iii)

5.0, Valves, Point no-

(i)

B. Regeneration

system, Point no.24

30 of 529

31 of 529

390 of 529

All the clauses are contradictory

.Kindly confirm the MOC of valves to

be considered in Condensate polishing

inlet & Condensate Polishing outlet

lines.

Refer Amendment 1

2Spec.No-PE-TS-

435-155-A001,

REV 0

Section-I,

SUBSECTION-C-1

4.0, Piping & Valves,

Point No-(v)

30 of 529 Please confirm whether the BFV to be

SS316 (or) SS304.

Refer Amendment 1

3

Spec.No-PE-TS-

435-155-A001,

REV 0

Section-I,

SUBSECTION-C-1

4.1.4 External

Regeneration Facility

3.1.4 External

Regeneration Facility

3.0 External

Regeneration Facilities

16 of 529

33 of 529

25 of 529

As per our process requirement, we

shall be supplying two vessel

1. SCRV (Separation cum

regeneration vessel) - 1 No.

2. ARV/MRSV (Anionic regeneration

vessel (or) Mixed resin storage vessel)

- 1 No

Kindly confirm.

Refer Amendment 1

4

Spec.No-PE-TS-

435-155-A001,

REV 0

Section-D,

SUBSECTION-D-1

B. Regeneration

system

390 of 529We shall provide Two numbers of

regeneration vessels as per our

process requirement .

a .Cation Regeneration Vessel

b.Anion Regeneration Vessel cum

Mixed Resin storage vessel.

However , we shall provide you the

system without affecting the

performance guarantees.

Refer Amendment 1

5

Spec.No-PE-TS-

435-155-A001,

REV 0

Section-D,

SUBSECTION-D-1

A. Service vessel

facility, Point no.20

390 of 529 As per the market availability, chloride

analyzer for this lower range of ppb

measurement is not available.Hence

request you to remove the same from

our scope of supply to reduce the

project cost. Eventhough , if we

supply this anlayser , this instrument

will not be capable of measuring the

chloride ions.

chloride analyser is delected from

scope. Refer Amendment 1

6

Spec.No-PE-TS-

435-155-A001,

REV 0

Section-D,

SUBSECTION-D-1

D. Additional

Requirement

395 of 529 Please confirm whether the same is in

BGR Scope.

yes. Refer Amendment 1

7

REF:

PE/PG/UDN/E-

6008/2018

Conditional Enquiry Please confirm the bid submission

date.

Cllrification reply shall be given by

BHEL-PEM-BOP group.

Pre-Bid clarification for Condensate polishing Unit Package

PE/PG/UDN/E-6008/2018Design, engineering, manufacturing, supply, erection, testing,commissioning, etc of Condensate Polishing Unit system for 2 x 660 MW UDANGUDI SUPERCRITICAL STPP

ST.

BFV –SS CF8M.

Condensate polishing plant

outlet butterfly valves shall be of stainless

steel construction, SS-316 (for body, disc and

shaft). Condensate polishing plant inlet

butterfly valves shall be of

Carbon Steel construction

All butterfly valves MOC used in service vessel

area in condensate inlet line shall be (body:

WCB

Disc:CF8M/SS316) and condensate outlet line

will be (Body & Disc both: CF8M/SS316)

Due Date :21.08.2018

Mail due date : 24.08.2018

One no. chloride analyser at condensate inlet

header of TG unit & one no. chloride analyser

at outlet of each Condensate polishing Mixed

Beds / Condensate Polisher Service vessels.

Hence total 4 nos. of chloride analyser shall

be supplied for each TG unit service vessel

area.

All handrails shall be of 32 mm nominal bore

MS pipes (medium class) as per IS: 1161

galvanized using 750 gm/sq. m of zinc. Hand

railing shall be a two-rail system with the top

rail 1000 mm above the walkway surface and

the intermediate rail 450 mm below the top

rail. Handrail post spacing shall be limited to

1500 mm as far

as possible but can be proportioned to the

length of the opening. In such a case spacing

shall not exceed 1850 mm centre to centre of

posts. Hand railing shall be shop fabricated

for specific locations and field welded or

bolted to the erected structural steel. Railings

shall be provided with 100 mm wide and 8

mm thick MS strip at bottom as toe guard all

along the length of railing in horizontal plane.

For RCC stairs, hand railing with 20 mm

square MS bar balustrade with suitable MS flat

and Aluminium / Teakwood handrail shall be

provided, unless specifically mentioned

Specification requirement

BFV –SS 316/ CF3M.

Two nos. resin separation/ regeneration

vessels, one no. mixed resin vessel and one

no.

mixed resin storage vessel

Two nos. resin separation/ regeneration

vessels, one no. mixed resin vessel and one

no.

mixed resin storage vessel.

a. Resin separation and cation/anion resin

regeneration vessel - 1 no

b. Cation/Anion resin regeneration vessel - 1

no

c. Mixed resin storage vessel - 1 no.1) One no. Resin Separation & Cation

Regeneration Vessel.

2) One no. Anion resin regeneration vessel.

3) One no Mixed resin storage vessel

6) The type of vessels indicated above (s.no

1, 2 and 3) shall be as per supplier process

requirement





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Specification Requirement M/s Driplex Clarification BHEL reply

Mechanical Clarification

1. Tender P & ID

D, Sub Sec-D-1


14.0

527 of

529

393 of

529

Air grid piping & Acid/alkali dosing line are not shown for N-pit. …. Acid and alkali piping from the customer terminal point up to N-pit ( both compartments), air grid piping arrangement in N-pit both compartments, piping from CPU regeneration area blower to CPU N-pit (both compartment),……

Please clarify the scope of supply of Acid and alkali piping up to N-pit and air grid piping arrangement in N-pit.

Refer Amendment 1

2. I, Sub Sec-C-1

c) of 3.1

26 of 529

Regeneration system: The vessels indicated against sr. no. a, b and c above is for reference only. Please note that number and type of regeneration vessels shall be as per supplier recommendation only.

We shall be offering the regeneration vessels arrangement inline with the regeneration system provided in our past recent jobs like Ennore, North Chennai.

Refer Amendment 1





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3. Vol II Section 1- GTS-Udangudi-R0

D, Sub Sec-D-1

15.2.0

11.10

137 of

529

400 of

529

Contract includes the supply (by the Contractor) of all chemicals, reagents, resins, and other consumables required for testing, commissioning and setting to work of each section of the Works. 11. Exclusion 11.10 Chemicals

Please confirm whether supply of Chemicals for testing, commissioning and setting to work of each section of the Works shall be in bidder’s scope or not.

Refer Amendment 1

4. Vol II Section 1- GTS-Udangudi-R0

D, Sub Sec-D-1

D, Sub Sec-D-1

15.2.0

9.0

11.10

137 of

529

398 of

529

400 of

529

The Contractor shall provide all chemicals and other consumables required for the efficient operation and maintenance of the plant at full load 24 hours per day for a period as specified under scope of supply and services. 9.0 Scope of service Scope of Operation and maintenance of plant is not defined in scope of service. 11. Exclusion 11.10 Chemicals

Please confirm whether operation of maintenance of plant shall be in bidder’s scope or not. If it is in bidder’s scope, then please define time period of O&M and bidder’s scope of supply i.e. chemical, man power etc

O&M of plant is excluded from scope .





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5. D, Sub Sec-D-1

I, Sub Sec-C-1

2) of II

a) Of 3.2

391 of

529

26 of 529

One (01) numbers acid measuring tanks for regeneration complete…. Acid day tanks Number required- 2x100%

Please clarify the requirement of number of acid measuring/day tanks, 2x100% or 1 no.

Refer Amendment 1

6. I, Sub Sec-C-1

I, Sub Sec-C-1

D, Sub Sec-D-1

iii) of 4.0

i) Of 5.0

24.0

30 of 529

31 of 529

390 of

529

Piping-Service vessel Inlet- BFV– SS CF8M Condensate polishing plant inlet butterfly valves shall be of Carbon Steel construction. All butterfly valves MOC used in service vessel area in condensate inlet line shall be (body: WCB Disc:CF8M/SS316) and condensate outlet line will be (Body & Disc both: CF8M/SS316)

Please clarify the MOC of Body and disc of butterfly valve used in service vessel area in condensate inlet line.

Refer Amendment 1





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7. - - - 197 of

529

Mandatory spares for Electrical

For Mandatory spares, only applicable spares, for equipment being supplied for Condensate Plant package shall be supplied. Spares for an item shall be supplied only once. All duplicate descriptions, if any in the list shall be deleted from scope of supply. Please confirm.

Please follow tender specification Annexure-II , section E page 453 to 456 of 529 .

8. - Section E

Annexure II 453 to

456 of

529

Annexure II: Mandatory Spares (Mechanical, Electrical, C&I)

9. - Section C

365 of

529

C& I Mandatory Spares