Volume 3A GTS

GMR (BADRINATH) HYDRO POWER GENERATION PVT. LTD.
Alaknanda Hydroelectric Project (300 MW) (UTTARAKHAND, INDIA)

BID DOCUMENTS FOR
Bid No: GBHPL/LOT-5: Design, Manufacture, Supply, Transportation to Site, Handling, Erection, Testing & Commissioning works of Generators, Turbines, Transformers, GIS equipment, Control and Protection System, Switching and Auxiliary equipment, EOT Crane and 220 kV Pothead yard Equipment etc complete along with Auxiliary Electrical and Mechanical Equipment
Volume-3A
(General Technical Specifications)
October 2009
Table of Contents
Volume- 0
Notice Inviting Bids (NIB) Instructions to Bidders (ITB)
Volume- 1
Information for Bidders
Volume - 2
General Conditions of Contract (GCC)
Volume- 3A
General Technical Specifications (GTS)
Volume- 3B
Particular Technical Specifications (PTS)
Volume- 3C
Technical Data Sheet
Volume- 3D
Quality Assurance and Testing Specification
Volume- 4
Drawings
Volume- 5
Forms and Procedures
Volume- 6
Bill of Quantities (BOQ)
GENERAL TECHNICAL SPECIFICATIONS
Alaknanda Hydroelectric Project (300 MW) General Technical Specification
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TABLE OF CONTENTS 1. INTRODUCTION .................................................................................................................. 1 2. TECHNICAL SPECIFICATIONS ......................................................................................... 3 2.1 Scope of Work ............................................................................................................. 3 2.2 Environmental Conditions ........................................................................................... 4 2.3 Seismic Design............................................................................................................ 4 2.4 Quality of Water ........................................................................................................... 5 2.5 Units ............................................................................................................................ 5 2.6 General Codes and Standards .................................................................................... 5 2.7 Basic Design standards ............................................................................................... 7 2.8 Manufacturing and Testing Standards ........................................................................ 7 2.9 Material standards ....................................................................................................... 8 2.10 Electrical Standards .................................................................................................... 9 2.11 Design Stress ............................................................................................................ 10 2.11.1 General .......................................................................................................... 10 2.11.2 Stress Limits .................................................................................................. 10 2.12 Reference Drawings and Documents ........................................................................ 11 2.12.1 Drawings and Documents ............................................................................. 11 2.13 Unit model ................................................................................................................. 13 2.14 Past Experience and Performance of Supplier ......................................................... 13 2.15 Materials .................................................................................................................... 13 2.15.1 Test of Materials ............................................................................................ 14 2.15.2 Trade Names ................................................................................................. 15 2.15.3 Fastenings ..................................................................................................... 15 2.15.4 Forgings ......................................................................................................... 16 2.15.5 Castings ......................................................................................................... 16 2.15.6 Steel Plates ................................................................................................... 18 2.16 Workmanship and Quality Assurance ....................................................................... 18 2.16.1 General .......................................................................................................... 18 2.16.2 Quality Assurance ......................................................................................... 19 2.16.3 Quality Assurance Programme ...................................................................... 19 2.16.4 Quality Assurance Documents ...................................................................... 20 2.16.5 Quality Assurance Plan ................................................................................. 21 2.16.6 Implementation of Quality Assurance Plans .................................................. 21 2.17 Structural Materials ................................................................................................... 23 2.17.1 General .......................................................................................................... 23 2.17.2 Flame Cutting ................................................................................................ 23 2.17.3 Bolts, Nuts, Studs, and Screwed Connections .............................................. 24 2.17.4 Machine Work ................................................................................................ 24 2.17.5 Surface Finishes ............................................................................................ 24 2.17.6 Types of Finishes .......................................................................................... 24 2.17.7 Unfinished Surfaces ...................................................................................... 25
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2.18
2.19
2.20 2.21
2.22
2.23 2.24
2.17.8 Templates and Gauges ................................................................................. 25 Electric Welding......................................................................................................... 25 2.18.1 General .......................................................................................................... 25 2.18.2 Preparation for Welding ................................................................................. 25 2.18.3 Welding Codes .............................................................................................. 26 2.18.4 Stress-relieving .............................................................................................. 26 2.18.5 Welders Qualifications ................................................................................... 27 2.18.6 Quality of Welds ............................................................................................ 27 2.18.7 Laminations ................................................................................................... 28 2.18.8 Electrodes ...................................................................................................... 28 2.18.9 Welded Fabrications and Residual Stress Relief........................................... 28 2.18.10 Non-destructive Tests ............................................................................... 28 Ladders and Platforms .............................................................................................. 31 2.19.1 Floor Plates ................................................................................................... 31 2.19.2 Ladders and Stairways .................................................................................. 31 2.19.3 Handrails ....................................................................................................... 31 Noise ......................................................................................................................... 32 Identification Plates ................................................................................................... 32 2.21.1 General .......................................................................................................... 32 2.21.2 Manufacturers Nameplates (Rating Plates) .................................................. 33 2.21.3 Functional Plates ........................................................................................... 33 2.21.4 Instruction & Diagram Plates ......................................................................... 33 Piping, Fitting and Valves .......................................................................................... 33 2.22.1 General Specifications ................................................................................... 33 2.22.2 Water / Air piping ........................................................................................... 35 2.22.3 Oil Piping ....................................................................................................... 37 2.22.4 Fittings ........................................................................................................... 38 2.22.5 Valves ............................................................................................................ 39 2.22.6 Hangers and Supports ................................................................................... 43 2.22.7 Cleaning and Shipping .................................................................................. 44 2.22.8 Testing ........................................................................................................... 45 2.22.9 Insulation ....................................................................................................... 45 2.22.10 Bolts and Nuts ........................................................................................... 45 2.22.11 Gaskets ..................................................................................................... 45 Gauges and Instruments ........................................................................................... 45 Tropicalization ........................................................................................................... 46 2.24.1 Metals ............................................................................................................ 46 2.24.2 Screws, Nuts, springs, Pivots etc. ................................................................. 46 2.24.3 Fabrics, Cork, Paper, etc. .............................................................................. 46 2.24.4 Wood ............................................................................................................. 47 2.24.5 Adhesives ...................................................................................................... 47 2.24.6 Rubber ........................................................................................................... 47 2.24.7 Finishes ......................................................................................................... 47
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2.25 Anti Corrosion Measures ........................................................................................ 48 2.25.1 General Specifications ................................................................................... 48 2.25.2 Surface Preparation for Protective Coating ................................................... 49 2.25.3 Extent of Protective Coating .......................................................................... 49 2.25.4 Shop Protective Coating Application ............................................................. 50 2.25.5 Field Protective Coating Application .............................................................. 51 2.25.6 Colours .......................................................................................................... 51 2.26 General Electrical Requirements ............................................................................... 52 2.26.1 General .......................................................................................................... 52 2.26.2 Power Supplies (Low Voltage) ...................................................................... 54 2.26.3 Standards ...................................................................................................... 55 2.26.4 Colour Code .................................................................................................. 55 2.26.5 Colour coding for mimic diagrams ................................................................. 55 2.26.6 Electric Motors ............................................................................................... 56 2.26.7 M.V. AND L.V Switchgear, Cubicles and Panels ........................................... 61 2.26.8 Power and Control Cables ............................................................................. 68 2.26.9 Cubicles and Control Panels ......................................................................... 69 2.26.10 Earthing ..................................................................................................... 71 2.26.11 Alarm Contacts .......................................................................................... 71 2.26.12 Electronic Equipment ................................................................................ 72 2.26.13 Protection Devices .................................................................................... 72 2.27 Equipment Identification: Rating Plates and Nameplates ......................................... 72 2.28 Electrical Instruments, Control Devices and Relays .................................................. 73 2.28.1 General .......................................................................................................... 73 2.28.2 Instruments .................................................................................................... 73 2.28.3 Indicating Lamps ........................................................................................... 74 2.28.4 Miniature Circuit Breakers (MCB) .................................................................. 75 2.28.5 Automatic Semaphore Indicators .................................................................. 75 2.28.6 Push Buttons ................................................................................................. 76 2.28.7 Switches ........................................................................................................ 76 2.28.8 Auxiliary Relays ............................................................................................. 76 2.29 SCADA System ......................................................................................................... 77 2.29.1 Control boards and panels ............................................................................ 77 2.29.2 Programmable controllers ............................................................................. 78 2.29.3 Power monitoring ........................................................................................... 79 2.29.4 Standards ...................................................................................................... 79 2.30 Network Characteristics ............................................................................................ 80 2.30.1 Protocols and standards ................................................................................ 80 2.30.2 Scalability and future extensions ................................................................... 80 2.30.3 Topology, redundancy and availability .......................................................... 81 2.30.4 Local control cubicles .................................................................................... 81 2.30.5 Plant Control Network .................................................................................... 81 2.30.6 Field Communication Network ....................................................................... 81
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2.31
2.32 2.33
2.34
2.35 2.36
2.37
2.30.7 Optical fibre ................................................................................................... 82 Factory Inspection and Testing ................................................................................. 82 2.31.1 General Specifications ................................................................................... 82 2.31.2 Factory Inspection ......................................................................................... 83 2.31.3 Factory Testing .............................................................................................. 83 Operation and Maintenance Manuals ....................................................................... 83 Packing and Transport .............................................................................................. 84 2.33.1 General .......................................................................................................... 84 2.33.2 Packing .......................................................................................................... 85 Installation and Supervision ...................................................................................... 85 2.34.1 Concreting and Erection Supervision ............................................................ 85 2.34.2 Inspection, Tests on Completion and Commissioning ................................... 86 Safety ........................................................................................................................ 87 Spare parts and tools ................................................................................................ 87 2.36.1 General .......................................................................................................... 87 2.36.2 Specified Spare Parts .................................................................................... 88 2.36.3 Recommended Spare Parts .......................................................................... 88 2.36.4 Tools and Appliances .................................................................................... 88 Training ..................................................................................................................... 89 2.37.1 General requirements of training ................................................................... 89 2.37.2 Training during engineering / manufacturing phase ...................................... 90 2.37.3 Training during the erection / installation / site work ...................................... 90 2.37.4 Training during the tests on completion phase .............................................. 91
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1.
INTRODUCTION
300 MW GMR (Badrinath) Hydro Electric project is located in Chamoli district of the state of Uttarakhand and is slated to utilize the waters in the upper reaches of Alaknanda River, one of the main tributary of the River Ganga. The project is a run of the river type with exploitation of power potential of the Alaknanda River (maximum reservoir level EL 2903.50 m). The Alaknanda River is diverted to two intake tunnels by raising a gated barrage across the river downstream of Badrinath. The intake tunnels connect to two underground desilting chambers which feeds a long head race tunnel. A surge shaft with a surge chamber is located at the end of head race tunnel. The underground power house complex comprises 3 vertical axis Pelton turbines with total installed capacity of 300 MW. The Transformers are placed in a separate cavern parallel to the power house cavern. Power evacuation is through GIS, XLPE cables, outdoor pot head equipments connected to two single circuit 220 kV transmission lines. The following equipments are covered under E&M package. Turbines Governing system Oil pressure system for governing system Turbine Instrumentation Main Inlet valves (Spherical type) Penstock Butterfly valve Model test requirement Oil pressure system for Butterfly valve Main inlet valve instrumentation Generator Stator Generator Rotor Generator braking system Generator high pressure lubrication system
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Brake dust and carbon dust collecting system Excitation system Bus duct and tap off transformers Generator instrumentation Generator Step up Transformer 220 kV and 11 kV XLPE cables Gas insulated switchgear Outdoor pothead yard equipment DC system (220V and 48 V ) Digital control system and SCADA Protection system Cabling system High voltage switchgear Low voltage switchgear Communication system Illumination system Electrical workshop EOT (PH, Penstock and GIS ) cranes Cooling water system Dewatering system & Silt Ejection System HVAC system Grounding system Compressed air system Fire Fighting system Mechanical workshop Oil handling System Elevator
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DG sets AC distribution system
The terms Owner/Purchaser/Buyer wherever appearing in these Technical Specifications, Volume 3A, 3B, 3C and 3D documents, mean the Employer and likewise the term Supplier means the Contractor. 2. 2.1 TECHNICAL SPECIFICATIONS Scope of Work
This specification defines the technical requirements for the design, manufacture, supply, shop assembly; shop testing, inspection, training of Owners engineers, packing, warranty and delivery of power plant equipments as defined in the commercial part of this document. The equipment offered shall be complete with all necessary fittings, auxiliary equipment and all parts that are necessary or usual for their efficient operation. Such parts shall be deemed within the Suppliers scope whether specifically mentioned or not in the specification. Requirements of special nature for the equipment are given in respective sections of Particular Technical Specifications (PTS), as necessary, and will take precedence over these general technical specifications in case of any contradiction. The detailed scope of works will be covered in Particular Technical Specifications. The scope of work is broadly defined as follows: Detailed design, documents and drawings for approval of client and Engineer Material specifications and quality plan Manufacturing and procurement schedule Equipment delivery schedule and transportation Installation and construction drawings and documents Field quality checklists for all equipments. Project execution schedule Site storage and material management Installation, testing and commissioning
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2.2
Operation and maintenance manuals As built drawings Spare parts and special tools Training of operating staff, assistance in trouble shooting and maintenance works. Environmental Conditions
The environmental conditions at the powerhouse site under which the equipment is required to operate satisfactory are as follows: Maximum ambient temperature (C) Exterior Minimum ambient temperature (C) Exterior Minimum ambient temperature (C) Interior Maximum daily average ambient temperature (C) Maximum relative humidity (%) Maximum water temperature (C) Minimum water temperature (C) Altitude (meters) Seismic zone Average rain fall (mm/year) Number of months with monsoon conditions 2.3 Seismic Design 34 -4 5 25 100 20 1 2300 m IV 800 mm 3
The project is situated in a seismic area and falls within Zone IV of the seismic zoning map of India incorporated in Indian Standard Criteria for Earthquake Resistant Design of Structures (IS: 1893 (Part 1): 2002). Value of peak ground acceleration is to be taken as 0.36g for Maximum Considered Earthquake (MCE) and 0.18g for Design Basis Earthquake (DBE). The forces being caused by Earthquake including hydraulic loads, which may occur additionally, shall be taken into account for the computations. Stresses resulting after including these loads shall not exceed permissible stresses.
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The supplier shall design all equipment supplied under this contract to satisfy the seismic criteria. The supplier shall submit to the purchaser the method of calculation and relevant codes he intends to use for this purpose. In addition to the above, IS 1893 shall be adopted for seismic design. Hydrodynamic forces due to seismic conditions shall be considered on E & M equipment in addition to hydrostatic loads. 2.4 Quality of Water
Water of Alaknanda River is expected to have high silt content throughout many months of the year. After award of Contract, water analysis shall be provided by the Purchaser to the Supplier in order to enable the latter to ensure proper operation of the Works under these conditions. The analysis shall be taken during period of the year representing highest silt concentration and shall include chemical analysis, type of solids (e.g. Quartz) as well as suspended solid concentration ppm as a % in function of particle size. 2.5 Units
Metric units according to the latest edition of the relevant International Standards Organization (ISO) publications shall be used in documents, calculations, correspondence, drawings, etc. for this Contract. 2.6 General Codes and Standards
Unless another standard is specifically mentioned in these specifications, all materials and Works used and provided under the Contract and all design calculations and tests shall be in accordance with the latest edition of the appropriate standards and codes published by the following issuing authorities where applicable as listed alphabetically in Table 1. Other standards and recommendations of standard international organizations will be acceptable provided they ensure equal or higher quality than those specified, and provided, furthermore, that the Supplier submits for approval detailed standards (in English version) which he proposes to use. If requested by the Purchaser the Supplier shall supply at his own expense one copy in English of any standards which are applicable to the Contract.
Volume 3A(GTS) Table 1
Abbreviation ACI AGMA AISC AISE AISI ANSI API ASTM ASME AWS AWWA BIS BSI CEMA CMAA CSA DIN EN IEC IEEE IIW IPCEA ISA
Designation American Concrete Institute American Gear Manufacturers Association American Institute of Steel Construction Association of Iron and Steel Engineers American Iron and Steel Institute American National Standards Institute American Petroleum Institute American Society for Testing and Materials American Society of Mechanical Engineers American Welding Society American Water Works Association Bureau of Indian Standards British Standards Institution Canadian Electrical Manufacturers Association Crane Manufacturers Association of America Canadian Standards Association Deutsches Institut fur Normung European Standards International Electro-technical Commission Institute of Electrical and Electronics Engineers International Institute of Welding Insulated Power Cable Engineers Association Instrument Society of America (Now International society for Automation)
ISO
International Organization for Standardization

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Abbreviation JEC JIS NEC NEMA NESC NFPA SAE SSPC TEMA UL VDE VDI
Designation Standards of the Japanese Electro-technical Committee Japan Industrial Standards National Electrical Code of the U.S.A. National Electrical Manufacturers Association (U.S.A.) National Electrical Safety Code of U.S.A. National Fire Protection Association Society of Automotive Engineers Steel Structure Painting Council (Now Society for Protective Coating) Tubular Exchangers Manufacturers Association Underwriters Laboratories, Inc. (U.S.A.) Verband Deutscher Electroingenieure (German equivalent of IEEE) Verein Deutscher Ingenieure (Society of German Engineers)
2.7
Basic Design standards ISO/286-1988 ISO/1829-1975 ISO/2768-1973
ISO System for limits and fits General Tolerances and deviations Part-I Permissible machining variations in dimensions without tolerance indication Screw threads
ISO-68-1998 ISO-262-1998 ISO-724-1998
2.8
Manufacturing and Testing Standards ASTM-A370-2009
Standard test methods and definitions for mechanical
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testing of steel products Tension testing of metallic materials Standard test method for Notched Bar impact testing of Metallic materials Bend test for steel Standard test method for Liquid penetrant inspection Standard guide for radiographic testing Standard practise for Ultrasonic examination of heavy steel forgings Standard test method for Guided bend test for ductility of welds Welders qualification tests AWS (American welding society) Group B, DIN EN 287 Preparation of steel surfaces for painting by sandblasting Designation of degree of rusting of paint surfaces Certificates of material testing SIS 05-5900 DIN-53210 DIN-10204 ASTM-E190-1992(2008) ISO/82-1959 ASTM-E23-2007 ISO/83-1976 ISO/85-1959 ASTM-E165-2002 ASTM-E94-2004 ASTM-A388 / A388-2008
2.9
Material standards
Following standard for supply of material can be adopted subject to specific provision in the Contract, if any: a) b) c) d) ASTM (American Society for Testing & Materials), DIN (German Industrial Standards) BSI (British Standards) BIS (Indian Standards)
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e)
Material test certificates according to DIN 10204 shall be provided for all important parts of the equipment such as: steel plates for parts under hydraulic pressure, all major castings (runner, shut-off valve, etc.), large forgings (turbine and generator shaft etc.), highly stressed large bolts etc.
f) g)
For less important parts, certificates according to DIN 10204 are acceptable. Materials shall be new and of first-class quality; suitable for the purpose, free from defects and imperfections, and the classifications and grades in conformance with the latest issue of the respective ASTM, AISI, DIN, IS or BS standard. Material to other standards may be used if approval by the Purchaser has been obtained. Material specifications, including grade or class data, shall be shown on the appropriate detail drawings submitted for review.
If using stock material not specifically prepared for the supply under this Contract, the Supplier shall submit evidence that the material complies with approved standards and that the material is for the intended use. The Supplier shall indicate in the Technical Data Schedules, the materials and applicable standards for all major parts of the supply. The materials shall be carefully selected for the intended purpose and due consideration of the site conditions and the tropical environment. Higher grade material shall be used where ordinary material is insufficient. 2.10 Electrical Standards
The following basic standards for electrical works or any other approved standard shall be applied. a) b) c) d) e) BIS (Indian Standards) Standards issued by IEC (International Electro-technical Commission) Standards issued by IEEE (Institute of Electrical and Electronic Engineers) Standards issued by ANSI (American National Standards Institutes) For specific standards refer the Particular Technical Specifications.
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2.11 2.11.1
Design Stress General
Liberal factors of safety shall be used throughout the design, and especially in the design of all parts subject to alternating stresses or to shock, including those due to electrical short circuit faults. The Supplier shall furnish for record of Purchaser complete information, including computations, regarding the maximum unit stresses used in the design. 2.11.2 Stress Limits
Unless otherwise specified in Technical Specifications, the following shall be the limits for the Unit stresses:a) ALLOWABLE UNIT STRESSES UNDER RUNAWAY CONDITIONS The maximum unit stress, due to operation at the guaranteed maximum runaway speed, shall not exceed two-thirds of the yield strength of the material. b) ALLOWABLE UNIT STRESSES UNDER NORMAL OPERATING CONDITIONS Under the most severe operating conditions, the unit stresses in the materials shall not exceed the values shown in Table 2.2 below:TABLE 2.2 MATERIAL MAXIMUM UNIT STRESS IN TENSION Cast Iron One-tenth of the ultimate strength One fifth of the ultimate strength or one-third of the yield strength, whichever is lower One-fourth of the ultimate strength but not to exceed 1050 kg/cm2 IN COMPRESSION 700 kg/cm2
Cast Steel, Alloy Cast Steel and Steel Forgings
One-fifth of the ultimate strength or one-third of the yield strength, whichever is lower One-fourth of the ultimate strength but not to exceed 1050 kg/cm2
Plate Steel for Principal parts subject to hydraulic stresses
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i)
For other materials not covered in Table 2.2, used in the construction of the generator, turbine, etc. the maximum stresses in tension or compression due to the most severe conditions occurring in normal operation shall not exceed 50% yield strength. Maximum stresses in shear shall not exceed 210 kg/cm2 for cast iron and 60 percent of the allowable stresses in tension for other materials.
ii)
Maximum stress in torsional shear in the turbine and generator shafts shall not exceed 50 percent of the allowable stress in tension.
iii)
For temporary overloads exceeding generator maximum continuous capacity at unity power factor, unit stresses should not exceeding one half of the yield strength.
c) Maximum stress in tension or compression under normal operation (including overload conditions) shall not exceed 40% of minimum yield strength (YS); 50% of minimum YS under over pressure conditions. 67% of minimum YS under severe operating conditions (including runaway speed) and 75% of minimum YS under test pressure condition. 2.12 2.12.1 Reference Drawings and Documents Drawings and Documents
Works shall be carried out in accordance with the technical specifications and drawings as well as additional specifications and drawings issued from time to time by the Purchaser. In case of conflict between a general and more detailed requirement of the specifications, the latter shall govern. The following drawings / documents shall be submitted for review and approval: Transportation Arrangement / Drawings For all larger pieces of works which, due to their dimensions and/or weight and transport limitations, will require special means for their transportation, the supplier shall submit binding loading drawings indicating dimensions, weight etc., of the respective pieces of works and the necessary trailer for its transportation to the site. Foundation drawings The contractor shall submit drawings indicating all essential details such as dimensions, static and dynamic loads and embedment etc for proper design of the foundations.
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Arrangement drawings All arrangement drawings shall be drawn to the scale. The general arrangement drawings shall show the physical arrangement of the works. The arrangement or layout drawings of electrical, instrumentation and control equipment shall indicate location of their installation with respect to other equipments in the power house. Outline Drawings The outline drawing shall show all elements and the main dimensions of individual components where necessary in plan view, cross-section, side and top views. Installation Drawings The installation drawings shall provide detailed information on the disposition of various assemblies. Installation drawing shall also indicate the sequence of installation of the equipment. Machining / Component drawings Complete fabrication, machining drawing with quality plan of the components subjected to wear shall be provided as per requirement of Purchaser during detail engineering. Assembly drawing Assembly / de-assembly drawing of all the components shall be provided with different views. Bill of materials Bill of material covering part name as mentioned in the drawing, tag number, material specifications, make and size shall be provided. Bill of material in soft copy in MS-Excel format shall also be provided. Single Line Diagram This is a simplified diagram of essential electric works and their interconnections. Each circuit is represented by a single line. It shall contain all required technical information of the system represented, e.g. voltage, current, capacity, ratios, etc. as applicable.
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Terminal Diagram Terminal diagram shall be prepared for all type of terminal boxes, marshalling rack, control cubicle, switch board, etc and shall show the terminals, internal and external conductors. Documents Documents such as all calculations specified in the technical specifications, erection / installation manual, operation & maintenance manual & quality plan All above drawings shall be provided in AutoCAD format, MS-word and in MS-Excel format. Any other drawing which is not specified and required by the Purchaser during detail engineering shall also be provided. The Drawings/Data required for the various equipment are indicated at Annexure-1 and their respective submission dates shall be proposed by the successful bidder during preaward discussions as per the proforma given in Annexure-2 of this document. 2.13 Unit model
A scaled model of section through a unit depicting the details of turbine generator set as closely as possible shall be supplied by the Contractor. The model should have high quality of craftsmanship to ensure the inclusion of all major details of the unit set. The details of model may be discussed during detailed engineering and should be approved by the Employer before acceptance of the same. 2.14 Past Experience and Performance of Supplier
The Supplier must have successfully designed, manufactured, type-tested, supplied, installed and commissioned the system or device in question of equivalent rating or higher. 2.15 Materials
The materials used in the construction of the Works shall be new, of high quality, strength, ductility, durability, of best engineering practice and suitable for the service to which the equipment will be subjected, free from defects, imperfections and selected particularly to meet the duties required of them. The material specification shall be indicated in the Suppliers detailed drawings. The use of materials liable to be attacked by termites or other insects shall not be allowed. All workmanship is to be of the highest quality throughout to ensure smooth and vibration free operation under all possible operating conditions, and the design, dimensions and materials of all parts are to be such that the stresses to which they
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may be subjected shall not render them liable to distortion or damage under the most severe conditions encountered in service. Materials not specifically described herein shall be the most suitable for the purpose and shall comply with the latest specifications of relevant Indian/International Standards. If the Supplier desires for any reason to deviate from or use materials not covered by these specifications he shall state the exact nature of the deviation or exception and shall submit for the approval of Purchaser complete specifications for the materials he proposes to use. All materials, supplies, and articles not manufactured by the Supplier shall be the products of recognized reputable manufacturers duly approved by the Purchaser. 2.15.1 Test of Materials
All materials, parts and assemblies thereof entering into the supply to be executed under these specifications shall be tested, unless otherwise directed, according to the applicable IS, ASTM standard or as per approved method for the particular type and class of material as per QAP requirements. The Supplier shall prepare specimens and perform tests and analysis to demonstrate conformance of the various materials with the applicable specifications given herein. In case the Supplier desires to use stock materials not manufactured specifically for the equipment covered by these specifications, he shall submit satisfactory evidence to Purchaser that such material conforms to the requirements herein stated, in which case tests on these materials may be waived. Certified mill test reports of plates will be acceptable. Routine test reports for minor components will be acceptable. Four certified copies of test reports shall be furnished to Purchaser as soon as possible after the tests are made. The results of these tests shall be in such form as to provide means of determining compliance with the applicable specifications for the material tested. When required, all tests shall be made in the presence of a duly authorized inspector representing Purchaser. The Supplier shall keep Purchaser informed in advance of the time of starting and of the progress of the work in its various stages so that arrangements can be made for inspection. No equipment shall be shipped until all tests, analysis and pre-shipment inspection have been completed and certified copies of test reports have been accepted. Over and above the inspection and test plan duly approved by the Purchaser, if during detail engineering any additional inspection is considered necessary, the same will be carried out and witnessed by the Purchaser. The cost of boarding / lodging and to and fro fare for witnessing the additional test at Suppliers works shall be borne by the Purchaser.
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All material, packages receiving at site shall be in good condition without any defects and meet the duties required there in. All packages receiving at site (Part of scope of supply) shall be informed to Purchaser for the inspection before use. 2.15.2 Trade Names
When, as described in these specifications, certain Works, articles, materials and / or manufacturing processes have been named by their trade names or by their catalogue name or number, these designations are meant to be followed by the words or approved equal even if they are not included in the text. The Supplier may substitute other Works, articles, materials and/or fabrication processes subject to the approval of the Purchaser, provided these are equivalent in quality and type to those indicated and/or specified. It will be the Suppliers responsibility to demonstrate and prove to the Purchaser the quality and suitability of the proposed alternatives. 2.15.3 Fastenings
Nuts, bolts, studs and washers for incorporation in the Works shall conform to the requirements of the appropriate standard. Where non-standard fasteners are used in the Works, appropriate tools, including wrenches, taps and dies, shall be provided. Nuts and bolts for pressure parts shall be of the best quality bright steel, machined on the shank and under the head and nut. All washers shall be included under the Contract, including locking devices and anti-vibration arrangements, which shall be subject to the approval of the Purchaser. Taper washers shall be fitted where necessary. Where there is a risk of corrosion, bolts and studs shall be finished flush with the surface of the nuts. Bolts, except for high strength friction grip bolts, shall be designed so that, with the nuts fully tightened, the stress intensity at the bottom of the thread shall not exceed one half of the yield point of the material under all conditions. Connections employing high strength friction grip bolts as per ASTM A325 or A490 shall follow the requirements of Specification for Structural Joints Using ASTM A325 or A490 Bolts as given in the AISC Manual of Steel Construction. Bolts, nuts and screws which are subject to frequent adjustment, frequent removal or immersion in the course of operation shall be made of corrosion-resistant steel or bronze. The material of stainless steel bolts and nuts shall be selected to prevent galling. Spring type washers will not be permitted where they may damage any protective coatings.
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2.15.4
Forgings
Forgings in excess of 150 mm in diameter shall be subjected to examination internally for the detection of flaws and to heat treatment for the relief of residual stresses. Particulars of the heat treatment proposed for all forgings, and in each case the name of the proposed maker, shall be submitted to the Purchaser for approval. Each forging incorporated into the Works shall be clearly stamped with the heat number readily visible. All such forgings shall be jointly examined at the place of manufacture by the Purchaser and by a representative of the Supplier during the heat treatment and shall be examined by the latest non-destructive methods for the detection of defects. 2.15.5 Castings
Steel castings shall conform to the following requirements: a) General
Castings shall be free from injurious defects and shall be free of foundry irregularities such as projections, ridges, hollows, honey-combing, pock marks, or chip marks, so that they will not require surface smoothing operations in the field prior to painting. The location of existing defects shall be determined, and they shall be completely removed to sound metal. The structure of the castings shall be homogeneous and free from excessive non-metallic inclusions. An excessive segregation of impurities or alloys at critical points in a casting will be cause for its rejection. All castings involving welded fabrication shall be stress-relieved. b) Inspection
Castings of main parts, including all those subject to hydraulic pressure and all castings which underwent major repair, shall be radio graphically examined as specified. Other
castings shall be tested using radiographic, ultrasonic, dye penetration, magnetic particle or any other standard non-destructive test method approved by the Purchaser. The Purchaser has the right to ask the Supplier to carry out non-destructive tests to determine: The presence of defects; The maximum extent of defects; That the area to be welded is satisfactorily prepared; That the repairs are satisfactory.
The costs incurred by such tests shall be at the Suppliers expense.

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The Supplier shall notify Purchaser in ample time to have an inspector present at the foundry, if Purchaser so desires, when the castings are cleaned and defects chipped to sound metal, before any repair welding is done. After the repairs of castings, same shall be heat-treated. Test pieces for tension and bend test specimens shall be removed from the castings at the time of inspection. Certified copies of the test reports shall be furnished as specified in clause 2.9.1. The Supplier shall make non-destructive tests for important load carrying castings as appropriate prior to final machining. Radiographic or magnetic particle inspection, ultrasonic or other non-destructive tests may be required by Purchaser when it is desired to make such tests as a means of judging acceptability of castings which contain defects of apparent borderline seriousness or to determine that repair welds have been properly made. Any such tests shall be at the expense of the Supplier. c) Repair Welding
No repairs of major defects shall be made to castings without prior approval from Purchaser. Defects shall be considered major when the depth of the cavity properly prepared for welding exceeds 20 percent of the effective wall thickness or 25 millimeters, whichever is smaller. Acceptance criteria shall be CCH 70-3 class 3. Welding of defects shall be performed only by welders or welding operators qualified in accordance with clause 2.12.1(d) and shall conform to the best modern welding practice. If the removal of metal to uncover a crack or remove a defect reduces the stress-resisting cross-section of the casting to such an extent that the computed unit stress in the remaining metal is more than 30 percent in excess of the allowable stress, the casting may, at the option of Purchaser, be rejected. Casting repairs by welding of major defects at any stage of manufacture after the first heat treatment (annealing) shall be stress-relieved. Minor defects or imperfection that will not ultimately impair the strength or service ability of the castings, may be repaired by welding in accordance with accepted commercial casting practice without securing approval. However, an accumulation of minor defects which in the opinion of Purchaser casts serious doubt as to the general quality of the casting may constitute cause for rejection. Before proceeding to repair any major defect a written report shall be submitted to the Purchaser in which the fault is fully described, together with diagrams, photographs and reports of metallurgical tests, when applicable, as well as with the description of the proposed repair method.
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d)
Dimensions
Thicknesses and other dimensions of the castings shall conform substantially to the dimensions on the drawings and shall not be reduced by shop or foundry practices to the extent that the resulting stresses in the metal will exceed the stresses allowed under these specifications. Castings shall not be warped or otherwise distorted, nor shall their dimensions be oversize to such an extent as to interfere with proper fit with other parts. e) i) Finish Surface finishes shall be indicated on the detail drawings and shall conform to the requirements of ANSI B46.1 "Surface Roughness, Waviness and Lay", or other approved equal standard. Also refer clause 2.11(f). ii) All parts shall be free from burrs, sharp edge and imperfections in cutting, machining and welding. All visible parts shall receive special attention in order to ensure aesthetic appearance of the completed machine. 2.15.6 Steel Plates
Rolled steel plates which are to be used in the fabrication of pressure vessels or parts that are subject to internal pressure and are encased in concrete, and rolled steel plates forming large highly stressed weldments shall be tested for laminations at the place of manufacture in accordance with ASTM A435. Mill sheets for all plates shall be supplied. 2.16 2.16.1 Workmanship and Quality Assurance General
a) Workmanship shall be of the highest grade and in accordance with the best modern practice for the manufacture of high-grade machinery, not withstanding any omissions from these specifications or drawings. All work shall be performed by workmen skilled in their various trades. b) Machining of renewable parts shall be accurate and to specified dimensions so that replacements made according to the drawings may be readily installed and are interchangeable among unit and spares. The Supplier shall maintain in storage for at least 10 years, at his own expense, sufficient templates, gauges, patterns, or other records to enable him to make repair and replacement parts. All special gauges and templates necessary for field erection shall become the property of Purchaser. All measurements
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and dimensions given on drawings submitted for approval shall be expressed in the metric system (millimeters, meters). 2.16.2 Quality Assurance
In general terms, the Supplier quality assurance program must be in compliance with ISO 9001 standards. The Purchaser reserves the right to verify the document pertaining to the Suppliers quality assurance program, as well as the application of the same in the manufacturing plant. In general the assembly of all the equipment components shall be carried out in the Supplier's workshops so that it shall be possible to perform inspections, tests, etc. that will ensure a subsequent satisfactory operation. Exceptions to this rule shall only be possible upon the Purchaser's consent. The Purchaser's authorized representatives shall have the right of access to the plant and to inspect and verify the quality of materials used in the manufacturing process. 2.16.3 Quality Assurance Programme
To ensure that the equipment under the scope of this contract whether manufactured or performed within the Suppliers Works or at his Sub-Contractors premises or at the Purchaser's site or at any other place of Work are in accordance with the specifications, the Supplier shall adopt suitable quality assurance programme to control such activities at all necessary points. Such programmes shall be outlined by the Supplier and shall be got approved from the Purchaser. A quality assurance programme of the Supplier shall generally cover the following: a) His organisational structure for the management and implementation of the proposed quality assurance programme. b) c) d) Documentation control system. Qualification data of Suppliers key personnel. The procedure for purchase of materials, parts, components and selection of SubSuppliers service including vendor analysis, source inspection, incoming rawmaterial inspection, testing, verification of materials purchased, etc. e) System for identification and traceability of parts/components
products/instruments/control devices etc.
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f)
System for process control, fabrication and assembly control during shop manufacturing and site erection.
g)
System
for
inspection
and
testing
when
parts/components/raw
material/instruments/control devices are received, during manufacture and during final product/equipment/assembly inspection and testing. h) i) Control of calibration and testing of measuring and testing equipments. System of documentation to indicate conformance or non conformance of product to specifications, inspection and test status. Also control of non-conforming items and system for corrective actions. j) k) l) m) 2.16.4 System for handling, storage, packaging and delivery. System for maintenance of quality records. System for quality audit. System for authorising release of manufactured product to Purchaser. Quality Assurance Documents
The Supplier shall be required to submit the following Quality Assurance Documents for approval of the Purchaser: a) All Non-Destructive Examination procedures, stress relief and weld repair procedure actually used during fabrication. b) c) Welder and welding operator qualification certificates. Welder identification list, listing welder's and welding operator's qualification procedure and welding identification symbols. d) e) Material mill test reports on components as specified by the specification. The inspection plan with verification, inspection plan check points, verification sketches, if used, and methods used to verify that the inspection and testing points in the inspection plan were performed satisfactorily. f) Sketches and drawings used for indicating the method of traceability of the radiographs to the location on the equipment. g) Non-Destructive Examination result reports including radiography interpretation reports.
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h) i)
Stress relief time temperature charts. Factory test results for testing required as per applicable codes and standards referred in the specification.
j)
Inspection reports duly signed by Quality Assurance personnel of the Purchaser and Supplier for the agreed inspection hold points. During the course of inspection, the following will also be recorded: i) Any important repair work carried out or to be carried out to make the job acceptable. ii) The repair work remains part of the accepted product quality. Quality Assurance Plan
2.16.5
A quality assurance plan detailing specific control procedure proposed to be adopted for controlling the quality characteristics relevant to each item of equipment shall be furnished. These shall include but not be limited to following to ensure conformance of equipment specifications and relevant codes/standards. a) b) c) d) e) f) g) 2.16.6 a) Material test of raw material. Non destructive examination as approved by Purchaser. Component Inspection and tests. Assembly Inspection and tests. Pressure test/high voltage dielectric and other test Operational tests Functional and Performance tests as applicable. Implementation of Quality Assurance Plans Detailed shop inspection/testing schedule shall be submitted by Supplier to Purchaser. Quality assurance plan shall take into account various provisions of specifications. b) Non destructive examination shall be carried out for the principal parts of materials and the weld seams of fabricated components in accordance with the requirements of A.S.M.E. code sections and A.S.T.M. standards as per Appendix 2.2 or as approved.
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c)
The Supplier shall give his own quality assurance plan with details and Purchaser hold points, keeping in view specification requirements, codes/standards provisions and Suppliers practices for approval by Purchaser.
d)
Notice for inspection shall be submitted to Purchaser thirty (30) days prior to proposed date for inspection as per provisions of Conditions of Contract.
e)
Material mill certificates and material identification record for important components shall be submitted after completion of fabrication.
f)
Electrical tests i.e. dielectric loss measurement, insulation resistance, dielectric tests and other tests as per specifications and applicable codes and standards shall be conducted during various stages of manufacture.
g)
Purchaser may appoint third party inspectors for inspection and testing to ensure that provisions of specifications and applicable codes and standards are complied with. Supplier shall extend all facilities for conduct of such inspections and tests and ensure intimation of programme for inspection and tests to third party inspectors as directed by Purchaser.
h)
The test and inspection certificates shall be submitted to Purchaser prior to shipment of components/assembly concerned.
i)
To ensure implementation of quality assurance plan, all inspection and tests on various material, components, assembly and equipment shall be sub-divided into following categories: i) Tests by vendor/sub-Contractors inspector, inspection certificates to be submitted to Purchaser. ii) Tests by manufacturer's inspector at his or vendor/sub-Contractors works and test certificates to be submitted to Purchaser. iii) Tests by manufacturer's inspector and witness by Purchaser's inspector on purchasers request. iv) Tests by manufacturer's inspector and witness by Purchaser's inspector and at Purchaser's option by third party inspector as well. v) All Inspection/tests are subject to Purchaser's review.
j)
Quality assurance plan shall be offered for all equipment covered under the contract including equipments such as static excitation equipment.
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k)
In so far as practical, provisions and guidelines of ISO 9001 will be applicable and implemented for quality control and assurance.
l)
Supplier shall furnish his proposed quality plan for all major components to Purchaser for approval.
2.17 2.17.1
Structural Materials General
Structural materials may be straightened by methods which will not result in injury, sharp kinks or bends which shall be cause for rejection. Finished members shall be free from kinks or bends. Shearing shall be done accurately and all portion of the work neatly finished. Corners shall be square and true unless otherwise shown on the drawing. Re-entrant cuts shall be made in a workmanlike manner. Where they cannot be made by shearing, a rectangular punch may be used. Re-entrant cuts shall be filleted, unless otherwise approved by Purchaser. Bends, except for minor details, shall be made by approved dies or bending tools. When heating is required for the satisfactory working of the metal, it shall be allowed to cool under conditions that will not destroy the original properties. Steel with welds other than those definitely indicated on the shop drawings, or specified or otherwise called for, will not be acceptable. All bolts, nuts, and screws shall be tight. The ends of all pipes shall have all burrs removed. 2.17.2 Flame Cutting
Low carbon structural steel may be cut by machine-guided or hand-guided torches instead of shears or saws. Flame cutting of material other than low carbon structural steel shall be subject to the approval of Purchaser and, where proposed, shall be definitely indicated on shop drawings submitted by the Supplier. Where the torch is machine-guided, no chipping or grinding will be required except to remove slag and sharp edges. Flame gouging will be permitted as a preparation for welding. Where the torch is handguided, the cut shall be chipped, cut, or machined to sound metal except where material is not to be welded, in which case the burrs and rough edges alone shall be removed.
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2.17.3
Bolts, Nuts, Studs, and Screwed Connections
All threads shall be clean and accurately cut before assembling. Screwed parts shall be lightly lubricated or coated with jointing compound as may be applicable before connection. All screwed connections shall be made without the use of force sufficient to permanently deform the material. Threads shall be metric. 2.17.4 Machine Work
Unless otherwise shown on the approved shop drawings, all allowances, tolerances, and gauges for metal fits shall conform to ANSI Standard B.4.1 for the class of it as shown or otherwise required. Sufficient machining allowance shall be left on placing pads to ensure true surface of solid material. Finished contact or bearing surfaces shall be true and exact to ensure full contact. All machined parts shall be accurately machined and like parts shall be interchangeable. Drilled holes for bolts shall be accurately located and drilled to templates when necessary or specified. The holes for fit-up bolts or dowels shall be carefully reamed and the bolt or dowel shall enter with a light driving fit. Bolt and screw threads shall conform to ISO standard 68. 2.17.5 Surface Finishes
Surfaces to be machine-finished shall be indicated on the shop drawings by symbols which conform to ANSI B46.1. Values of roughness height are specified in microns as "average deviation from the mean surface". Values of roughness, width and waviness height are not specified but shall be consistent with the general type of finish as specified by the roughness height. Compliance with the specified surface will be compared to roughness comparison specimens. 2.17.6 Types of Finishes
Surfaces which are to be machined to dimensions where the tolerance is 0.5 mm or greater shall have a maximum roughness value of 12.5 microns. Stationary mating surfaces, where reasonably accurate positioning of the members or a moderately tight joint is desired, shall have a maximum roughness value of 6.3 microns. Surfaces in sliding or rotating contact, where motion is slow and loads are light, shall have a maximum roughness value of 3.2 microns.
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Surfaces in sliding or rotating contact, when loads and speeds are moderate, shall have a maximum roughness value of 1.6 microns. Surfaces in sliding or rotating contact where loads are heavy and / or the motion is rapid, shall have a maximum roughness value of 0.8 microns. 2.17.7 Unfinished Surfaces
So far as practicable, all work shall be laid out to secure proper matching of adjoining unfinished surfaces. Where there is a large discrepancy between adjoining unfinished surfaces, they shall be chipped and ground or machined to secure reasonable alignment. Unfinished surfaces shall be true to the lines and dimensions shown on the drawings and shall be chipped or ground free from projections or rough spots. Depressions or holes not affecting the strength or usefulness of the parts may be filled in a manner approved by Purchaser. 2.17.8 Templates and Gauges
All parts that may require renewal shall be made to template and gauge so that original and spare parts will be interchangeable. All special gauges and templates necessary for site erection and runner maintenance shall become the property of Purchaser as specified in PTS. 2.18 Electric Welding
Electric welding shall conform to the following requirements: 2.18.1 General
All welding shall be performed by the electric-arc method, by a process that excludes the atmosphere from the molten metal, and where practicable, using automatic machines. Complete procedures for both shop and field welds shall be submitted for approval. 2.18.2 Preparation for Welding
Members to be joined by welding shall be cut accurately to size, with edges sheared, flamecut, or machined to suit the required type of welding and to allow thorough penetration and good fusion of the weld with the base metal. The cut surfaces shall be free of all visible defects such as laminations, surface defects caused by shearing or flame cutting operations, or any other injurious defects. The surfaces of plates to be welded shall be free from rust, grease, and other foreign matter along the edges prepared for welding.
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All welds exposed to water flow shall be ground to a smooth and even surface flush with the adjacent plate. 2.18.3 Welding Codes
All welding for the fabrication of principal stress-carrying parts shall be in accordance with Part UW of Section VIII of the American Society of Mechanical Engineers (ASME) "Boiler and Pressure Vessel Code", with the exceptions regarding stress-relieving stated below. All welding for the fabrication of less important parts shall be in accordance with the applicable requirements of paragraphs 401 through 403 and 406 through 410 of the "Standard Code for Arc and Gas Welding in Building Construction" of the American Welding Society (AWS) or other equal approved standard. 2.18.4 Stress-relieving
Important Parts For principal stress carrying parts, localized stress- relieving will not be permitted for shop-welded parts. All weld-fabricated parts except minor parts, those where stress is not important, or those which are specifically exempted from stressrelieving shall be stress-relieved as a unit prior to final machining. Radiographic and ultrasonic examination of welds will be required, as specifically stated in these Specifications, and when, in the opinion of Purchaser, doubt exists as to the quality of certain welds. Any such radiographic and ultrasonic inspection shall be at the expense of the Supplier. The Supplier shall furnish all special materials, equipments, or techniques required for pre-heating or post-heating of members to be joined by field welding. The design and construction of welded joints shall conform to the applicable requirements of the ASME Boiler and Pressure Vessel Code, Section VIII. Machine parts, including all parts directly and permanently attached to the turbine distributor or spherical valve shall be stress-relieved prior to final machining. The stress-relieving furnace shall be equipped with suitable recording
thermometers to record the temperature of the furnace and parts during the heating and cooling of the parts. All temperature records shall be submitted to Purchaser for record. Localized stress-relieving will not be permitted for shop welded parts. Field welding of stress-relieved parts will not be permitted.
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LESS IMPORTANT PARTS - The fabrication of less important parts, such as wheel pit liners and oil sump tank shall be in accordance with the applicable requirements of Paragraphs 401 to 403 and 406 to 410 of the American Welding Society. Stressrelieving of such parts will not be required.
2.18.5
Welders Qualifications
For welding of principal stress-carrying parts, the qualification of welding procedures, welders, and welding operators assigned to work covered by these specifications shall conform to the requirements of Section IX of the ASME "Boiler and Pressure Vessel Code", Welding & Brazing Qualifications and, Section VIII Part UW, Requirements for Pressure Vessels Fabricated by Welding. For welding of less important parts/ structural steel parts, the qualifications of welding procedures, welders, and welding operators shall conform to AWS Section D1.1 - 75 Section 5B A "Standard Qualification Procedure". If at anytime, in the opinion of the concerned engineer, work of any welder or welding operator appears questionable, such operator will be required to pass additional qualification tests to determine his ability to perform the type of work on which he is engaged. All such additional qualification tests for welding operators and the physical test of the welded specimens shall be made in the presence of Purchasers inspector. All expenses in connection with making such qualification tests for welders and welding operators shall be borne by the Supplier. 2.18.6 Quality of Welds
The design of welded joints and the welding procedures for both field welds and shop welds, in addition to conforming to the requirements set forth in the applicable code and/or in these Specifications, shall meet the following requirements for workmanship and visual quality: i) Butt welds shall be slightly convex, of uniform height, and shall have full penetration. ii) iii) Fillet welds shall be of specified size, with full throat and with legs of equal length. Repair chipping, or grinding of welds shall be done in such a manner as not to gouge, groove, or reduce the base metal thickness.
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2.18.7
Laminations
Any plate in which lamination has been discovered after cutting shall be rejected unless the laminated portion of plate is local and can be cut out and replaced by welding of a new sound plate in the cut-out area. In such cases the Purchasers approval for repairs will be required. Where such repairs are authorized the welds of the repairs shall be ground smooth to assure neat appearance. 2.18.8 Electrodes
The Supplier shall indicate on all detail drawings the type, size and material of electrodes he proposes to be used for shop and / or field welding. Field welding electrodes will be provided by the Supplier. 2.18.9 Welded Fabrications and Residual Stress Relief
All parts manufactured using welding methods, except those in which the stresses are not important, shall be designed, manufactured and inspected according to the ASME Boiler and Pressure Vessel Code, Section VIII, Requirements for Unfired Pressure Vessels Fabricated by Welding or equivalent. Welds shall be balanced in so far as practical to minimize distortion and residual stresses. The requirements of welding methods shall be submitted for approval. 2.18.10 Non-destructive Tests Unless otherwise requested by the Supplier and approved by the Purchaser, all nondestructive testing of materials shall be carried out in accordance with the following specifications: Radiographic methods ASME Section VIII, division - 1 UW51 (welds) ASTM E446, E186 and E280 (castings) Ultrasonic methods ASME Section VIII, Appendix 12 (welds) ASTM A418 and A388 (forgings) Magnetic particle methods Liquid penetrant methods ASTM E709 ASTM E165
The Supplier shall supply the Purchaser with procedure sheets and test data confirming the effectiveness and validity of each method he proposes to use.
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All inspection and non-destructive testing requirements must be clearly specified on the drawings. Radiographic Inspection Radiographic inspection with X-ray machines or radioactive isotopes will be permitted. Limitations on the use of each method are outlined in ASTM and ASME standards. X-ray machines shall be used in preference to isotope cameras whenever possible. Single control kilovoltmilliampere X-ray machines shall not be used without the express approval of the Purchaser. All welds of components subjected to penstock hydrostatic pressure and welds of other important stress-carrying parts shall be 100% radiographically inspected where practical in the opinion of the purchaser. For other welds minimum 20% radiography to be carried out. Final decision on acceptability shall rest with the Purchaser. Radiographic plates will only be accepted if they comply with the conditions specified in the ASME Code, Section VIII. All welds which are rejected on the basis of the ASME Code, Section VIII or other, shall be repaired or replaced by an acceptable weld. Where radiographic inspection is not practical, other non-destructive testing such as ultrasonic, dye-penetrant, magnetic particle, or a combination of tests, shall be used. The results shall be submitted to Purchaser for record purposes. Ultrasonic Inspections Ultrasonic Inspection of cast, forged and welded parts will be acceptable if an inspection program is presented together with evidence to prove the validity of the proposed method, all subject to the Purchasers prior approval. Whenever radiographic inspection of welds is not possible, such as certain angular and back-plated welds, the Supplier shall demonstrate the validity of ultrasonic methods by inspecting a test sample which has been prepared by identical methods and checked by radiography. Ultrasonic testing shall only by acceptable if it is carried out with equipment of recognized brand. Welds, castings and forgings shall be inspected by direct contact of the probe with the surface. Under special conditions, ultrasonic inspection by immersion of forged parts may be required. Whenever angled probing is used, the angle of incidence shall be suitable for the thickness of the part, and shall be as recommended in ASTM and ASME standards.
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Equipment shall be calibrated regularly on a test sample prepared as described above, or on a test sample containing flaws similar to those being sought. The ultrasonic method shall not be used until technical literature describing the process, proposed methods, equipment sensitivity, probes, etc. is submitted to the Purchaser together with proof of the competence of the Suppliers technicians. Inspection reports and supporting drawings, sketches or photographs shall be submitted to the Purchaser, together with all details needed to reproduce accurately any ultrasonic test at any time. The final decision on acceptance rests with the Purchaser. Complementary Inspection Complementary inspections of castings, forgings and welded joints may be carried out using liquid penetrant and magnetic particle methods. These methods shall conform to the requirements of ASTM E165 and ASTM E709. These methods are only acceptable for detection of flaws on the surfaces of components or on welds. Striations and irregularities shall be removed before testing. For liquid penetrant testing, the surface shall be conditioned or effectively cleaned before the application of the penetrant. Magnetic particle examination shall be so conducted that surface deterioration or burning does not occur at electrode contact points. Current intensity and duration of application and orientation of the magnetic field shall be as specified in the standards. A magnetic field meter shall be used regularly. Provision shall be made for demagnetization of components if residual magnetism is a potential problem. Final acceptance rests with the Purchaser. Special Inspection For all components fabricated with segments joined by full penetration butt welds, the inspection requirements shall be specified on the drawings and submitted for the Purchasers approval. Ultrasonic inspection shall be done when radiographic inspection cannot be performed and/or where the design standards allow it. Non destructive testing shall be performed after heat treatments. When the verifications specified on the drawings are partial, the Supplier shall perform them at the locations specified by the Purchaser. When defects are found, the necessity of repair
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will be evaluated by the Purchaser allowing for the level the stresses may reach in that spot and for the severity of the defects. The repair work shall be done by gouging to defect-free metal, as conformed by a nondestructive inspection. Repair welding will be allowed only if the defect has been eliminated to the satisfaction of the Purchaser. The repaired welds will be checked again according to a procedure approved by the Purchaser. 2.19 2.19.1 Ladders and Platforms Floor Plates
Floor plates shall be chequered steel plates with a minimum plate thickness excluding raised pattern of not less than 8 mm. Edges of plates shall be planed and joints shall be cut where practicable so as to maintain continuity of pattern. 2.19.2 Ladders and Stairways
Steel ladders or stairways shall be provided where necessary to access for operation and maintenance of the equipment. Ladders shall not exceed 7.5 m in length and suitable platforms with handrails shall be provided between each length. Where a ladder does not extend above a floor or platform level, hand grips or other suitable means of support shall be provided. Protective cages shall be provided for ladders longer than 4.5 m. Ladder rungs shall not be less than 20 mm diameter and stringers not less than 400 mm apart. Stairways shall be provided with handrails and shall have a slope not greater than 45. 2.19.3 Handrails
Handrails shall be provided wherever necessary for the safety of personnel. The handrails shall consist of at least two horizontal tubular members approximately 35 mm diameter mounted on tubular or flat bar upright. The handrail shall be approximately 1100 mm above finished floor level. The handrails and supports shall be designed to withstand vertical and horizontal uniformly distributed loads of 750 N/m applied simultaneously on the top of the railing. Openings in the handrails shall be closed by removable chains.
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2.20
Noise
The noise level caused by the installed Works shall not exceed the following values if not otherwise stated in the Particular Technical Specifications: Machine hall, workshops, etc. max. 85 dB(A) at any place 1 m distant from operating equipment. Offices, control rooms, first aid rooms, canteens, etc. max. 55 dB(A) Residential areas, daytime max. 50 dB(A) night time max. 35 dB(A) Emergency diesel generators max. 85 dB(A) at 7 m distance, open field
The noise level and measurement shall be in accordance with ISO and IEC. The values stated shall be adhered to taking a normal civil construction into account. 2.21 2.21.1 Identification Plates General
Each important part to be delivered under this Contract shall be equipped with permanent identification/name plates in readily visible locations. Whether a part shall be considered as important in this respect shall be decided by the Engineer. The identification/name plates shall be protected during erection and especially during painting. Damaged or illegible identification plates shall be replaced by new ones. The identification plates of non-corroding, non-disintegrating material (except manufacturers nameplates of small standardized components) shall be inscribed in English and fixed with non-rusting screws. Where item of Works may be subject to handling, the nameplate shall be chrome plated brass 3 mm thick with the engraved lettering filled with enamel. The inscription shall be printed / engraved and stenciled or hand-written, but in any case, water-proof, oil-proof, and wear resistant. The wording, size and material of all labels and plates shall be approved by purchaser or conform to the appropriate section of this specification. Devices shall be identified by nameplates on both front and rear of all desks, panels, cubicles etc. Nameplates or labels manufactured for indoor panels shall be of non-hygroscopic laminated plastic material with white plate and black engraving. The materials used shall be nonfading, non-aging and suitable for tropical conditions.
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2.21.2
Manufacturers Nameplates (Rating Plates)
The following data shall be shown in accordance with the relevant standards: Manufacturers name and address works serial number and date of manufacture main design data like full load rating, rated voltage & current, temperature rise, class of insulation, frequency, type no. & other data deemed necessary. As a general rule, standardized components, such as small or medium-sized electric motors, transformers, instruments, etc., may be delivered with the manufacturers standard nameplate. The design of the manufacturers nameplates for the main components such as turbines, generators, transformers, gates, cranes, valves, hoists, servo motors, pumps etc., shall be submitted for the Purchasers approval sufficiently in advance. 2.21.3 Functional Plates
Each part appearing under a certain symbol or number in functional, schematic and/or piping diagrams or in the Operation and Maintenance Instructions, etc., shall be equipped with a plate showing the same symbol or number. 2.21.4 Instruction & Diagram Plates
All plates showing designations or instructions for operation, safety, lubrication, etc., shall have a uniform design. Wherever required by Purchaser, diagram plates shall also be supplied. 2.22 2.22.1 Piping, Fitting and Valves General Specifications
Piping, joints, hangers and supports shall conform to the American National Standards Institute Specification B31.1. Pipes which connect with piping supplied by the Owner shall be terminated by a flange or by a pipe union. Welded connections at termination points will not be allowed. Oil and air piping shall be of steel. Unless otherwise specified, water piping, fittings and valves shall be made of the following materials:
Volume 3A(GTS) Material Steel Stainless steel, copper nickel Stainless steel Stainless steel Stainless steel, Copper nickel Stainless steel
Location Exposed
Diameter 50 mm and above Less than 50 mm & up to 25 mm Less than 25 mm
Embedded
50 mm and above Less than 50 mm & up to 25 mm Less than 25 mm
Embedded pipes less than 50 mm in diameter shall be enclosed in a conduit for protection during concrete placement. The entire piping system shall be prefabricated in the shop, insofar as practicable, leaving only such joint connections as may be necessary for assembly or possible subsequent dismantling for repair and consistent with the requirements of shipment. Pipes below 50 mm in diameter shall be fitted with screwed or socket type welding fittings. Pipes over 50 mm in diameter shall be flanged. Alternatively, Victaulic type
couplings may be used where approved by the Purchaser. Junction of copper to ferrous pipes shall be made with bronze adapters. Wherever feasible, long radius pipe bends shall be used in place of pipe fittings. Plugged drain holes shall be provided at low points in each pipe run. Necessary provisions such as suitable
location, long stems, etc., shall be made so that all valves can be conveniently operated from floor level. Unless otherwise stated, all water piping shall be designed for a normal pressure of PN 10. All piping shall be tested with 1.5 times the design/nominal pressure. All necessary studs, bolts, screws, cold finished nuts, flanges, joints, expansion joints ,washers, gaskets, valves, drains, vents, ,packing, supports, pipe suspensions, supports, insulation, test plugs etc., required in connection with the field assembly of the piping systems shall be designed and supplied by the Supplier.
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Steel structures, walkways, platforms, stairs and ladders shall be provided to the pipes crossing floor as per pipe size. All the steel structures shall be galvanized or shall be of suitable anti-corrosive materials and/or coatings. Welding as well as application of corrosion protection coats shall be done in the manufacturers shop as far as possible. Flanged connections or joints shall be provided only as required for transport, installation or for reasons of dismantling for repair. Metric-ANSI standard flanges shall be used throughout. Welded flanges shall be weld-neck or slip on flanges. The raised face shall be machined. Joints between stainless and normal steel flanges shall be of the insulated type. If the piping crosses over joints of civil structures of different settlement, the piping shall be provided with flexible joints to allow for vertical, horizontal, and angular deviations. Piping installation shall be sloped to prevent trapping of air bubbles. Suitable venting system shall be provided, wherever required. Adequate clearance shall be given to parallel pipes to allow for easy maintenance without disturbing other lines. All overhead piping shall have a minimum clearance of 2 m from operating floors and platforms. Water piping shall be provided with suitable anti-condensation insulation except pipes which are embedded or in trenches. Piping shall be painted in different colours to indicate their contents. The colours to be used shall comply with the Owners standard colour code. 2.22.2 i) Water / Air piping
Pipes of diameter <150 mm shall be of stainless steel. Pipes larger than 150 mm in diameter shall be made of carbon steel and/or stainless steel. Pipe connections embedded in concrete shall be stainless steel or hot dip galvanized. Pipes crossing electrical systems shall also be welded. Other pipe connections shall be flanged. The flange material shall be in conformance with the pipe material. The Supplier shall select
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the location of the weldments as to ensure sufficient access for adequate touch-up treatment for corrosion protection. ii) Pipes above >150mm shall be of carbon steel and shall be in accordance to IS 3589, seamless (S) Gr. Fe 410 of 6 mm thick min. Piping of any equivalent standard shall be got approved by the Purchaser. The steel tubes shall be supplied in single random length of 6m. The straightness of the pipe shall not deviate by more than 0.2 percent of the total length. The ladle analysis shall be carried out by the method specified in IS 228 and its relevant parts or any other established instrumental / chemical method. The tubes shall be supplied with the surface treatment (mechanical cleaning). The grit blasting operations must be carried out only if the temperature is over +5 Deg. C and the hygrometry less than 85%; it must be ensured that the surfaces are not moist not condensating (surface temperature +3 deg.C higher than the environmental dew point). The standard specification ISO 8501-1 B Rust degrees for steel surfaces and cleaning degrees during treatment of steel surfaces prior to application of rust-inhibitive paint shall be referred. iii) Material standard for the pipes below <150mm shall be ASTM SS 304 and shall be produced as per ASTM A 213 seam less. The tests shall be as per ASTM A 450. The thickness of the pipes shall be to suit the working pressures but not less than Schedule 20. iv) The electrodes for the welding at site shall match the parent metal composition. The locations of site weld shall be clearly specified in the drawings and shall be approved by the Purchaser. The bill of material along with type of electrode shall be mentioned in the drawing for approval. v) Stress calculations of steel pipes for minimum wall thickness shall be in accordance with DIN 2413, Steel Pipes under Internal Pressure or with AD-Merkblatter; German Association of Manufacturers of Pressure Vessels, Memos. In no case, the superimposed stress of bending, tension, compression, etc., calculated to the shape variation hypothesis, shall exceed 0.7 of the yield point at maximum applied load at any point of the piping.
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vi)
The maximum applied load shall be taking into account test pressure, water hammer pressure waves, thermal forces, dead weight, etc. On request of the Purchaser, a calculation on pipe stresses has to be submitted by the Supplier at no extra cost. The requested calculation will be subject to the Purchasers approval.
vii)
The wall thickness of pipe shall be the next value in the applicable standard to the minimum steel pipe wall thickness calculated by DIN 2413/1.
viii) For joining of Carbon steel and Stainless steel electrode of composition SS 316 shall be used. 2.22.3 i) Oil Piping All oil piping shall be seamless Carbon steel to ASTM A 53 / ASTM A 106. The tests shall be as per ASTM A 450. The dimensions of the pipe shall also be as per ASTM A 53 / ASTM A 106. ii) Oil pipes shall be as far as possible prefabricated in the Suppliers workshop. They shall be welded except at terminal points and as necessary for erection and future dismantling. The Supplier shall select the location of the weldments as to ensure sufficient access for adequate touch-up treatment for corrosion protection. iii) Pipe connections for the pipes less than 38 mm shall be with Ermeto couplings and for the pipes above 38 mm shall be with steel-flanged connections. iv) All oil piping shall be hydrostatically tested at a pressure 150% of the maximum static pressure. The entire pipe arrangement shall be subjected to the pressure test after complete assembly at site. v) Oil pipes shall not be embedded in concrete. Oil pipes crossing civil structures shall be routed through sleeves embedded in the concrete. vi) The electrodes for the welding at site shall be of the parent metal composition. The locations of site weld shall be clearly specified in the drawings and shall be approved by the Purchaser. The bill of material along with type of electrode shall be mentioned in the drawing for approval. vii) All oil piping shall be completely free from welding residues.
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2.22.4 i)
Fittings Elbows
Elbows of size from 50NB and up to 150NB shall be made of SS 304 and dimensions shall be according to ANSI B 16.11 for socket weld ends or ANSI B16.9 for butt weld ends. The welding shall be with TIG welding and the electrode shall be of base metal composition. ii) Mitre Bends
Bend of size above 150NB shall be fabricated from parent pipe and shall be pre fabricated in shop 3 cut, 4 piece construction for 90 degree and 2 cut 3 piece construction for 45 degree. The table for different sizes shall be provided for approval. iii) Tees
Tees of size from 50NB and up to 150NB shall be made of SS 304 and dimensions shall be according to ANSI B 16.11 for socket weld ends or ANSI B16.9 for butt weld ends. The welding shall be with TIG welding and the electrode shall be of base metal composition Tees of size above 150NB shall be fabricated from parent pipe and shall be pre fabricated. iv) Reducers
Reducers of size from 50NB and up to 150NB shall be made of SS 304 and dimensions shall be according to ANSI B 16.11 for socket weld ends or ANSI 16.9 for butt weld ends. The welding shall be with TIG welding and the electrode shall be of base metal composition Reducers of size above 150NB shall be fabricated from parent pipe and shall be pre fabricated. v) Flanges
Flanges, unions of size from 50NB and up to 150NB shall be made of SS 304 and dimensions shall be according to ANSI B 16.5. Flanges of size above 150 NB shall be fabricated from plates conforming to IS-2062 Gr. B and dimensional standard shall be as per ANSI B 16.5.
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2.22.5
Valves
Generally, valves shall be leak-proof in either flow direction (except for non-return valves) when the nominal pressure is applied. All valves with design pressures higher than PN 16 and diameters larger than DN 100 shall be workshop-tested to DIN 3230 for tightness and soundness of materials. Valves shall close clockwise and be provided with position indicators. The drive units of motor-driven valves shall also be provided with hand wheels for manual operation along with position indicator. The hand wheel shall be operable under all conditions and shall be independent of the motor drive. Further, it shall not be rigidly coupled to the motor drive and shall not compulsory turn when the motor is energized. To facilitate operation, large valves and gates shall be provided with by-pass lines for pressure balancing, if required. All valves shall be readily accessible for both operation and maintenance, and where necessary for ease of operation the spindles shall be extended and an approved form of pedestal hand-wheel provided at convenient operating floor level. Shut-off valves shall be suitable for opening and closing against full unbalanced pressure, including closure against free discharge. If necessary, bypasses are to be provided to meet these requirements. Valves spindles and pins shall be of stainless steel, spindle nuts and bushes of bronze, the body shall be of Cast Steel. All pressure reducing valves, safety valves and similar components shall be workshop-tested and provided with a work certificate 2.3 to DIN 10204. Technical particulars of the different types of valves shall be generally as given hereunder. Any change in the specifications shall be got approved from the Purchaser.
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a)
Butterfly Valves (excluding Penstock B.F. Valve) Particulars Wafer Flangeless, suitable for mounting
Sl. No. Description 1 Type
between line flanges confirming to ANSI B 16.5, 150# 2 3 4 5 Purpose Size Design code Pressure class Isolation 65 NB and above BS 5155 150# / PN16 / as calculated during detail Engineering 6 Operation Shall be able to open under unbalanced pressure 7 Mode of Operation Up to 200 NB Above 200 NB Manual Flow Control Lever with Pad lock hole Gear unit operated with self locking feature with position indicator on top 8.0 8.1 8.2 Material of construction Body Disc Cast carbon steel ASTM A 216 Gr WCB Stainless steel ASTM A 351 Gr CF8M / AISI 410 8.3 8.4 Shaft Accessories Hand wheel, Stainless steel AISI 410 like Cast carbon steel ASTM A 216 Gr. WCB flow
control lever etc. 9 Hydrostatic pressure in bar 10 Bolts and nuts SS with nickel coated and dimensions as per standard
test As per Standard.
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b)
Globe Valves Particulars Outside screw & yoke type with rising Stem
Sl. No. Description 1 Type
2 3 4 5
Purpose Size Design code Pressure class
Regulation and control of flow 65 NB and above BS 1873 150# / PN16 / as calculated during detail engineering
6 6.1 6.2 6.3 6.4 6.5 6.6 6.7 7
Material of construction Body Bonnet Disc Body / Disc Seat Ring Stem Back seat bush Hand Wheel Cast carbon steel to ASTM A 216 WCB Cast carbon steel to ASTM A 216 WCB AISI 410 AISI 410 AISI 410 AISI 410 Carbon steel
Hydrostatic test pressure in As per standard bar
Bolts and nuts
SS with nickel coated and dimensions as per standard
9 10 11
Gasket Accessories End connection
Armid fibre with NBR Hand wheel with Handle lock Flanged connection to ANSI standard
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c)
Check Valves Particulars Swing check To prevent flow reversal 65NB and above BS 1868 150# / PN 16 / as calculated during detail Engineering
Sl.No. Description 1 2 3 4 5 Type Purpose Size Design code Pressure class
6 6.1 6.2 6.3 6.4 6.5 6.6 7
Material of construction Body Cover Disc Body / Disc Seat Ring Hinge Hinge pin Cast carbon steel to ASTM A 216 WCB Cast carbon steel to ASTM A 216 WCB AISI 410 AISI 410 AISI 410 AISI 410
Hydrostatic Test pressure in As per standard Bar
Bolts and Nuts
SS with nickel coated and dimensions as per standard
9 10
Gasket End Connection
Armid fibre with NBR Flanged connection to ANSI std.
d) Sl. No. 1
Forged Carbon steel Gate, Globe, Check valves
Description Type
Gate Valves
Globe Valves
Check Valves
Outside screw & Outside screw Lift check valve yoke type with & yoke type with rising stem rising stem
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2 3 4
Purpose Size Design code
Isolation 50 NB and Below ANSI B 16.34 / BS:5352 / API 602 800 # or higher
Regulation and control of flow
To prevent flow reversal
ANSI B 16.34 / BS: 5352 / API 602
ANSI B 16.34 / BS: 5352 / API 602
5 6.0 6.1 6.2 6.3 6.4 6.5 6.6 7 8
Pressure class Matl of constn. Body Wedge / Disc / cover Spindle Back seal Seat ring Hand wheel Hydrostatic test pressure in bar Bolts & nuts
ASTM 105 AISI 410 AISI 410 AISI 410 AISI 410 ASTM 105 As per standard SS with nickel coated & dimensions as per standard Armid fibre with NBR As per standard Flange connection Hand wheel gate/globe valves
9 10 11 12
Gasket Gland packing End connection Accessories
2.22.6
Hangers and Supports
The Supplier shall supply all pipe hangers, brackets and supports required for the support of the piping. Supports for brackets shall be by means of steel inserts cast into the concrete
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substructure or substantial clamps to the superstructure. Drilling for expansion anchors in concrete or welding to the superstructure will not be permitted. All pipe work and accessories shall be mounted and supported in a safe and neat manner. All brackets, stays, frames, hangers and supports for carrying and staying the pipes, including their fasteners shall be included in the supply and completed by the Supplier at the Site. Pipes and fittings shall be supported at or near flanges wherever possible. All heavy valves and other mountings shall be supported independently of the pipes to which they connect, to the satisfaction of the Purchaser. Where hanger rods are proposed for piping, they shall be vertical without bends or offsets and provided with lateral bracing to resist earthquake generated forces. Vertical runs shall be supported by means of pipe clamps or collars and horizontal runs shall be provided with flexible joints where the pipe crosses contraction joints. Chain or strap hangers shall not be used. Hangers and supports shall be painted unless they are for copper tubing, in which case they shall be copper plated. supported so as to avoid pockets which will not completely drain. The Supplier shall supply drawings showing arrangement the standard arrangement of Supports / Hangers along with the bill of material and shall be got approved by the Purchaser. Location of anchor and support and the weight to be carried by that support also to be mentioned in the drawings. All supports and hangers shall be of galvanized steel. All supports and hangers shall be prefabricated at works and shall be supplied for fixation by Hilti / Fischer make Anchors included in scope. Fabrication at site is not allowed. 2.22.7 Cleaning and Shipping All piping shall be
Pipes and fittings shall be thoroughly cleaned before being shipped. Oil piping shall be acid pickled and flushed. For shipping, the ends of oil pipes shall be equipped with end protectors. All other pipes shall be positively protected against ingress of foreign matter. Pipes shall be suitably protected against corrosion in transit and storage.
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2.22.8
Testing
The Supplier shall shop test all pipelines to 50% above their maximum working pressure and shall supply all labour, material, test media, pumps, plugs, gauges and other equipment necessary to make the complete test. Piping systems shall be flushed clean prior to and after the testing. Piping shall be tested and flushed using the same media for which the system is designed. Where practicable, piping may also be tested in sections, in which case temporary supports and end caps shall be fitted. 2.22.9 Insulation
To avoid condensation on the pipes carrying water because of dew point of ambient air, cold insulation shall be provided. The cold insulation tape shall be made from high quality polyurethane foam and quick and easy to install on pipes and fittings e.g. COLEX insulation tape or equivalent. 2.22.10 Bolts and Nuts The bolts and nuts shall be of stainless steel or zinc bath galvanised. Corrosion resisting steel or bronze shall be used for bolts and nuts when either or both are subject to frequent adjustment / removal. Bolts on manholes shall be of high-strength stainless steel. Protective measures against electrolytic corrosion shall be foreseen where necessary. 2.22.11 Gaskets Gasket for the all the flange sizes shall be 3mm thick armid fibre with NBR. 2.23 Gauges and Instruments
Scales of all gauges and instruments shall be graduated in metric (ISO) units. Provisions shall be made for all gauges and instruments to be suitably located so that they can be conveniently read from floor level. Where this is not possible, permanent platforms shall be provided by the Supplier. All gauges and instruments shall be tested by the Supplier, including those used during commissioning at Site, using suitable means to demonstrate their proper functioning and to confirm factory calibration and contact settings.
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2.24
Tropicalization
In choosing materials and their finishes, due regard shall be given to the humid tropical conditions under which Works are to operate. Some relaxation of the following provisions may be permitted where Works are hermetically sealed but it is preferred that tropical grade materials be used wherever possible. 2.24.1 Metals
Iron and steel shall generally be painted or galvanized as appropriate. Indoor parts may alternatively have chromium or copper-nickel plating or other approved protective finish. Small iron and steel parts (other than rustless steel) of all instruments and the metal parts of relays and mechanisms shall be treated in an approved manner to prevent rusting. Cores, etc., which are built up of laminations or cannot for any other reason be anti-rust treated, shall have all exposed parts thoroughly cleaned and heavily enamelled, lacquered or compounded. When it is necessary to use dissimilar metals in contact these shall, if possible, be so selected that the potential difference between them in the electrochemical series is not greater than 0.5 V. If this is not possible the contact surfaces of one or both of the metals shall be electroplated or otherwise finished in such a manner that the potential difference is reduced to within the required limits, or, if practicable, the two metals shall be insulated from each other by an approved insulating material or a coating of approved varnish compound. 2.24.2 Screws, Nuts, springs, Pivots etc.
The use of iron and steel shall be avoided in instruments and electrical relays wherever possible. Steel screws, when used, shall be zinc, cadmium or chromium plated, or when plating is not possible owing to tolerance limitations, shall be of corrosion-resisting steel. Instrument screws (except those forming part of a magnetic circuit) shall be of brass or bronze. Springs shall be of non-rusting material, e.g. phosphor-bronze or nickel silver, as far as possible. 2.24.3 Fabrics, Cork, Paper, etc.
Fabrics, cork, paper and similar materials, which are not subsequently to be protected by impregnation, shall be adequately treated with an approved fungicide. Sleeves and fabrics treated with linseed oil or linseed oil varnishes shall not be used.
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2.24.4
Wood
The use of wood in equipment shall be avoided so far as possible. When used, woodwork is to be thoroughly seasoned teak or other approved wood which is resistant to fungal decay and shall be free from shakes and warp, sap and wane, knots, faults and other blemishes. Woodwork shall be suitably treated to protect it against the ingress of moisture and from the growth of fungus and termite attack, unless it is naturally resistant to these causes of deterioration. possible. Metal fittings where used shall be of non-ferrous material. Wood screws shall be of dull nickel plated brass or of other approved finish. 2.24.5 Adhesives Joints in woodwork shall be dovetailed or tongued and pinned as far as
Adhesives are to be specially selected to ensure the use of types which are impervious to moisture, resistant to mould growth, and not subject to the ravages of insects. Synthetic resin cement only shall be used for joining wood. Casein cement shall not be used. 2.24.6 Rubber
Neoprene and similar synthetic compounds, not subject to deterioration due to the climatic conditions, shall be used for gaskets, sealing rings, diaphragms, etc. instead of the standard rubber-based materials. 2.24.7 Finishes
Galvanized Work Materials to be galvanized shall be of the full dimensions shown or specified and all punching, cutting, drilling, screw tapping and the removal of burrs shall be completed before the galvanizing process commences. Galvanizing shall be done by the hot dip process with spelter, not less than 98% of which must be pure zinc. No alternative process may be used without the approval of Purchaser. No components shall be galvanized which are likely to come into subsequent contact with oil. Bolts shall be completely galvanized including the threads, but the threads shall be left uncoated in the case of nuts. The zinc coating shall be uniform, clean, smooth and as free from spangle as possible. In the case of component parts the zinc coating shall weigh not less than 0.6 kg/sq.m over the
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area covered and is not less than 0.09 mm in thickness. All galvanizing shall comply with the requirements of the relevant ASTM standards. The Purchaser may select for test as many components to be weighed after pickling and before and after galvanizing as he may think fit. All galvanized parts shall be protected from injury to the zinc coating due to differential aeration and abrasion during the periods of transit, storage and erection. Chromium Plating The chromium plating of the Works shall comply with the requirements of the relevant ASTM standards. 2.25 2.25.1 Anti Corrosion Measures General Specifications
Materials shall be approved by the Purchaser. Materials shall be of first grade and used strictly in accordance with these specifications and the manufacturers written directions as approved by the Purchaser. Paint shall only be applied to dry, clean surfaces. Painting specifications to be adopted shall be proposed by the Supplier in his Bid offer. These specifications shall be equal to or better than proposed in Appendix-2.1. The guarantee period for all paintings shall be minimum 3 years, starting from the date of Commissioning. In general, materials and paint systems which meet the following shall be used: Cement Latex Milk Cement Latex Milk shall consist of ten parts Portland cement (by weight), five parts of water and one part of modified latex emulsion. Primer Where specified, the primer shall be zinc-rich inorganic coating in conformity with SSPC PS 12.00-68T. Red lead based primers shall not be used. Coal Tar Epoxy Coal Tar Epoxy shall be of the two package cold curing type, one package containing resin and the other the curing agent. Coal Tar Epoxy shall conform to SSPC-PS11.01.
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Aluminium Paint Aluminium paste for aluminium finish paint coat shall conform to ASTM Specification D962, Type - II, Class - B. Aluminium paint shall conform to SSPC-Paint 101-64T. Rust Preventive Coating Rust Preventive Coating shall be gasoline soluble and shall conform to SSPC PS8.01-64T Type D. Alkyd Enamel It shall conform to SSPC-Paint 104. Vinyl Paint It shall conform to SSPC-PS4.02 or SSPC-PS4.04. 2.25.2 Surface Preparation for Protective Coating
Interior and the exterior surfaces that will not be embedded in concrete shall be cleaned as specified and in accordance with SSPC-SP-10 for steel surfaces immersed in water and in accordance with SSPC-SP-6 for non-immersed steel surfaces. Exterior surfaces which will be embedded in concrete shall be cleaned by power tool cleaning in accordance with SSPC-SP3-63. Grease and oil deposits shall be removed by wiping the surfaces with a clean cloth dipped in mineral solvent. After dry-blast cleaning, the surface shall be dusted off or blown off with compressed air free of detrimental oil and water. Surfaces to be painted shall be completely dry, clean and free from moisture at the time of painting. 2.25.3 Extent of Protective Coating
After surface preparation for each component, the surface shall be protected using the paints specified in the following manner: Paint shall be applied in accordance with SSPC-PA 1-64.
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Steel Immersed in Water Immersed steel surfaces shall be shop painted with 3 coats of coal tar epoxy paint. Each coat shall be applied to a minimum dry film thickness of 0.125 mm. The paint for each coat shall be tinted so as to give distinct and easily visible colour difference to facilitate inspection. Areas adjacent to field welds shall be left unpainted and shall be protected for shipment by application of one coat of rust preventive coating. Non-Immersed Surfaces Except where otherwise specified all non-immersed steel surfaces shall be painted with one shop coat of primer. The primer shall be applied to a minimum dry film thickness of 0.075 mm. Areas adjacent to field welds shall be left unpainted and shall be protected for
shipment by application of one coat of rust preventative coating. The shop intermediate coat shall have a dry film thickness of not less than 0.04 mm. The intermediate coat shall be tinted to a colour contrasting with the shop and field prime coats. The field finish coat shall be applied to a minimum dry film thickness of 0.04 mm. Embedded Surfaces Embedded surfaces and all attachments to be embedded shall receive one coat of Cement Latex Milk. 2.25.4 Shop Protective Coating Application
The shop paint application shall be carried out in accordance with SSPC-PA-1. Except where otherwise specified, shop painting shall be: a) b) c) d) e) f) Immersed steel - 3 coats of coal tar epoxy paint; Non-immersed steel - 1 prime coat and one intermediate coat; Machined Surfaces - 1 coat anti-rust compound; Embedded steel - 1 coat cement latex milk; Field Weld Areas - 1 coat anti-rust compound; Instrument Cubicles, Gauge Panels and Terminal Boxes:
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- Steam Phosphate treatment - 1 coat alkyd metal primer with dry film thickness 0.025 mm; - Interior - 1 coat white enamel with dry film thickness 0.025 mm; - Exterior - 1 coat glossy alkyd paint with dry film thickness 0.025 mm. g) Certain mechanical and other electrical auxiliary equipment (pumps, motors, cabinets, etc.) may be shop painted with primer and finish coats with the prior approval of the Purchaser. 2.25.5 Field Protective Coating Application
Site painting and Site repair to shop painting shall be carried out by the Owner. Supplier shall however provide the following: a) All paint needed for the Owner to apply the following Works at Site: Immersed steel, at welds - 3 coats of coal tar epoxy paint; Non-immersed steel - final coat (after prime coat and intermediate at welds, if applicable); Surfaces and other appurtenances not shop painted which are rendered inaccessible after completion of erection - intermediate and finish coat (before erection). b) 25 litres of each type of paint used for shop painting for Site repair; c) 25 litres of each type of paint provided for Site painting for the Owners subsequent use. 2.25.6 Colours
Purchaser shall specify the final paint colours to be provided by the Supplier for the various components of the Works after award of Contract. Colour scheme and the painting specifications will be approved by Purchaser. For small standard items supplied by 3rd party Sub-Suppliers, if there is a deviation in colour scheme, the same shall be provided with prior approval of the Purchaser. All the equipment furnished and installed by the Contractor shall be completely painted for final use, with the exception of those parts or surfaces that are expressly designated as unpainted. Surfaces to be painted shall receive the preparatory treatment and number of coats prescribed in the relevant standards.
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The Contractor shall perform all painting work in the shop, before shipment, followed by a field touch-up during or after installation. If accepted by the Employer, the Contractor may apply the last coat of paint at the site instead of applying it in the shop. Colour standard references to major equipment / system shall be as mentioned in below table: Raw water pumps Mint green RAL 6029 Raw water strainers Mint green RAL 6029 Heat exchangers Mint green RAL 6029 Turbines Silicon grey RAL 7032 Turbine shut-off valve Mint green RAL 6029 Governors Silicon grey RAL 7032 Oil pressure piping Yellow orange RAL 2000 Oil purification system Yellow orange RAL 2000 Lubrication oil piping Yellow orange RAL 2000 Air compressors Sky blue RAL 5015 Air piping Light blue RAL 5012 Tops of generators to be decided later Transformers to be decided later GIS to be decided later Enclosures for electrical power equipment Melon yellow RAL 1028 Enclosures for electrical control and protection equipment Pearl white RAL 1013 2.26 2.26.1 General Electrical Requirements General
The electrical items of Works of any electrical or mechanical installation to be provided under this Contract according to the Particular Technical Specifications shall - if not stated otherwise therein - fulfil the requirements of this Section.
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In so far as possible, similar products of same manufacturers shall be used. The Works shall be pre-assembled to the highest possible extent in the Supplier or Sub-Supplier's workshop, complete with all devices and wired up to common terminal blocks. The power supply and control cables shall be laid up to these common terminal blocks. The required control and protection devices, instruments, etc., within the different scopes of work shall be supplied and connected by the relevant Supplier. I/O Modules of all equipments shall be pre-wired to appropriate terminal block.. Unless otherwise agreed, ratings of main electrical Works (in-feeds, bus-ties) as selected or proposed by the Supplier, whether originally specified or not, shall generally include a safety margin of 20% under consideration of the worst case to be met in service. Prior to approval of such basic characteristics, the Supplier shall submit all relevant information such as consumer lists, short circuit calculations, de-rating factors, etc. Short-circuit calculations shall be evaluated giving full evidence that every electrical component can withstand the maximum stresses under fault conditions, for fault levels and durations obtained under the worst conditions, e.g., upon failure of the corresponding main protection device and time delayed fault clearing by the back-up protection device. Electrical Equipment shall be designed to prevent ingress of vermin, dust and dirt. Where wiring, piping or ductwork passes through openings in equipment housings, such openings shall be constructed to prevent ingress of vermin. Wiring and piping enclosures and duct work shall also be vermin proof. Anti-condensation heaters shall be fitted in generator housing, cubicles or panels containing control and/or relay equipment, whether or not they are ultimately to be in an air conditioned zone. They shall also be installed in all outdoor junction boxes. The heaters shall be suitable for single phase, 240 V ac, and 50 Hz operation with sufficient capacity to raise the internal ambient temperature by 5 C. The design shall be such that when the equipment is in service with the heaters energized, the maximum permitted rise in temperature for the equipment shall not be exceeded. The construction of panels and the location of heaters shall be such that an effective circulation of air is ensured. Equipment shall be provided with suitable drainage for
condensation and shall be designed to be free from pockets where moisture can collect. Cable entries shall be sealed type.
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Outdoor installations needing protections shall be protected against solar radiation by means of adequate covers, protection from external lightning/ induced surges, as specified by IEC/VDE standards, where required. The Supplier shall ensure that all the supplied Equipment is insensitive to any signals emitted by wireless communication equipment. 2.26.2 Power Supplies (Low Voltage)
Equipment and devices requiring electric power shall conform to the following power supply parameters: AC DC 415 volt, 50 Hz, 3 - phase, 4 wire-power circuits 240 volt, 50 Hz, single phase (PH-N) - lighting and control circuit where specified 220 volt - control and relay protection circuits 48 volt - for communication system The Supplier shall clearly indicate voltage, current and power requirements for each item of equipment. Unless otherwise specified in this specification or any appropriate standard specification, all electrical equipment shall be suitable for reliable operation at voltages and frequencies over the following ranges: Voltage variations: AC DC 90% to 110% of nominal 75% to 120% of nominal
Frequency variations are between 47.5 Hz and 52.5 Hz. Equipment furnished shall withstand the voltages and frequencies unbalanced continuously without damage, overheating, undue vibration or degradation beyond that expected for normal balanced three phase operation. The main and auxiliary single line diagrams are included in the tender drawings. The
Supplier shall supply and connect all control, protection, annunciation, signalization and power supply cabling required between equipment supplied under this Contract and the control and instrumentation panel supplied with the equipment.
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2.26.3
Standards
The design, manufacture and testing of all Equipment and installations shall strictly comply with the latest edition of the relevant Standards listed under clause 2.5. 2.26.4 Colour Code
Colour coding for electrical connections Live parts of electrical connections shall be colour coded as follows: Sl. No. i) Alphanumeric Coding phase 1 phase 2 phase 3 neutral ii) AC single phase phase neutral iii) DC network th Positive negative
Conductor Designation AC network 3 phase
Symbol R Y B N P N E a b
Colour red yellow blue black red black red ll back
2.26.5
Colour coding for mimic diagrams
Mimic diagrams to be arranged on switchgear cubicles, control panels/desks, etc. shall be with colour codes as follows: a) b) c) d) e) 400 kV 11 kV 415 V 220 V DC 48 V DC : : : : : red blue black green violet
Note:- Colours given above shall be finally agreed upon during detailed design. The colour code for equipment not listed above shall be agreed upon after award of the Contract.
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The colouring of pipelines, moving parts, etc., shall be according to internationally recognized standards. 2.26.6 General All motors shall be of approved make and shall comply with the requirements of this Section. Motors of the same type and size shall be fully interchangeable and shall comply - as far as applicable - to IEC standard motor dimensions. The general construction shall be stiff and rigid; no light metal alloy casings will be accepted. All precautions shall be taken to avoid any type of corrosion. All motors shall be fitted with approved types of lifting hooks or eyebolts as suitable. AC motors shall be preferably squirrel cage type & totally enclosed fan cooled. The Supplier shall be fully responsible for determining that the motor duty cycle, rating, performance, tests and mechanical arrangements are all entirely relevant and suitable for compliance with all standards for the application in the power station and environmental and Site conditions specified. Motors shall be sized so that calculated horse power requirements do not exceed 85% of nameplate ratings. Motor Voltages and Power Ratings The service voltages and corresponding power ratings for electric motors to be used in the Project shall be as follows: a) Motors above 0.37 kW (0.5 HP) Service voltage : Mode of starting: 3-phase a.c. 415/240 V,50 HZ direct-on-line up to 50 kW, above 50 kW with suitable starters preferably soft starters. b) Motors up to 0.37 kW (0.5 HP) Service voltage : Mode of starting: single-phase a.c. 240 V, 50 HZ condenser Electric Motors
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c)
Motors intended to work on the d.c. System Service voltage : Mode of starting: 220 V D.C. resistor
Rating The rating of the motors shall be adequate to meet the requirements of its associated equipment. The service factor, being the ratio of the installed motor output to the required power at the shaft of the driven machine at its expected maximum power demand, shall be applied as follows: Power Demand of Driven Machine Up to 5 kW More than 5 kW Service Factor 1.2 1.1
A.C. motors shall be capable of operating continuously under rated output conditions at any frequency between 95% and 105% of the rated frequency and/or with any voltage variation between 90% and 110% of the nominal voltage. A transient over voltage of 130% of the nominal voltage shall as well be sustained. Further, the motors shall be capable of maintaining stable operation when running at 70% nominal voltage for a period of 10 seconds. The pullout torque for continuously loaded motors shall be at least 160% of the rated torque and for intermittently loaded motors 200% of the rated torque. D.C. motors shall be capable of operating continuously under rated output conditions at any voltage between 90% and 110% of the nominal voltage with a fixed brush setting for all loads. Unless otherwise approved, the speed drop between no-load and full-load shall not exceed 10% of no-load speed. Starting A.C. motors shall be designed for direct on-line starting. They shall be capable of being switched on without damage to an infinite busbar at 110% of the nominal voltage with an inherent residual voltage of 100% even in phase opposition. For starting the motors from the individual main and auxiliary busbars, a momentary voltage drop of 20% referred to nominal voltage should be taken into consideration. With 85% of the nominal voltage applied to the
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motor terminals, each motor shall be capable of accelerating its associated load to full speed with a minimum accelerating torque of 5% of full load torque. The maximum starting currents (without any tolerance) shall not exceed the following values: 5 times of rated current for AC motors 2 times of rated current for DC motors (by means of starting resistors)
Windings and insulation class The insulation of all motors shall be of class F but maintain in operation the temperature limits of class B materials where practicable on full continuous rated load. It shall be suitable for operation in damp locations, for occasional contact with corrosive gases and vapours and for considerable fluctuations in temperature. The stator winding shall be suitably braced to withstand the forces due to direct-on-line starting and transfer conditions as mentioned before. The stator winding shall withstand the maximum fault current for the period determined by the associated protective devices. The rotor winding (if applicable) shall be designed to give trouble-free continuous service including repeated direct-on-line starting. The rotor shall be subjected to a 120% overspeed test for 2 minutes without showing any winding dislocation. Ventilation and type of enclosure All motors shall be of the totally enclosed fan-cooled type, protection class IP 54 according to IEC recommendation 60947. Cable termination points shall be of class IP55. They shall have a closed internal cooling air circuit re-cooled by an external cooling air circuit drawn from the opposite side of the driving end. Bearings As far as possible, the motors shall have sealed ball or roller bearings lubricated for live and the ball & roller locating cage shall not be in contact with the races. All other motors with ratings of about 1 kW and above shall be equipped with lubricators permitting greasing while the motor is running and preventing over-lubrication. Additionally, the bearings shall be fitted with grease nipples permitting the use of a universal grease gun. Vertical motors shall have approved thrust bearings.
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Where sleeve bearings are being used, they shall be of the self or forced lubricating type. If forced lubrication is required, it shall be arranged common to both the motor and the driven machine and provisions shall be made to ensure lubrication during start-up and shutdown operations without the necessity to start an auxiliary lube oil pump. Self-lubricated bearings shall be equipped with an easily accessible oil reservoir with overflow pipe and oil collecting vessel. All bearings shall be easily controllable during operation or standstill without dismantling the bearings. The bearings shall further be protected and sealed against dust penetration and oil leakage. In case of independent bearings, motor and bearing pedestals shall be fitted on a common base plate. For the transport of motors equipped with ball or roller bearings, special bearing inserts shall be provided to prevent transport damage. Shafts and couplings The motors shall be provided with a free shaft extension of cylindrical shape with key and keyway according to IEC Recommendation 600 72-1 and with the motorside-coupling, which shall be pressed on the motor shaft and be balanced together with it. A coupling guard shall be provided. Brush gear and commutators Brush-gear for D.C. motors shall be designed to ensure constant brush pressure. Carbon brushes shall be provided which stand at least 6 months of operation without replacement. Each brush shall be independently adjustable but should not require adjustment throughout its life. A design of brushgear which permits the brush holder to touch the commutator as the brushes wear or which passes current through the pressure fingers will not be accepted. Terminal boxes and earthing The terminal leads, terminals, terminal boxes and associated equipment shall be suitable for terminating the respective type of cables as specified in these General Technical Specifications and in the Particular Technical Specifications.
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The terminal boxes shall be of ample size to enable cable connections to be made in a satisfactory manner. Supports shall be provided at terminal boxes as required for proper guidance and fixing of the incoming cable. The termination / junction boxes shall have preferably cage clamp type terminals. The terminal boxes with the cables installed shall be suitable for connection to supply systems with the short-circuit current and the fault clearance time determined by the motor protective devices. A permanently attached connection diagram shall be mounted inside the terminal box cover. If motors are provided for only one direction of rotation, this shall be clearly indicated. The terminal box shall be weatherproof and firmly fixed to the motor frame. The terminal studs shall be sized to be adequate for the current duty required and marked in accordance with applicable Standards. Terminal boxes shall have approved cable adaptor plates,
sealing chambers or conduit entries. All joints shall be flanged with gaskets of neoprene or similar material. For motors above 1 kW, the terminal box shall be sealed from the internal air circuit of the motor. The arrangement of the terminal box shall be such as to facilitate installation of cables, and allow interchanging of any two phase leads, without disturbing the sealing compound, if this is used at cable terminations. Where practicable, the motor end cover remote from the driving end shall have a removable plug to allow the speed to be checked by means of a portable tachometer. All motors supplied under this Contract shall be furnished with its combination of magnetic starting contactors with disconnect switches and thermal overload devices which shall be mounted on or adjacent to pumping unit. Motors weighing 50 kg or more shall be fitted with lifting lugs. Depending on the size, the terminal box of L.V. motors shall be fitted either with an approved cable sealing-end or with a gland plate drilled as required and provided with suitable fittings for cable fixing and sealing. Such openings shall be temporarily plugged or sealed during transportation.
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For earthing purposes, each motor shall have adequately sized bolts with washers at the lower part of the frame. In addition, each terminal box shall contain one earthing screw. Each equipment/panel shall be earthed by at least two separate earthing strips. Noise-level and vibrations Under all operating conditions, the noise level of motors shall not exceed 85 dB (A). In order to prevent undue and harmful vibrations, all motors shall be statically and dynamically balanced. Vibration displacements or velocity shall be measured in accordance with DIN 45 665 for IEC motor sizes 80 to 315. Tests Each motor shall be factory tested and shall undergo a test at site, if required, as per relevant Standards. The tests shall be performed under full responsibility of the Supplier. 2.26.7 M.V. AND L.V Switchgear, Cubicles and Panels
Starters and Contactors Motor starters shall be equipped with short circuit protection and local disconnecting devices. Preferably all starters shall be of one manufacture. The control circuit voltage shall be obtained from a 415/240 V isolating transformer with primary circuit breaker and secondary fuse. The secondary winding of this transformer shall be grounded. The operating coils of the contactor shall be connected between the grounded side of the transformer and the control contacts. Starters and contactors shall comply with IEC 60947-4-1 and be suitable for direct on-line starting, uninterrupted electrical duty and capable of 30 operations per hour.. They shall be installed in ventilated enclosures for indoor installation and weatherproof enclosures for outdoor installation unless otherwise approved by the Purchaser. The enclosures shall be complete with locks, cable sealing boxes, conduit entries, cable gland plates, bus bars, internal wiring, terminal boards, etc., as required by the duty of the starter, or contactor.
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Starters and contactors shall be of minimum size compatible with motor size and capable of satisfactory operation, without injury, for a period of 5 minutes at a voltage 25% below nominal, at nominal frequency. Thermal type overload and phase failure relays, shall be supplied with starters for motors of 7.5 kW or greater. For motors of less than 7.5 kW, suitably rated 3 phase thermal overloads shall be accepted. Ammeters to read current in one phase shall be provided for motors above 7.5 kW. Each starter shall have sufficient number of auxiliary contacts required for interlocking and indication purposes plus two spare convertible contacts for Purchaser's use. Moulded Case Circuit Breakers Moulded case circuit breakers shall be two or three pole as required, having thermal time delay and instantaneous trips with "On-Trip-Off", indicating operating mechanism. Circuit breakers used in combination type motor starters or contactors shall have the operating mechanisms interlocked with the starter or contactor cover so that the cover cannot be opened unless the circuit breaker is open. The breakers shall comply with applicable section of IEC 60947-2 or equivalent standards. Relays All relays shall conform to the requirements of IEC Publications or other applicable approved standards and shall be designed for satisfactory performance under the specified conditions. Relays used as auxiliary control devices in conjunction with motor starters and magnetic contactors shall be of the type designed for machine tool application featuring contact convertibility. All contacts shall have a minimum thermal current rating of 6A - 10A over a range of 6 to 600 V AC. Control and protective systems shall consist of rack-mounted static modular equipment wherever possible. All plug-in heavy current modules that carry CT circuits shall be equipped with CT shorting features when the module is withdrawn. Case mounted static relays shall be provided with front withdrawal, switchboard type, flush/semi-flush, rectangular, dust-tight transparent cover, back connected cases with CT shorting facilities.
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Stringent measures including shielding of long internal wiring shall be taken to make static relays immune to voltage spikes. The relays shall be so designed that over the nominal temperature range, no part or component shall reach a temperature in excess of that given in the relevant component and/or material specification, or suffer irreversible damages as a result of thermal testing. Suitable facilities such as test plug terminals shall be provided on each measuring relay or system to disconnect trip outputs and then short and disconnect the current transformer and to disconnect any potential transformer, alarm or critical dc circuit, without affecting any other device, prior to removing or testing the relay element. Suitable test facilities shall be provided to enable the measuring relay element to be tested in-site without affecting the external circuitry. Target relays shall be provided to indicate the operation of each measuring system. Target on trip rather than target on start are preferred. Means shall be provided for resetting these targets without removing any covers. If electrically, reset a push button shall be provided. Repeat relays shall be provided where necessary to provide contacts into the local and supervisory equipment for status and alarms as specified. Repeat relays shall be equipped with supply failure alarm circuits. Any relays requiring auxiliary dc power shall use the supply from the circuit in which the relay is connected. This supply shall be monitored at the relay and an alarm initiated in the event of loss of supply. Wherever electromagnetic relays are used, the following requirements shall also be met: All relay coils shall be rated for nominal 220 V dc, and shall operate satisfactorily down to 75 percent of nominal dc voltage. The circuits shall be designed so that all the dc relay coils which are normally connected to one side of the battery supply shall be connected to the negative pole to reduce the effect of electrolysis. Relays used as auxiliary control devices in conjunction with motor starters and magnetic contactors shall be of the type designed for machine tool application featuring contact convertibility.
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All electrical contacts for relays shall be rated accordingly to the relevant IEC Standards or equivalent. The contacts shall be able to withstand the corrosive effect of H2S where it may be present. Instruments Indicating instruments shall be flush mounted switchboard type and back connected. The minimum size shall be 72 mm x 72 mm. They shall be analog transducer or direct fed as appropriate with concentric circular scales of matching style, white background with black lettering. Instruments shall have integral illumination and be protected with anti-glare glass. The individual accuracy of all instruments shall be within 1% of full-scale deflection. The instruments shall be provided with a zero adjustment device so that zero positioning of the pointer can be adjusted without removing the cover. The zero shall be on the left of the scale except for varmeters and wattmeters that must have centre zeros. All ammeters, wattmeters and voltmeters shall be calibrated up to a minimum of 120% of the CT current and system voltage rating. Any scale beyond the 100% point need not be linear. Control Switches and Push Buttons Control switches for circuit breakers, motor operated disconnects shall have pistol grip handles, or shall be of the discrepancy type where specified. Clockwise rotation shall close or start and counter-clockwise rotation shall open or stop. The design shall be such as to prevent accidental operation. Control switches which are required to be spring returned to the neutral position shall be restored by means of independent springs. Push buttons shall be shrouded and of the non-retaining type, manufactured of nonhygroscopic, non-swelling material and installed to avoid any possibility of sticking. Nameplates with wording and engraving approved by the Owner and indicating the switch function shall be provided for each switch along with direction of each operation.
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All control switches shall be located at heights on panels to permit convenient operation with instrumentation located in a logical sequence above the switches and be to the approval of the Owner. Pilot Devices Pilot devices such as selector switches, push-button stations and thermostats shall be of heavy duty type, and where mounted outdoors they shall be housed in weatherproof enclosures especially designed for the environment. Electrical contacts for control, alarm and shutdown shall have a capacity of not less than 10 A at 220 V DC. Plugs and Sockets Plugs and sockets shall meet Indian Standards. Terminal Blocks The terminal blocks shall be located to allow a neat and easy connection work and shall be safely accessible while the equipment is in service. Control circuits and power circuits shall be completely separated by use of divided or separate terminal blocks. Power terminal blocks shall be rated in accordance with applicable standards, and shall be provided with covers. Terminal blocks shall be 1100V grade and have continuous rating to carry the maximum expected current on the terminals. The terminal blocks shall be cage clamp type or nondisconnecting stud type. The insulating material of terminal block shall be nylon 6.6 which shall be free of halogens, fluorocarbons etc. The fire retardant classification shall be of V0/V2 grade, as per UL94. All metal parts including screws shall be made up of copper alloy. The terminal block shall be mountable on both DIN type as well as G type rail. All the metal parts shall be captive, shall be covered in moulded housing to prevent shock. The terminal block shall withstand vibration level up to 5g. Terminal blocks for current transformer and voltage transformer secondary leads shall be provided with test links and isolating facilities. The current transformer secondary leads shall also be provided with short circuiting and earthing facilities.
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The terminal shall be such that maximum contact area is achieved when a cable is terminated. The terminal shall have a locking characteristic to prevent cable from escaping from the terminal clamp unless it is done intentionally. The conducting part in contact with cable shall preferably be tinned or silver plated however nickel plated copper or zinc plated steel shall also be acceptable. The terminal blocks shall be of extensible design. The terminal blocks shall be provided with shorting links and paralleling links where applicable, and mounted identification numbers and/or letters. Terminal identification shall be provided corresponding to wire number of connected leads. 415/240 V ac circuit terminals shall be segregated from other terminals. Warning labels with red lettering shall be mounted thereon in a conspicuous position. The terminal blocks shall have locking arrangement to prevent its escape from the mounting rails. The terminal blocks shall be fully enclosed with removable covers of transparent, nondeteriorating type plastic material. Insulating barriers shall be provided between the terminal blocks. These barriers shall not hinder the operator from carrying out the wiring without removing the barriers. Unless otherwise specified terminal blocks shall be suitable for connecting the following conductors on each side.
All circuits except CT /PT circuits
Minimum of two of 2.5 sq. mm copper flexible
All CT/ PT circuits
Minimum of 2 nos. of 6 sq. mm copper flexible
The arrangements shall be made in such a manner so that it is possible to safely connect or disconnect terminals on live circuits and replace fuse links when the cabinet is live.
At least 20% spare terminals shall be provided on ach panel/ cubicle/ box and these spare terminals shall be uniformly distributed on all terminals rows.
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There shall be minimum clearance of 250 mm between the first/ bottom row of terminal block and the associated cable gland plate. Also, the clearance between two rows of terminal blocks shall be a minimum of 200 mm. The terminal blocks shall be of M/s PHOENIX or approved equivalent make. Panel Wiring A panel wiring shall be neatly fixed in single layer on the sides of the cubicles and shall be carried out with tinned copper wire, PVC insulated, sheathed and fire proof treated cable, fixed in rustless metal cleats. Unless otherwise approved, no insulated wire shall have less than three strands and each strand shall not be less than 0.91 mm in diameter. If single conductor is approved for instrument wiring annealed copper or circular cross section shall be used and the diameter of the copper shall not be less than 2 mm. All panel wiring shall be taken to approved terminal boards. The relay and control cubicles shall be supplied complete with necessary terminal glands and end boxes for terminating the multi-core cables. Multi-conductor cables shall be connected to the terminal blocks in such a manner as to minimize crossovers. Approved claw washers of crimp type connector shall be used to terminate all small wiring. Larger size wiring shall be used where needed for the current carrying capacity requirements. Cables shall have at least 1000 V PVC insulation except for 220 V DC and tele-metering and communication system equipment for which 650 V and 300 V ratings respectively are acceptable. For current and potential transformer secondary circuits, the minimum cross section of the conductors shall not be less than 4.0 sq.mm. Small Wiring Except for rack-mounted equipment, each panel conductor shall be individually identified at both ends through a system providing ready and permanent identification, utilizing slip-on ferrules approved by the Purchaser. The markers may be typed individually or made up from sets of numbers and letters firmly held in place. Open (C-Type) markers shall not be accepted. Trip circuits shall employ markers having a red background.
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Sensitive control circuits shall be effectively shielded against extraneous signals and interference. Wiring connections shall be readily accessible and removable for test or other purposes. Wiring between terminals of the various devices shall be point to point, and shall not be jointed between terminal points. Splices of tee connections are not acceptable. Wire runs shall be neatly trounced inside the panels or in wiring troughs. Whenever possible, unused areas of the panels shall be kept free of wiring to facilitate the installation of future equipment. With the exception of wiring direct to specific equipment, all wiring shall be located on side of the panels. 2.26.8 Design Power and auxiliary multi-core control cables shall, unless otherwise specified herein, be XLPE insulated, with copper conductors, aluminium interlocking armour with PVC sheath overall and ground wire. The cables shall be 600/1000 V grade. Instrumentation electronic circuits and supervisory control cables shall be polyethylene insulated, individually shielded, twisted shielded pairs, PVC bedded, with aluminium armour and overall neoprene jacket. The cables shall be rated 300 V. Wire insulating material shall not spread fire or give off corrosive or other dangerous substances when heated. Conductors Power and control cable conductors shall be of copper and have a minimum cross-sectional area of 2.5 sq mm made up of 7/0.67 mm strands. Single strand conductor shall not be accepted. Conductors for electronic circuits and supervisory control cables shall be of annealed copper and shall have a minimum cross-sectional area of 0.80 sq. mm. Core Identification and Laying Up Single core and multi-core power cables shall be coloured black with yellow numerals indicating number of the core 1, 2, 3, 4, etc. Power and Control Cables
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Multi-core control cables shall be made up of the following standard number of cores: 2, 5, 7, 12, 19, 27 and 37. Cores shall be coloured white and shall be identified by black numbers arranged in sequence, e.g., 1, 2, 3, 4, 5, 6, etc. They shall be laid up in this sequence, as far as possible, with a right-hand lay. The figure 9 shall be distinguished from the figure 6 thus 9 or by the word nine alternating with the figure. The numerals shall be printed in black on the core insulations at intervals of not more than 75 mm throughout the core. The print shall be permanent and not easily removed. Cables shall have cable length printed in meters at every meter length of the cable. Identification of Cable The PVC outer sheath shall be embossed throughout the length of the cable with the identification of the manufacturer and with its type and voltage class. The Supplier shall supply and install at each end of the cables permanent cable markers of a non-corroding metal stamped with the cable number. The type and material of the cable marker shall be subject to the approval of the Purchaser. Terminations Compression type glands with armour and bonding clamps for the termination of all PVC insulated cables shall be designed to secure the armour wires, to provide electrical continuity between the armour and the threaded fixing component of the gland and to provide watertight seals between the cable outer sheath and gland and between the inner sheath and threaded fixing component. Glands shall be fitted with an earth bond terminal attachment. Cables entering or leaving terminal boxes shall be provided with separate terminations so that any cable out of a number of such cables can be removed or replaced without disturbing the remainder. 2.26.9 Cubicles and Control Panels
Cubicle and control panel enclosures shall be of sheet steel with minimum thickness of 2.5 mm, of rigid, self-supporting construction and supplied with channel bases. Cubicles shall be fitted with close fitting gasket lined hinged lift-off doors capable of being opened through 90 degrees. The doors shall be provided with integral lock and master key.
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Cubicles and panels shall be vermin proof. Removable gland plates shall be supplied and located to provide adequate working clearance for the termination of cables. Under no circumstances shall the floor or roof plate be used as a gland plate. The cables and wiring shall enter from bottom or top as approved or directed by the Purchaser. The cubicles and panels shall be adequately ventilated, if required, by screened vents or louvers. All ventilating openings shall be provided with corrosion-resistant metal screens or a suitable filter to prevent entrance of insects or vermin. Space heating elements with thermostatic control shall be included in each panel. Where cubicles are split between panels for shipping, terminal blocks shall be provided on each side of the split with all necessary cable extensions across the splits. These cable extensions shall be confined within the panels with suitable internal cable ducts. Unless stated otherwise, cubicles and panels shall be provided with a ground bus with 40 mm x 5 mm copper bar extending throughout the length. Each end of this bus shall be drilled and provided with lugs for connecting ground cables ranging from 70 to 100 sq. mm. The standard phase arrangement when facing the front of the motor control centres and switchboards shall be RYB from left to right, from top to bottom and front to back. All instruments, devices, buses and other equipment involving three phase circuits shall be arranged and connected in accordance with the standard phase arrangement, where possible. Electrical clearances shall conform to applicable standards and shall not require the cutting away of adjacent framework. Instruments, control buttons and indicating lamps shall be flush mounted on the panels. Relays and other devices sensitive to vibration shall not be installed on doors or hinged panels, and no equipment shall be installed on rear access doors. Cubicles and panels shall be securely fastened down to the floor and braced against lateral movement induced by earthquake forces. The instrument and control wiring including all electrical interlocks and all interconnecting wiring between sections, shall be completely installed and connected to terminal blocks by the Supplier. Control panels and cubicles shall be supplied with switched interior lights, socket outlets and jacks with provision for connection to the station telephone system.
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The arrangement of control and protection devices on the panels and the exterior finish of the panels shall be subject to the approval of the Purchaser. The interior of all cubicles and panels shall have a white finish unless specified otherwise. The cubicles and enclosures shall be of protection class IP 40 or higher according to their location. For outside installation and area which are prone to dripping and/or spray of water, the protection class of cubicles shall be IP 65 cubicles housing electronic / modules shall have a protection class of IP 5X. Switched interior light and socket outlets shall be provided for all cubicles and control panels. All cubicles and control panels shall be provided with lamacoid nameplates, identifying the purpose of the panel and all of its components. 2.26.10 Earthing The Supplier shall provide earthing terminals on all the equipment supplied under the Contract and shall supervise connection of the earthing conductors to these terminals as approved or directed by the Purchaser. Unless specified otherwise, earthing conductors from the station earthing bus to the equipment shall be provided by the Purchaser. 2.26.11 Alarm Contacts All alarm contacts shall be of galvanically isolated Wherever required, relays shall be provided as contact multipliers and provide inputs to the following devices. Local annunciator Station annunciator Supervisory control and sequence of events / fault recorder system. All alarm contacts shall be changeover type. Where required, relays shall be provided as contact multiplier.
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2.26.12 Electronic Equipment All components and assemblies shall meet the requirements of the appropriate sections of the International standards listed in section 2.5 and in particular those sections which refer to equipment stored and operated in a tropical environment. 2.26.13 Protection Devices For short circuit and overload protection of power and control circuits, MCCBs or MCBs shall be used. Surge protection devices (SPDs) shall be provided to protect the power and control circuit from external lightning surges and induced switching surges. It shall be used in accordance with IEC-61643-12/VDE 0675 standards. Outlets from AC (and DC) distribution panels shall also be protected in their respective panels as per the above guidelines.
2.27
Equipment Identification: Rating Plates and Nameplates
A rating plate of non-corrodible material shall be attached to each major and auxiliary item of the Works. Major equipment nameplates shall be of stainless steel and shall be fixed to the apparatus with non rusting screws. This plate shall be permanently engraved in English with the designed full load ratings, rated voltage, temperature rise, class of insulation, frequency, serial number, type number, date of manufacture, and other identification deemed necessary. Where required by the Purchaser, diagram plates shall also be supplied. A nameplate shall be provided to identify the service of all items of Works supplied. The identifying inscription shall be approved by the Purchaser or conform to that designated in the appropriate sections of this specification. Devices shall be identified by nameplates on both front and rear of all desks, panels, cubicles etc. Nameplates or labels manufactured for indoor panels shall be of non-hygroscopic laminated plastic material with white plate and black engraving. The materials used shall be nonfading, non-aging and suitable for tropical conditions. Where item of Works may be subject to handling, the nameplate shall be chrome plated brass 3 mm thick with the engraved lettering filled with enamel.
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2.28 2.28.1 a) Type Size
Electrical Instruments, Control Devices and Relays General Electrical indicating instruments shall be as under: : Analogue : 96 mm square : 90o or reed arrangement horizontal (for synchronising instruments) : Flush, back flanges only projecting. : IEC/VDE
Scale Mounting Standard Color of bezel Degree of protection Accuracy class (b)
: Black : IP 54 : 0.5 or better
Instruments shall withstand overload without injury or change in calibration as per approved standards.
2.28.2
Instruments
For field instrumentation following norms shall be adhered to. a) Pressure / Level / Temperature Switches:
All the field switches shall provide minimum 2 nos potential free contacts. More number of contacts shall be provided as per requirement. Each changeover contact shall be used either as NO or NC only. b) Pressure / Level / Flow Transmitters All analog transmitters shall preferably be 2 wire transmitters. Wherever 4 wire transmitters are used, power supply used shall be 230V AC / 220V DC. Analog signal range shall be 4-20 mA. The transmitters shall have a provision for local display of process value. Analog transmitters shall be capable of digital communication without disruption via Foundation Field bus protocol or 4-20mA with HART protocol. The transmitter shall perform continuous diagnostics, capable of self-test
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functions and be able to provide specific diagnostic information. Basic configuration capabilities of the transmitter shall allow the user the ability to input and store information including the range, engineering units, damping, drain/vent valves, flange, and O-ring materials, date, message, descriptor, tag number and serial number. c) Electrical Transducers Universal transducers shall be provided for measurement of electrical quantities. The input signal range shall be from 1 to 10 A for current signals and max. 600 V (3 phases) or max. 346 V (1 phase) for voltage signals from transformer. The transducer shall be equipped with 3 electrically isolated analog outputs, a digital output and a serial interface. It should be possible to assign an individual measurand (current, voltage, active power, reactive power etc.) to each analog output. The transducers shall be of 0.2 class accuracy. Wherever transducers for electrical measurements are used the analog output for SCADA interfacing shall be a 4 wire, 4-20 mA d) Temperature sensors For temperature monitoring RTDs of suitable range (generally PT 100 unless specifically called for) shall be used. Wherever temperature signals are interfaced directly to SCADA, they shall be wired to RTD input card 2.28.3 a) Indicating Lamps Switch-board purpose, filament lamps of low watt consumption for 220V DC operation shall be furnished. Each lamp shall be furnished with a suitable rated series resistor to avoid short circuiting of control supply in the event of fusing of lamp filament. Lamp shall be provided with screwed translucent lamp covers to diffuse light, coloured red, green, amber or white as required and shall be preferably un-breakable moulded from heat resisting, translucent and fast colour material. Any other type of assembly shall be subject to Purchasers approval. b) Selection of lamp cap colours shall be as follows:
Red, Yellow, Blue
Potential indication
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White: Red, Green Amber
c)
Bulbs and their caps shall be interchangeable and easily replaceable from the front of the panel and shall normally not require any special tools for replacement. However, in case any special tools are required for this purpose, two of these tools shall be supplied by the Tenderer with the panels.
2.28.4 a)
Miniature Circuit Breakers (MCB) Potential circuits for relaying and metering shall be protected by suitable MCBs located in such a position that they are easily and safely accessible. Individual MCBs as well as set of MCBs shall be fully and properly identified.
b)
Miniature circuit breakers shall be supplied for DC & AC auxiliary supplies. Separate MCBs for control, protection, indication and alarm circuits shall be supplied with proper identification. MCBs shall be provided on both positive as well as negative side of DC supply.
c)
MCBs shall be provided with phase circuit labels. MCBs shall have imprints of the current as well as voltage ratings.
d) e)
The MCBs shall have contacts to operate the alarm when the same are OFF. Operating characteristics of MCBs shall be properly co-ordinated to achieve proper discrimination to isolate faulty circuits.
f)
Switch rating shall not be less than 10 amperes continuous for working at 220 volts DC/110 volts AC control circuits. The DC breaker rating shall be adequate and subject to approval. The contacts shall be silver faced.
2.28.5
Automatic Semaphore Indicators
Automatic semaphore indicators shall be of standard make for automatic indication in mimic diagrams of the position (open or closed) of circuit breakers, isolators and other remote switches. The switches shall be of the supply failure indication type in which the disc comes to neutral position when both units of the indicator are de-energised.
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2.28.6
Push Buttons
Unless otherwise stated, all push buttons shall be self reset type and provided with coloured knobs in approved colour and back connected terminals. They shall be suitable for semiflush mounting on panels. They shall be provided with integral engraved inscription plates. The inscription being placed below the push buttons. All push buttons shall be fitted with two pairs of changeover contacts. The contacts shall be rated to make, break and carry not less than 1A at 250 Volts DC or 6A at 415 volts AC. Illuminated type pushbutton switches as per logic requirement shall be used preferably in groups. Push button for emergency control shall be provided with covers to protect against inadvertent operation. Push buttons can be arranged as push button station, i.e. start/ stop, raise/ stop/ lower as per logic control scheme. 2.28.7 a) Switches Control and selector switches shall be of rotary type and provided with properly designed esutcheon plates, clearly marked to show operating positions. Circuit labels inscribed as approved by Purchaser shall form integral part of the switches. b) Switches shall be supplied with contact developments to suit approved schemes or to contact arrangement drawings. c) Switch ratings shall not be less than 10 Amperes continuous and the DC breaking rating shall be adequate and subject to Purchaser's approval. d) As far as possible all the switches, pushbuttons, lamps, relays, instruments etc. should be interchangeable. e) The control and indication devices on various panels shall be of same make to limit inventory requirement, as far as practicable. 2.28.8 Auxiliary Relays
These shall conform to the following: Type : Plug-in type receptacle snap-on type
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Voltage test Ambient Temperature Contact
: : :
Acc. to IEC 60439-1 0 to 45o C As per relay logic scheme. Trip relay shall be heavy duty and good for breaking duty involved.
Reset
Self reset with hand-reset type flag or hand-reset with flag as per logic control scheme approved.
Standards Operating
: :
IEC/VDE 24/220 Volts ungrounded DC, -15% to + 10%, 415 Volts, 3 phase, 50 Hz, 10%
Testing Facilities
Facilities to check operation of all the relays shall be provided. Special test set and tool kit if required shall be furnished.
2.29 2.29.1
SCADA System Control boards and panels
All electronic components of local control boards, panels and cubicles shall be housed in a cubicle. The cubicle shall be a dust tight steel cabinet with doors for convenient adjustment, test and maintenance. The cabinet shall meet the following requirements: a) Be NEMA type 12 b) Have a rack type support system, doors with three point latches, gaskets and locking handles, interior light operated by a light switch, suitable locks with triplicate keys and a master key for locking and opening all panels. c) Have one DIN rail mountable duplex, 20 amperes, 240 volts A.C., 3 wire grounded type plug receptacle, Have the Class C type Surge Protection devices at the input of the power supply. d) Have an internal wire gutter system with removable covers, sufficient terminal blocks to accommodate all circuits with approximately 20 percent spare terminal points,
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e) Have means to support cables leaving the bottom of the cabinet, 2.29.2 Programmable controllers
Each functional block shall have a pair of redundant controllers. The PLCs to be supplied shall be modular in architecture and microprocessor based design suitable for power plant environments. All power supply cards, I/O module connections and other external interfaces shall be provided with suitable surge protection devices as specified by IEC 61643-12/VDE 0675, Class D protection for control Power Supply to protect the controllers and internal circuitry from external/ induced switching surges. Unless otherwise specified, the equipment shall be in compliance with IEC 61131 standard. For each type of PLC, the supply shall include all equipment and services for operating and maintenance, such as programming and debugging tools, test equipment, all software with license for use and source codes for the application programs, spare parts and full documentation along with training. Each PLC shall have long-life internal battery backup for storing running data and programs. For each output a safe position shall be defined for cases of failure of power supply, output module, CPU, etc. This safe position shall be clearly defined by the Supplier and submitted to the Purchaser. Each controller shall have built-in functions of on-line self diagnostics / watch dog features etc and shall report failures to the operators of the control system. The CPU shall be able to accept external time synchronization from GPS system, adjust its internal clock with the time synchronization system and then time tag data with an absolute clock. Each I/O point of the controllers shall be supplied in standard rack-mounted I/O modules with plug-in boards. Each I/O point shall be furnished with:
a) Protective devices such as DIN rail mounted surge protection pluggable and test-able devices shall be used as specified by IEC-61643-21 b) Protective network for optical coupling and/or other 3- way galvanic isolators should be used in accordance to UL standards. The isolators should have a transmission error of less than 0.2 %, should have common bus system for power supply and 6.2 mm in width with DIN rail mounting.
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c) Filter for noise reduction, test points and fault indication lamps, fuse protection and fuse failure detection. 2.29.3 Power monitoring
For monitoring of electrical parameters Power analysers shall be provided for all lines and feeders, HV / LV boards. All measurements such as voltage, current, power, energy etc., used for monitoring, shall be provided as per drawings. All the monitors used for measurements shall have minimum accuracy of 0.2% and shall be connected to the control system for automatic meter readings. 2.29.4 Standards
Unless specific requirements are otherwise specified, standards concerning computerized control and monitoring (SCADA) system shall comply with the provisions and requirements of the latest applicable International Standards. The list of applicable standards shall be at least as described below in this section. Standard a) b) c) IEC 60255 IEC 62326 IEC 60446 Description Electrical relays Printed Boards Basic and safety principles for man-machine interface, marking and identification, identification of conductors by colours or numerals Stabilized power supplies, DC output Higher performance protocol for the standard digital interface for programmable instrumentation : Part-1 Standard digital interface for programmable instrumentation : Part-2 Surge Protection Devices for Power lines Surge Protection Devices connected to telecommunication and signaling networks Electromagnetic compatibility for industrial process B measurement and control equipment Programmable controllers Digital data communications for measurement and control B Field bus for use in industrial control systems
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d) e) f) g) h) i) j) k)
IEC 60478 IEC 60488-1 IEC 60488-2 IEC 61`643-12 IEC 61643-21 IEC 61000 IEC 61131 IEC 61158
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Standard l) ISO/IEC 8802
Description Information technology Application guide for distributed digital control and monitoring for power stations Tele-control equipment and systems
m) IEEE 1046 n) o) p) IEC 60870-5
IEC 60793 Part 1 Optical Fiber- Measurement and test procedures IEC 60793 Part 2 Optical Fiber- Product specifications
Optical Fiber Cables used shall comply with the provisions of latest ITU-T Specifications and IEC standards. The communications and networks of the control system shall be implemented on open network standards conforming to IEC 60870-5 series standards. Any design feature or detail not specified herein shall be in accordance with the abovementioned standards, which shall supplement these specifications. All the mimic views, software, printouts, documentation symbols, reports, labels etc. shall be in English language only. To achieve redundancy and operational centralization, a Central Control Room shall be implemented from where all units along with all their unit auxiliaries, all Station Services, all Common Services, all switchyard and electrical power supply distribution shall be operated and supervised. 2.30 2.30.1 Network Characteristics Protocols and standards
All the communication and control networks shall based on IEC 60870-5 series of communication protocols and shall use redundant optical fibre cable as media for communication. It shall be the responsibility of the Supplier to verify and solve all interoperability issues of various components / equipment connected to the network. The Supplier shall perform a type conformance test to validate the implementation of the communication protocols. 2.30.2 Scalability and future extensions
All the networks provided shall be scalable for future needs to operate the project as a Group Control Centre for control of all projects of the Purchaser. The Plant LAN and Central Control Room networks shall be suitable for transmission of data, Video and VOIP services.
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The network equipment where the connecting cable are entering from exposed environmental conditions, must be protected by relevant surge protection device in accordance with IEC 61643-21 standards. 2.30.3 Topology, redundancy and availability
The networks shall be configured using redundancy of servers, routers and switches to achieve high operational availabilities for top order events. The system availability shall analyse and calculations shall focus on availability of the control system for the top order event: The overall system unavailability shall be computed by considering individual device unavailability in a fault tree analysis using MTTR, MTTF and MTBF values of each device as supplied by its manufacturer. The Ethernet network equipment shall be protected by a suitable Surge Protection System in accordance to IEC 61643-21 standards with corresponding category 5 according to EN 50173 and transmission quality in accordance with Class D (Cat. 5e). 2.30.4 Local control cubicles
Separate Local Control Cubicles (LCC) provided for Station services and Common services shall be controlled along with complete sequence interlocks from the corresponding Local Control Board and also from the Central Control Room. It shall be possible to operate the units in auto and manual modes even when corresponding Local Control Board is not functional or even when communication between LCB and LCC is not established. The input power supply to every LCB shall be provided with a pluggable surge protection device (Class C) with the facility of fault indication. (as per IEC standards). 2.30.5 Plant Control Network
The data transmission between the Local Control Boards and the workstations shall be implemented through a redundant fiber optic Plant Control Network. The network shall be based on ETHERNET standard and use of TCP/IP protocol. 1GBPS data transfer rate shall be used to guarantee fast and reliable data transmission. The two redundant optical fiber buses shall be routed through physically different paths. 2.30.6 Field Communication Network
A redundant field communication network of high data transfer rate shall be configured for connecting Local control cubicles and other I/O to the Local Control Boards or Unit Control
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Boards. The network shall be based on Open Field Bus Standard / Ethernet international standard / TCP/IP and IEC standards. The media for data transmission shall be optical fiber cable. Fiber Optic converters used for the required serial interface shall be of DIN rail mounting type, industrial grade, redundant, shall have the integrated optical diagnostic with proactive alarm to ensure the exact information on the status of Fibre Optic connection strength. 2.30.7 Optical fibre
Design of optical fibers shall be in accordance with recommendations and practices of relevant IEC standards and ITU-T series standards. Optical source safety shut off shall be provided to prevent exposure to laser light during maintenance. Equipment shall have sufficient test points to facilitate complete monitoring of the equipment performance without service interruption. Fibers shall be designed to limit degradation after thirty years of intermittent exposure to stagnant water, ambient temperature and 100% relative humidity conditions. The availability of 1 Gbps data channel between two remote stations shall be greater than 99.99% and this availability shall consider a maximum mean-time-to-repair (MTTR) of 2 hours. The Dam site shall be linked to the Power Station through redundant
overground/underground fiber optic cables/PLCC. The link shall provide facilities for voice and data channels required for control and monitoring system, Security and Surveillance system, Public Address System etc. Each optical fiber cable shall consist of at least 12 cores and shall be of single mode type. 2.31 2.31.1 Factory Inspection and Testing General Specifications
The Supplier must have all necessary facilities at his works for carrying out routine and acceptance tests as are prescribed in the relevant CSA, IEC, ANSI, IEEE, standards and other routine and acceptance tests specified in the relevant specifications. Documentary evidence of the existence of such facilities shall be submitted along with the bid.
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Routine and acceptance tests on the finished product as per relevant standards shall be carried out in the presence of the Purchasers representative, if so required by the Purchaser. A minimum 4-week notice shall be given to the Purchaser before commencement of the tests. 2.31.2 Factory Inspection
All systems and devices along with their respective auxiliary components shall be subject to inspection by the Purchaser during manufacturing and testing. 2.31.3 Factory Testing
All equipment, apparatus, materials and supplies provided shall be subject to tests in the shop in the presence of the Purchasers and Owners representative and in the field under the supervision of the Supplier, for ensuring conformity to requirements of the specifications. The method and procedure of the tests for specified particular items shall be submitted which shall be in conformity of the applicable recognized standards. Unless otherwise specified, manufacturer shall perform all factory testing. The Supplier shall, at its own expense, promptly make good all defects evidenced by the testing. After defects have been remedied, the equipment shall be retested. The test reports shall indicate the tests performed the results Routine and type tests to be preformed shall be in accordance with CSA, ANSI, IEEE, and IEC- 60076-1. 2.32 Operation and Maintenance Manuals
For the guidance of the Owners operating and maintenance staff, the Supplier shall prepare and furnish an operating and maintenance manual for all of the Works. The manual shall include but shall not necessarily be limited to the following: i) Technical and design data;
ii) General description of components; iii) Operating instructions; iv) General information (including sequence of operations if applicable); v) Specific information (dealing with any unusual feature or safety precautions); vi) Maintenance instructions fully describing all aspects of preventive and repair maintenance, including maintenance schedule and repair procedures, a detailed
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lubrication chart showing all lubrication points, lubricant grades required and a lubrication schedule; vii) Adjustments (and assembly) including design clearances and settings where applicable; viii) All drawings, diagrams, material and parts list, including spare parts and special tools; ix) All pertinent bulletins and instructions prepared by the various manufacturers of component parts. If the complete text is unduly bulky, then the manual shall be appropriately subdivided and produced in a multi-volume form. Final manuals shall be reproduced as a book or books of approximately quarto size generally in the form of the title page to this document except that the references to Specification, Conditions of Contract, Drawings, etc., will be replaced by Operating and Maintenance Instructions. The name of the main Supplier but not that of any subcontractor may also be inscribed upon the cover after the description of the Works. A brief description of the Works is to be inscribed upon the spine of the cover and, if the instructions are contained in several books, these are to be marked with the appropriate volume number. The drawings and diagrams shall be the latest revision of the approved drawings, reproduced to a convenient size and bound into the volume. Insertion of loose drawings into cover pockets is not acceptable. Any additional information, data or changes found necessary during commissioning shall be sent to the Purchaser for insertion in the manuals. 2.33 2.33.1 Packing and Transport General
The Supplier shall arrange for shipping, loading, transportation, unloading, storage, installation, testing and commissioning of all plant and equipment covered under scope of supplies of this contract. The Supplier shall insure all equipments under his scope against damages during transport, storage and installation, commissioning and service period as per the terms of the contract.
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The Supplier shall provide detailed packing list of the equipments before shipment. 2.33.2 Packing
The equipment shall be shipped completely assembled and shall be provided with lifting devices for attachment of crane slings to facilitate its handling. Components which are liable to be damaged during shipment shall be packed separately, and shall carry complete identification. Packages size, as far as possible, shall not exceed 3 m x 3 m. Drying agent shall be kept in each package and crating shall be air tight. Packing shall be sea worth transportation and shall be suitable for long term storage. 2.34 2.34.1 Installation and Supervision Concreting and Erection Supervision
Requirements During Concreting of Embedded Parts The Supplier shall supervise the placing of anchor bolts to be embedded in the foundation concrete and shall satisfy himself that these are accurately positioned, securely anchored in the concrete and are adequate to hold down the associated parts of the Works while these are being embedded in concrete. The Supplier shall carry out all measures necessary to ensure that parts to be embedded in concrete are securely held in position and in particular will ensure that tie rods are evenly tensioned to the correct degree by means of turnbuckles and that the anchors are properly welded to form a complete ring and are not left as open hooks. Embedded parts shall be designed to permit a concrete pouring rate of 0.3 m /hour. During concrete pours, vibrators will not be allowed to touch any metal part embedded in the concrete, and the concrete will be placed evenly and neither dumped nor discharged from chutes in such a manner as to disturb the embedded parts. Where possible, the Owner will keep the interior of the embedded parts wet by water spray to prevent expansion by the heat of hydration. Grouting of voids will not be undertaken sooner than 7 days after concreting the embedded parts. Requirements During Erection General Specifications
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The Supplier shall ensure that the Works are correctly installed in accordance with approved erection drawings and procedures. Layout, Measurements and Datum The Owner will lay out basic building lines and establish datum but such layout shall not relieve the Supplier of his responsibility for the proper performance of the Works. 2.34.2 Inspection, Tests on Completion and Commissioning
General Specifications Testing and commissioning of all Works at site will be in accordance with detailed programs and procedures prepared by the Supplier and approved by the Purchaser. Such programs and procedures shall include all tests specified in the current specifications. Wherever
equipment supplied under several contracts is tested together as a unit, the Purchaser will coordinate the preparation of test programs and procedures, and the execution of the tests among the respective Suppliers. Field testing and commissioning shall be carried out by the Supplier prior to the acceptance of the Works or part of the Works. All tests shall be witnessed by the Purchaser. The Supplier shall provide on site all personnel, equipment, instruments, wiring, etc. required to carry out the tests and record their results in a satisfactory manner. The Supplier shall calibrate all necessary test instruments and equipment, and include calibration records in the respective test reports. In cases where doubt exists regarding the tests, the Purchaser may request repetition of such tests. The Purchaser and Owner reserve the right to witness any tests both at factory and at site. The Supplier shall advise the Purchaser at least 10 working days prior to the start of such tests. Tests on Materials The materials, parts and assemblies shall be tested to comply with the ASTM Standards or other standards specified and shall be in accordance with the best commercial methods applicable to the relevant type and class of work. The tests and trials shall be recorded and certified by the Supplier.
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The test records for materials shall identify the component parts in which the materials are to be used and the certificate shall be prepared in such a way that it can be easily determined if the applicable specifications or standards have been complied with. All radiographs, test specimens and test records shall become the property of the Owner. Test Reports Test reports shall indicate the tests performed, instruments used, names of testing personnel and provide for witnesses signatures. They shall also be numbered and dated. The Supplier shall compile and submit records of and reports on each and every test specified under this Contract and bind such test documents in the same manner as the operating and maintenance manuals. 2.35 Safety
The operation of any items of energized Works shall be subject to a "Permit to Work" system in a form agreed between the Supplier and the Owner in accordance with the Owners standard safety regulations for such work. While the Works are still under the control of the Supplier the permit to work shall be endorsed by the Supplier. Permits to operate on Works which have been handed over shall be under the control of the Owner. The Supplier shall observe all statutory safety ordinances, regulations and laws which are in effect at the Site. 2.36 2.36.1 Spare parts and tools General
All spare parts to be supplied shall be interchangeable with the corresponding parts of all the works supplied under these Specifications and shall be of the same material and workmanship. They shall be replaceable without cutting or destruction of adjacent components. Before issue of the Taking-Over Certificate the spare parts shall be checked at the Site by the Contractor in presence of the Engineer/Owner. Acceptance of any spare parts will not take place before the Contractor has submitted the complete final detailed list of all spare parts and tools.
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All spare parts shall be protected against corrosion and shall be marked with identification labels in the English Language. The identification shall be in accordance with the agreed works Identification System. All spare parts, tools and materials shall be delivered in marked boxes of sufficient sturdy construction to withstand long term storage. 2.36.2 Specified Spare Parts
The required specified spare parts are listed separately in the Particular Technical Specifications. The price for each listed special spare part shall be quoted individually in the Price List; the total price shall be included in the Total Tender Price. 2.36.3 Recommended Spare Parts
The Supplier shall provide a list of recommended spare parts and special tools with the respective unit prices for Purchasers approval and supply sufficient parts, as per approved list, to assure satisfactory operation for at least five years. All spare parts and accessories shall be electrically and mechanically identical to corresponding parts in the equipment supplied and shall be suitably packed and clearly marked, ready for long term indoor storage. 2.36.4 Tools and Appliances
The scope of work shall include all customary and special tools, as well as auxiliary devices including lifting devices, ropes, etc. necessary for total assembly and disassembly of all parts of the supplied Works. Furthermore, all accessories for maintenance shall be supplied and included in the Tender. The total price for tools and devices as required by this article shall be included in the Total Tender Price. The tools, wrenches, etc. shall be unused. Customary tools for erection shall be of the forged and polished chrome-vanadium type. Use of special tools and devices for erection shall be allowed, but shall be approved by the Engineer in each case. Special tools and devices shall be provided with means for ready identification. All lifting devices and wire ropes slings to be used at site shall be tested at works and test certificate shall be supplied to the Engineer.
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Suitable hardwood or steel boards arranged for wall mounting as well as tool carts and/or toolboxes shall be included in the delivery. An itemised list and description of all provided tools, auxiliary devices, storage equipment, etc. shall be included in the Tender. Acceptance of any tool or device shall not take place before the Contractor has submitted the complete final detailed List of Tools and Appliances. Ropes, slings etc. shall be handed over in new condition. The Employer shall be entitled to take over from the Contractor the entire erection tools, appliances, instruments at mutually agreed conditions. 2.37 Training
The Contractor shall arrange training to familiarize the owners personnel about constructional and O&M aspects of equipment wherever need of specialized training is felt during detail engineering. Cost of such training shall be borne by the Contractor. Travelling and living expenses, of the personnel deputed on such training, however, shall be borne by the Owner. Besides above, the Contractor shall hold training sessions to familiarize the Owner's personnel with all aspects of operation and maintenance of the plant and sub-systems before the beginning of the dry tests on site. The technical documentation used in the training sessions shall include the Contractor's draft operation and maintenance manuals and test procedure descriptions approved by the Owner. The Contractor shall provide training for each phase of work as per details agreed at the time of award of contract. 2.37.1 General requirements of training
The Contractor shall provide suitable instructors, training material and facilities (instruments, apparatus, simulators, documents, drawings, protective clothing, rooms, office supplies, etc.) for the Owners personnel. The Contractor shall assist the Owner in obtaining any visas and other formalities for entering or leaving the territory on which the training is being provided.
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The Contractor shall bear responsibility for ensuring the safety of the trainees during their stay in the country of the training. On their part, the trainees shall comply with the laws, regulations and customs of the country in which training is being provided. In the event of illness or accident, the Contractor shall take all steps to provide the trainees with the appropriate medical care. 2.37.2 Training during engineering / manufacturing phase
This shall cover all disciplines viz, Mechanical, Electrical, C&I & QA etc. and shall include all the related areas like design familiarisation, training on product design features and product design software of major equipment and systems, engineering, manufacturing, erection, commissioning, training on operating features of equipment, quality assurance and testing, plant visits and visits to manufacturers works, exposure to various kinds of problems which may be encountered in fabrication, manufacturing, erection, welding etc. The training in areas of Operation and Maintenance shall take place preferably during end of manufacture/ tests. The duration of proposed training for various equipment and systems shall be agreed between owner and contractor. 2.37.3 Training during the erection / installation / site work
Independently from the supervision and inspection functions of the Owner's Representative, the Contractor shall authorise the Owners Personnel to follow the erection / installation / site work at his site. The Owners representative shall take no part in the equipment erection and/or installation operations, which shall be exclusively carried out by the Contractor and under his entire responsibility. This on site training shall cover each phase of erection / installation / site work and shall be of sufficient duration. The Contractor shall supply the information or measurements concerning the erection requested by the Owners Representative.
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2.37.4
Training during the tests on completion phase
The Contractor shall provide on the-job training in the operation and maintenance of the Works to the Owners Operating Personnel. Such training shall start prior to commencement of Tests on Completion and continue until Taking Over. Its scope and quality shall be such as to provide the trainees with comprehensive understanding of all operational and maintenance aspects of the work. Such training shall also include safety and environmental protection aspects applicable to the work.
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Appendix - 2.1
GENERAL APPLICATIONS FOR PAINTS, COATINGS AND RELATED MATERIALS IN HYDRO POWER PLANTS
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1.
PURPOSE AND APPLICATION OF THE STANDARD
This standard defines the painting and protection systems to be applied to all hydro turbines and pumps, shut-off valves, steel structures and auxiliary equipment. The painting system to be applied to a specific surface shall be indicated in the manufacturing drawing by an icon containing a brush and a reference designation for the painting system to be provided. Supplier shall propose in his offer painting specifications for various equipments, which shall be generally in line with these provisions: a) Selection of color code for the final coat (i.e. by RAL number) to be approved by Purchaser b) Parts to be coated in the field shall be identified and clearly mentioned in Bid document c) General selection of the paint system for: i) ii) iii) iv) v) vi) Water exposed surfaces Air exposed surfaces with condensation Air exposed surfaces without condensation (i.e. control cubicles) Oil exposed surfaces Concrete exposed surfaces Water pipes
vii) Weld seams (Weld primer) viii) Machined surfaces (for temporary protection)
2.
APPLICABLE NORMS
If applicable and not explicitly excluded in this document, the following international norms shall be followed: i. ISO 8501
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ii. iii. iv. v. vi. 3.
ISO 8502 ISO 8503 ISO 8504 EN ISO 12944 DIN 55670 GENERAL REQUIREMENTS
All equipment to be supplied shall be in general coated at the manufacturers shop. Paints which include lead and/or other heavy metals or chemicals considered to be hazardous shall not be used for coating. Surfaces shall be uncoated unless specified on the manufacturing drawing. 4. PREPARATION OF SURFACES IN GENERAL
Before applying any paint, weld spatter and sharp edges must be removed. All surfaces to be coated shall be cleaned with approved equipment before application of coating materials. Surfaces not requiring coating and surfaces already coated shall be protected from contamination and damage during the cleaning operations. Any grit or dust remaining on the surface after the cleaning operations shall be removed before proceeding with the application of coating materials. Surface upon which rust forms, or which become contaminated during processing, shall be cleaned again. Surface preparation for each specific item shall be in accordance with one of the following methods, as specified in the description of the coating systems. Surface preparation shall be done according to ISO 8501. 4.1 Cleaning Procedure
Surfaces to be coated shall be dry and free of all dirt, mildew, chalk, spent abrasive and any other contamination of foreign material that could inhibit adhesion. Removal of impurities: Impurity Dust, loose deposits Adhesive deposits Oils, greasy impurities Removal Vacuum-cleaning, brushing Power brushing Wet blasting/pressure wash; use of detergent additives
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Salt deposits Damages, burns, weld smoke, markings, corroded areas White rust
by agreement. Rinse with fresh water and hose to remove cleaner. Rinsing with fresh water Disc sanding to St3 according to ISO 8501-1:2007 or abrasive sweeping to Psa 2 according to ISO 85012:1994 Fresh water hosing and scrubbing with stiff brushes
Surfaces to be coated shall be degreased once more by solvent wiping, using non-fraying white rags. Surfaces shall be wiped until rags remain white after wiping to verify adequate cleaning has taken place. Make sure that the surface is not again contaminated by any impurities whilst the following working steps. Wear clean gloves during handling the workpiece. 4.2 Grit Blasting
Any surfaces, which are not to be blasted or painted, shall be covered with Polyethylene (PE) - sheets and protective tape. Unless otherwise specified in the documents, the surface shall satisfy the following requirements after blasting: 4.2.1 Non Stainless Steel
Blasting acc. to ISO 8504-2 (and if applicable, ISO 8501-1), grade Sa 2 with a uniform surface profile. To do so, use hard, sharp, dry sand or steel grit to achieve a uniform surface shading. For the determination of the surface profile, Testex replica tape can be used. After finishing, remove all sheetings and clean the surface by means of vacuum cleaner and oilfree compressed air. The blasted surface must be dry and free from any contamination like grease, oil, water etc. 4.3 Solvent Cleaning
All paint, grease, oil and wax shall be removed by wiping or scrubbing the surface with clean rags or brushes wetted with solvent. A final wiping shall be performed with clean solvent and rags or brushes to avoid leaving a thin film of greasy residue on the surfaces being cleaned. Mineral spirits or other approved low-toxicity solvents having a minimum flash point of 38oC shall be used as general purpose cleaning solvent during normal weather conditions. In hot weather, heavy mineral spirits, with a minimum flash point of 50oC shall be used.
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5.
APPLICATION OF COATING MATERIALS
Surfaces to be painted shall be completely dry, clean and free from moisture at the time of paint application. Painted surfaces shall be protected against cold, humidity and dust until completely dried. No painting shall be done when the surrounding air temperature is lower than 7oC, nor in damp weather, nor on wet surfaces, nor on an earlier coat of paint that has not thoroughly dried and hardened, or when the metal surface temperature is less than 3oC above the dew point of ambient air. All coating materials shall be thoroughly mixed at the time of application as recommended by the paint manufacturer. Any dust remaining on prepared metal surfaces shall be removed before proceeding with the application of coating materials. Application of the first prime coat shall be done directly after sandblasting before passing through the workshop. For different layers of coating, different colors shall be used. The drying times stated in the paint manufacturers material data sheets shall also be complied with, between individual coats. 6. QUALITY ASSURANCE INSTRUCTIONS
To achieve a high quality and to control the applied paints and coatings, samples have to be treated the same way as the work piece where the coating is to be applied. This includes cleaning, blasting and also the whole application process. The samples shall be made out of the same material as the work piece which is to be coated and in a size of around 200 mm X 200 mm X 3 mm. For applications of the coating system W6, W17 and W24, a porosity check according to DIN 55670 has to be done. In case of high guarantee requirements like: guarantee period more than 3 years Rust grade after the guarantee period Ri 2" or better according to DIN 53210.
The puncture voltage test according to DIN 55670 has to be done at least with the specified puncture voltage of the next higher film thickness. 7. INSPECTION
The final painted surface shall be inspected and approved. The measurement of the dry film thickness shall be done in accordance to EN ISO 12944 or similar standards.
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8.
TOUCH UP OF PAINT
Touch up is normally possible. Proper workmanship with kiss grinding of the surface is required. The instructions of the paint manufacturer must be observed. 9. PREPARATION OF THE FIELD WELDING SEAMS
Along the field welding seams a shop primer should be applied in the workshop on both sides with the width of 150 mm each maximum 30 microns thick. 10. 10.1 SPECIAL APPLICATIONS Corrosion Protection of Pipes
10.1.1 Protection during shipment and after welding Pipes shall be generally supplied to site untreated. For overseas transportation or long term outside storage, temporary protection by spraying with a light oil and sealing with end plastic caps shall be done. After welding the pipes shall be cleaned prior to erection. Each pipe piece must be visually checked for foreign particles and blown out with low-pressure air. Apply the first prime coat directly after cleaning. 10.1.2 Coating on the Inside 1 Water Pipes:
a) Drain pipes and dewatering pipes: Stainless steel, no corrosion protection b) Pressurized pipes Dia d < 80 mm Dia 80 < d < 250 mm used stainless steel or copper or red brass carbon steel, with 2 mm corrosion allowance, no corrosion protection Dia d > 250 mm carbon steel, inside coated (W24 or W6)
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Oil pipes
After welding, and before installation, all oil pipes shall be pickled and protected after wards by flushing with corrosion protection oil. .3 Compressed air pipes
Typically stainless steel is used, without corrosion protection. 10.1.3 Coating on the outside Embedded pipes in concrete Pipes which are only partially in concrete have to be coated in those areas, which are exposed to the environment (water or air). The coating shall be applied on the pipe also in a length of about 200 mm, where the pipe is to be embedded. 10.2 Machined Surfaces A corrosion protective material shall be applied to all machined surfaces, except stainless steel ones. 10.3 Shipment and Storage
Defined in the separate shipping and storage instructions 11. APPLICATION AND SYMBOLS
No. of Painting System A) 1. WATER - EXPOSED SURFACES Standard Application
Painting Symbol
Characteristics of Painting Application
W6
Highly abrasion resistant pack reaction coating
2.
For extended guarantees
W17
Highly abrasion resistant pack reaction coating
3.
Standard without sandblasting,
W24
98
Volume 3A(GTS)
No. of Painting System for low and medium demands 4. Special coating Application
Painting Symbol
WS
According request
to
Purchasers
B) 1.
AIR - EXPOSED SURFACES Inside the powerhouse not L1 Decorative machine coat Acryl Polyurethane resin paint
exposed to condensation (i.e. electrical cubicles) 2. Special coating LS
According request
to
Purchasers
C) 1.
EXPOSED TO HUMIDITY (i.e. Condensation) Condensation and weather LT3 Thick-coated micaceous iron ore coat. Can be touched up without problem
resistance for inside and outside
2.
Special coating
LS
According request
to
Purchasers
D) 1. 2. 3.
OIL - EXPOSED SURFACES For pressure tanks For oil tanks Special coating OE6 OE7 OES 2 K Epoxy resin Primer 2 K Epoxy resin Primer According request to Purchasers
E) 1. 2. 3.
CONCRETE EXPOSED SURFACES Standard For embedded components Special coating B1 B2 BS No blasting or coating 2 K Epoxy-Primer According request to Purchasers
F) 1.
WELD SEAMS (Weld Primer) Protection for weld seams (to P1 2 K Epoxy-Primer
99
Volume 3A(GTS)
No. of Painting System avoid corrosion during transport) G) 1. WELD SEAMS (Weld Primer) Standard Application
Painting Symbol
K1
No blasting or coating, only Holterol P1068 to be applied.
2.
Special coating
KS
According to purchases request
12. 12.1
SPECIFICATION OF PAINTING SYSTEMS System W 6
System Application Surface preparation Primer coat
W6 Water resistance Sandblasting Sa 2,5 acc. to ISO 8504-2 2 pack, highly pigmented zinc - rich primer based on epoxy resin
Intermediate coat
Epoxy
anthracene
oil-combination
(component A and B) Top coat Epoxy anthracene oil-combination
(component A and B) Note Highly abrasion resistant - pack reaction coating Desired layer thickness per coat Primer coat Intermediate coat Top coat Desired final layer thickness min. 240 microns 40 microns 100 microns 100 microns
12.2
System W 17
System Application
W 17 Water resistance
100
Volume 3A(GTS) Sandblasting Sa 2,5 acc. to ISO 8504-2 2 pack, highly pigmented zinc - rich primer based on epoxy resin
Surface preparation Primer coat
Intermediate coat 1
Epoxy
anthracene
oil-combination
(component A and B) Intermediate coat 2 Epoxy - anthracene oil-combination (component A and B) Top coat Epoxy anthracene oil-combination
(component A and B) Note Highly abrasion resistant - pack reaction coating Desired layer thickness per coat Primer coat Intermediate coat 1 Intermediate coat 2 Top coat Desired final layer thickness min. 340 microns 40 microns 100 microns 100 microns 100 microns
12.3
System W 24
System Application Surface preparation Primer coat Intermediate coat
W 24 Resistance to condensation water and weather Clean and grease removing
Epoxy
anthracene
oil-combination
(component A and B) Top coat Epoxy anthracene oil-combination
(component A and B) Note Machined surfaces or bright semi-finished products Desired layer thickness per coat Intermediate coat Top coat Desired final layer thickness min. 200 microns 100 microns 100 microns
101
Volume 3A(GTS)
12.4
System L 1
System Application Surface preparation
Primer coat Intermediate coat Top coat Note Desired layer thickness per coat Desired final layer thickness 12.5 System LT 3
L1 Resistance air-exposed Sand blasting Sa 2, 5 acc. to ISO 8504-2 (thin plate components such as cubicles. Clean and grease removing) 2 K-Epoxy resin 2 K-Acryl/Polyurethane Primer coat Top coat min. 100 microns 50 microns 50 microns
System Application Surface preparation Primer coat Intermediate coat Top coat Note Desired layer thickness per coat
LT 3 Resistance to condensation water Sand blasting Sa 2, 5 acc. to ISO 8504-2 2 K-Epoxy resin 2 K-Epoxy resin 2 K-Acryl/Polyurethane Primer coat Intermediate coat Top coat min. 150 microns 50 microns 50 microns 50 microns
Desired final layer thickness 12.6 System OE 6
System Application Surface preparation Primer coat Intermediate coat Top coat Note Desired layer thickness per coat Desired final layer thickness
OE 6 Pressure tanks Sand blasting Sa 2, 5 acc. to ISO 8504-2 2 K-Epoxy resin
Primer coat 30 microns min. 30 microns - max. 50 microns
102
Volume 3A(GTS)
12.7
System OE 7
System Application Surface preparation Primer coat Intermediate coat Top coat Note Desired layer thickness per coat Desired final layer thickness 12.8 System B 1
OE 7 Oil tanks Sand blasting Sa 2, 5 acc. to ISO 8504-2 2 K Zinc phosphate Epoxy resin Primer
Primer coat 25 microns min. 50 microns
System Application Surface preparation Primer coat Intermediate coat Top coat Note Desired layer thickness per coat Desired final layer thickness 12.9 System B 2
B1 For embedded components No sand blasting
Without coating
B2 For embedded components Sand blasting Sa 2 acc. to ISO 8504-2 Epoxy resin basis (Hardener polyaminoamide basis) Epoxy resin basis (Hardener polyaminoamide basis) Primer coat 20 microns Top coat 20 microns min. 40 microns
103
Volume 3A(GTS)
12.10 System P 1
System Application Surface preparation Primer coat Intermediate coat Top coat Note Desired layer thickness per coat Desired final layer thickness 12.11 System K 1
P1 Protection for weld seams As cut and/or ground Epoxy resin basis (Hardener polyaminoamide basis)
Should be removed from welding edges before welding Primer coat 20 microns Top coat 20 microns
K1 Protection for transport and storage Clean and grease removing Holterol P 1068
Primer coat: 20 microns Top coat 20 microns
104
Volume 3A(GTS) Appendix - 2.2
QUALITY ASSURANCE PLAN Criteria for Acceptance - Non Destructive tests Abbreviation RT Material to be inspected Welded joint Forgings Cast steel UT Welded joint Steel plates Cast steel MT Welded joint PT List of Codes (1) A.S.M.E. Sec. V A.S.M.E Boiler and pressure "Nondestructive examination vessel code Welded joint A.S.M.E. Sec. VIII Division 1, Appendix 12 A.S.T.M. A-435 A.S.M.E. Sec. VIII Appendix 7. But linear discontinuities which don't exceed degree 2 will be permitted. A.S.M.E. Sec. VIII Division 1, Appendix 6 A.S.M.E. Sec. VIII Division 1, Appendix 8 Acceptance standards A.S.M.E. Sec. VIII UW-51, 52 A.S.M.E. Sec. III NB -2542.2 A.S.M.E. Sec. V SA-609 Quality Level 4
(2)
A.S.M.E. Sec. VIII Division 1 Appendix 6 Appendix 7 Appendix 8 Appendix 12 UW-51 UW-52
A.S.M.E. Boiler and pressure vessel code "Rules for construction of pressure vessels." Methods for magnetic particle examination (MT). Examination of steel castings. Methods for liquid penetrant examination (PT). Ultrasonic examination of welds (UT). Radiographic examination of welded joints (RT). Spot examination of welded joints.
(3) (4) (5) (6) (7) (8)
105
ANNEXURES
Alaknanda Hydroelectric Project (300 MW) Drawing/Data Requirement
Annexure -1
TABLE OF CONTENTS 1 2 3 4 5 6 7 8 9 TURBINE AND ACCESSORIES .................................................................................... 1 GENERATOR ................................................................................................................ 2 STATIC EXCITATION SYSTEM .................................................................................... 3 DIGITAL GOVERNING SYSTEM AND ACCESSORIES ............................................... 4 MAIN INLET VALVE ...................................................................................................... 5 PENSTOCK BUTTERFLY VALVE ................................................................................. 6 ISOLATED PHASE BUS DUCT, GENERATOR PHASE & NEUTRAL GROUNDING CUBICLE ................................................................................................ 7 GENERATOR STEP UP TRANSFORMER ................................................................... 8 220 KV GAS INSULATED SWITCHGEAR .................................................................... 9
10 220 KV XLPE CABLES ................................................................................................ 10 11 CONTROL, MONITORING AND DATA ACQUISITION SYSTEM (SCADA) ............... 11 12 PROTECTION SYSTEM .............................................................................................. 12 13 COMMUNICATION SYSTEM ...................................................................................... 13 14 415V STATION AUXILIARY SUPPLY SYSTEM ......................................................... 14 15 STATION DC SUPPLY SYSTEM ................................................................................ 15 16 DIESEL GENERATING SET........................................................................................ 16 17 ILLUMINATION SYSTEM ............................................................................................ 17 18 CABLES AND CABLE TRAYS..................................................................................... 18 19 ELECTRICAL WORKSHOP......................................................................................... 19 20 POT HEAD YARD EQUIPMENT ................................................................................. 20 21 GROUNDING SYSTEM ............................................................................................... 21 22 ELECTRIC OVERHEAD TRAVELLING CRANES ....................................................... 22 23 HEATING, VENTILATION AND AIR CONDITIONING SYSTEM (HVAC) ................... 23 24 FIRE FIGHTING SYSTEM ........................................................................................... 24 25 COOLING WATER SYSTEM ....................................................................................... 25 26 LOW PRESSURE COMPRESSED AIR SYSTEM ....................................................... 26 27 OIL HANDLING SYSTEM ............................................................................................ 27 28 MECHANICAL WORKSHOP ....................................................................................... 28 29 ELEVATOR .................................................................................................................. 29 30 DEWATERING CUM SILT EJECTION SYSTEM ........................................................ 30 31 ERECTION AND COMMISSIONING ........................................................................... 31
Alaknanda Hydroelectric Project (300 MW) Drawing/Data Requirement
Annexure -1
TURBINE AND ACCESSORIES ARO: After receipt of Order ARAD: After receipt of approved drawings
Total no of copies with bid No of copies No of copies No of copies No of weeks (ARO) No of weeks (ARAD) No of weeks (ARO)
Drawing and data required
For review Soft copy
Final (certified)
Without review
CD
Notes Updated drawings and documents to be submitted in 30 days
1. Detailed seller data list and schedule 2. Dimensional arrangement outline drawings and crosssectional drawings 3. Foundation drawings and loading requirements and embedment details 4. Assembly and/or erection drawings 5. Performance data, design calculation, performance curves and parts list 6. Recommended spare parts list (priced) procedures 7. Catalogues, information, etc. 8. Mfr's inspection, test report and code certificates 9. Installation detail drawings parts list 10. Sellers quality control program 11. Detailed shipping bill of material 12. Detailed fabrication/erection Schedule 13. Completed equipment data sheets 14. Factory test procedures 15. Operation, maintenance manuals 16. Installation manuals 17. Commissioning procedures 18. As built drawings
12
3 3 3 -
4 3 3 4 3 4
1 1 1 -
6 6 After tests 12 4 4
4 4 4 -
1 1 -
4 4 4 4 4 2 prior to shipment 6
4 4 4 4 4 3
6 20 24 24 20
4 4 20 20 4 4
4 4 4 4 4 As built drawings to be submitted for review within 30 days of the last machine commissioning and final drawings within 4 weeks after approval
Alaknanda Hydroelectric Project (300 MW) Drawing/ Data Requirement
Annexure-1
GENERATOR ARO: After receipt of Order ARAD: After receipt of approved drawings
Final (certified)
Without review
CD
1. Detailed seller data list and schedule 2. Dimensional arrangement outline drawings and crosssectional drawings 3. Foundation drawings and loading requirements and embedment details 4. Assembly and/or erection drawings 5. Performance data, design calculation, performance curves and parts list 6. Recommended spare parts list (priced) procedures 7. Catalogues, information, etc. 8. Mfr's inspection, test report and code certificates 9. Installation detail drawings parts list 10. Sellers quality control program 11. Detailed shipping bill of material 12. Detailed fabrication/erection schedule 13. Completed equipment data sheets 14. Factory test procedures 15. Operation, maintenance manuals 16. Installation manuals 17. Commissioning procedures 18. As built drawings
12
3 3 3 -
4 3 3 4 3 4
1 1 1 -
4 4 4 -
1 1 -
4 4 4 4 4
6 20 24 24 20
4 4 20 20 4
Annexure-1
STATIC EXCITATION SYSTEM ARO: After receipt of Order ARAD: After receipt of approved drawings
Final (certified)
Without review
CD
12
3 3 3 -
4 3 3 4 3 4
1 1 1 -
4 4 4 -
1 1 -
4 4 4 4 4
6 20 24 24 20
4 4 20 20 4
Annexure-1
DIGITAL GOVERNING SYSTEM AND ACCESSORIES ARO: After receipt of Order ARAD: After receipt of approved drawings
Final (certified)
Without review
CD
12
3 3 3 -
4 3 3 4 3 4
1 1 1 -
4 4 4 -
1 1 -
4 4 4 4 4
6 20 24 24 20
4 4 20 20 4
Annexure-1
MAIN INLET VALVE ARO: After receipt of Order ARAD: After receipt of approved drawings
Final (certified)
Without review
CD
12
3 3 3 -
4 3 3 4 3 4
1 1 1 -
4 4 4 -
1 1 -
4 4 4 4 4
6 20 24 24 20
4 4 20 20 4
Annexure-1
PENSTOCK BUTTERFLY VALVE ARO: After receipt of Order ARAD: After receipt of approved drawings
Final (certified)
Without review
CD
12
3 3 3 -
4 3 3 4 3 4
1 1 1 -
4 4 4 -
1 1 -
4 4 4 4 4
6 20 24 24 20
4 4 20 20 4
Annexure-1
ISOLATED PHASE BUS DUCT, GENERATOR PHASE & NEUTRAL GROUNDING CUBICLE ARO: After receipt of Order ARAD: After receipt of approved drawings
Final (certified)
Without review
CD
12
3 3 3 -
4 3 3 4 3 4
1 1 1 -
4 4 4 -
1 1 -
4 4 4 4 4
6 20 24 24 20
4 4 20 20 4
Annexure-1
GENERATOR STEP UP TRANSFORMER ARO: After receipt of Order ARAD: After receipt of approved drawings
Final (certified)
Without review
CD
12
3 3 3 -
4 3 3 4 3 4
1 1 1 -
4 4 4 -
1 1 -
4 4 4 4 4
6 20 24 24 20
4 4 20 20 4
Annexure-1
220 KV GAS INSULATED SWITCHGEAR ARO: After receipt of Order ARAD: After receipt of approved drawings
Final (certified)
Without review
CD
12
3 3 3 -
4 3 3 4 3 4
1 1 1 -
4 4 4 -
1 1 -
4 4 4 4 4
6 20 24 24 20
4 4 20 20 4
Annexure-1
10
220 KV XLPE CABLES ARO: After receipt of Order ARAD: After receipt of approved drawings
Final (certified)
Without review
CD
1. Detailed seller data list and schedule 2. Dimensional arrangement outline drawings and crosssectional drawings 3. Foundation drawings and loading requirements and cable tray and support details 4. Assembly and/or erection drawings 5. Performance data, design calculation, performance curves and parts list 6. Recommended spare parts list (priced) procedures 7. Catalogues, information, etc. 8. Mfr's inspection, test report and code certificates 9. Installation detail drawings parts list 10. Sellers quality control program 11. Detailed shipping bill of material 12. Detailed fabrication/erection schedule 13. Completed equipment data sheets 14. Factory test procedures 15. Operation, maintenance manuals 16. Installation manuals 17. Commissioning procedures
12
3 3 3 -
4 3 3 4 3 4
1 1 1 -
4 4 4 -
1 1 -
4 4 4 4 4
6 20 24 24 20
4 4 20 20 4
4 4 4 4 4
10
Annexure-1
11
CONTROL, MONITORING AND DATA ACQUISITION SYSTEM (SCADA) ARO: After receipt of Order ARAD: After receipt of approved drawings
Final (certified)
Without review
CD
1. Detailed seller data list and schedule 2. Dimensional arrangement outline drawings and crosssectional drawings 3. Foundation drawings and embedment details 4. Assembly and/or erection drawings 5. Performance data, design calculation, performance curves and parts list 6. Recommended spare parts list (priced) procedures 7. Catalogues, information, etc. 8. Mfr's inspection, test report and code certificates 9. Installation detail drawings parts list 10. Sellers quality control program 11. Detailed shipping bill of material 12. Detailed fabrication/erection schedule 13. Completed equipment data sheets 14. Factory test procedures 15. Operation, maintenance manuals 16. Installation manuals 17. Commissioning procedures 18. As built drawings
3 3
1 1
2 12
4 4
1 1
4 4
3 3 3 -
4 3 3 4 3 4
1 1 1 -
4 4 4 -
1 1 -
4 4 4 4 4
6 20 24 24 20
4 4 20 20 4
11
Annexure-1
12
PROTECTION SYSTEM ARO: After receipt of Order ARAD: After receipt of approved drawings
Final (certified)
Without review
CD
3 3
1 1
2 12
4 4
1 1
4 4
3 3 3 -
4 3 3 4 3 4
1 1 1 -
4 4 4 -
1 1 -
4 4 4 4 4
6 20 24 24 20
4 4 20 20 4
12
Annexure-1
13
COMMUNICATION SYSTEM ARO: After receipt of Order ARAD: After receipt of approved drawings
Final (certified)
Without review
CD
3 3
1 1
2 12
4 4
1 1
4 4
3 3 3 -
4 3 3 4 3 4
1 1 1 -
4 4 4 -
1 1 -
4 4 4 4 4
6 20 24 24 20
4 4 20 20 4
13
Annexure-1
14
415V STATION AUXILIARY SUPPLY SYSTEM ARO: After receipt of Order ARAD: After receipt of approved drawings
Final (certified)
Without review
CD
1. Detailed seller data list and schedule 2. Dimensional arrangement outline drawings and crosssectional drawings 3. Foundation drawings , loading requirements and embedment details 4. Assembly and/or erection drawings 5. Performance data, design calculation, performance curves and parts list 6. Recommended spare parts list (priced) procedures 7. Catalogues, information, etc. 8. Mfr's inspection, test report and code certificates 9. Installation detail drawings parts list 10. Sellers quality control program 11. Detailed shipping bill of material 12. Detailed fabrication/erection schedule 13. Completed equipment data sheets 14. Factory test procedures 15. Operation, maintenance manuals 16. Installation manuals 17. Commissioning procedures 18. As built drawings
12
3 3 3 -
4 3 3 4 3 4
1 1 1 -
4 4 4 -
1 1 -
4 4 4 4 4
6 20 24 24 20
4 4 20 20 4
14
Annexure-1
15
STATION DC SUPPLY SYSTEM ARO: After receipt of Order ARAD: After receipt of approved drawings
Final (certified)
Without review
CD
12
3 3 3 -
4 3 3 4 3 4
1 1 1 -
4 4 4 -
1 1 -
4 4 4 4 4
6 20 24 24 20
4 4 20 20 4
15
Annexure-1
16
DIESEL GENERATING SET ARO: After receipt of Order ARAD: After receipt of approved drawings
Final (certified)
Without review
CD
12
3 3 3 -
4 3 3 4 3 4
1 1 1 -
4 4 4 -
1 1 -
4 4 4 4 4
6 20 24 24 20
4 4 20 20 4
16
Annexure-1
17
ILLUMINATION SYSTEM ARO: After receipt of Order ARAD: After receipt of approved drawings
Final (certified)
Without review
CD
1. Detailed seller data list and schedule 2. Dimensional arrangement outline drawings and crosssectional drawings 3. Foundation drawings and loading requirements and embedment details 4. Assembly and/or erection drawings 5. Performance data, design calculation, performance curves and parts list 6. Recommended spare parts list (priced) procedures 7. Catalogues, information, etc. 8. Mfr's inspection, test report and code certificates 9. Installation detail drawings parts list 10. Sellers quality control program 11. Detailed shipping bill of material 12. Detailed fabrication/erection schedule 13. Completed equipment data sheets 14. Operation, maintenance manuals 15. Installation manuals 16. Commissioning procedures 17. As built drawings
12
3 3 3 -
4 3 3 4 3 4
1 1 1 -
4 4 4 -
1 1 -
4 4 4
24 24 20
20 20 4
4 4 4 As built drawings to be submitted for review within 30 days of the last machine commissioning and final drawings within 4 weeks after approval
17
Annexure-1
18
CABLES AND CABLE TRAYS ARO: After receipt of Order ARAD: After receipt of approved drawings
Final (certified)
Without review
CD
1. Detailed seller data list and schedule 2. Dimensional arrangement outline drawings and crosssectional drawings 3. Foundation drawings , loading requirements and embedment details 4. Assembly and/or erection drawings 5. Performance data, design calculation, performance curves and parts list 6. Cable schedule 7. Interconnection diagram 8. Catalogues, information, etc. 9. Mfr's inspection, test report and code certificates 10. Installation detail drawings parts list 110. Sellers quality control program 12. Detailed shipping bill of material 13. Detailed fabrication/erection schedule 14. Completed equipment data sheets 15. Operation, maintenance manuals 16. As built drawings
12
3 3 3 3 -
3 4 4 3 3 4 3 4
1 1 1 1 1 -
6 12 12 6 After tests 12 4 4
4 4 4 4 4 -
1 1 1 1 -
4 4 4 4 4 4 4 2 prior to shipment 6
24
20
4 As built drawings to be submitted for review within 30 days of the last machine commissioning and final drawings within 4 weeks after approval
18
Annexure-1
19
ELECTRICAL WORKSHOP ARO: After receipt of Order ARAD: After receipt of approved drawings
Final (certified)
Without review
CD
1. Detailed seller data list and schedule 5. Performance data, design calculation, performance curves and parts list 6. Recommended spare parts list (priced) procedures 7. Catalogues, information, etc. 8. Mfr's inspection, test report and code certificates 9. Installation detail drawings parts list 10. Sellers quality control program 11. Detailed shipping bill of material 12. Completed equipment data sheets 13. Factory test procedures 14. Operation, maintenance manuals 15. Installation manuals 16. Commissioning procedures
3 3 3 -
4 3 3 4 3 4 4 4 4 4
1 1 1 -
6 6 After tests 12 4 6 20 24 24 20
4 4 4 4 4 20 20 4
1 1 -
4 4 4 4 4 4 4 4 4 4 2 prior to shipment 6
19
Annexure-1
20
POT HEAD YARD EQUIPMENT ARO: After receipt of Order ARAD: After receipt of approved drawings
Final (certified)
Without review
CD
12
3 3 3 -
4 3 3 4 3 4
1 1 1 -
4 4 4 -
1 1 -
4 4 4 4 4
6 20 24 24 20
4 4 20 20 4
20
Annexure-1
21
GROUNDING SYSTEM ARO: After receipt of Order ARAD: After receipt of approved drawings
Final (certified)
Without review
CD
12
3 3 3 -
4 3 3 4 3 4
1 1 1 -
4 4 4 -
1 1 -
4 4 4 4 4
6 20 24 24 20
4 4 20 20 4
21
Annexure-1
22
ELECTRIC OVERHEAD TRAVELLING CRANES ARO: After receipt of Order ARAD: After receipt of approved drawings
Final (certified)
Without review
CD
12
3 3 3 -
4 3 3 4 3 4
1 1 1 -
4 4 4 -
1 1 -
4 4 4 4 4
6 20 24 24 20
4 4 20 20 4
22
Annexure-1
23
HEATING, VENTILATION AND AIR CONDITIONING SYSTEM (HVAC) ARO: After receipt of Order ARAD: After receipt of approved drawings
Final (certified)
Without review
CD
12
3 3 3 -
4 3 3 4 3 4
1 1 1 -
4 4 4 -
1 1 -
4 4 4 4 4
6 20 24 24 20
4 4 20 20 4
23
Annexure-1
24
FIRE FIGHTING SYSTEM ARO: After receipt of Order ARAD: After receipt of approved drawings
Final (certified)
Without review
CD
12
3 3 3 -
4 3 3 4 3 4
1 1 1 -
4 4 4 -
1 1 -
4 4 4 4 4
6 20 24 24 20
4 4 20 20 4
24
Annexure-1
25
COOLING WATER SYSTEM ARO: After receipt of Order ARAD: After receipt of approved drawings
Final (certified)
Without review
CD
12
3 3 3 -
4 3 3 4 3 4
1 1 1 -
4 4 4 -
1 1 -
4 4 4 4 4
6 20 24 24 20
4 4 20 20 4
25
Annexure-1
26
LOW PRESSURE COMPRESSED AIR SYSTEM ARO: After receipt of Order ARAD: After receipt of approved drawings
Final (certified)
Without review
CD
12
3 3 3 -
4 3 3 4 3 4
1 1 1 -
4 4 4 -
1 1 -
4 4 4 4 4
6 20 24 24 20
4 4 20 20 4
26
Annexure-1
27
OIL HANDLING SYSTEM ARO: After receipt of Order ARAD: After receipt of approved drawings
Final (certified)
Without review
CD
1. Detailed seller data list and schedule 2. Dimensional arrangement outline drawings and crosssectional drawings 3. Assembly and/or erection drawings 4. Performance data, design calculation, performance curves and parts list 5. Recommended spare parts list (priced) procedures 6. Catalogues, information, etc. 7. Mfr's inspection, test report and code certificates 8. Installation detail drawings parts list 9. Sellers quality control program 10. Detailed shipping bill of material 11. Detailed fabrication/erection schedule 12. Completed equipment data sheets 13. Factory test procedures 14. Operation, maintenance manuals 15. Installation manuals 16. Commissioning procedures 17. As built drawings
12
3 3 3 -
4 3 3 4 3 4
1 1 1 -
4 4 4 -
1 1 -
4 4 4 4 4
6 20 24 24 20
4 4 20 20 4
27
Annexure-1
28
MECHANICAL WORKSHOP ARO: After receipt of Order ARAD: After receipt of approved drawings
Final (certified)
Without review
CD
12
3 3 3 -
4 3 3 4 3 4
1 1 1 -
4 4 4 -
1 1 -
4 4 4 4 4
6 20 24 24 20
4 4 20 20 4
28
Annexure-1
29
ELEVATOR ARO: After receipt of Order ARAD: After receipt of approved drawings
Final (certified)
Without review
CD
12
3 3 3 -
4 3 3 4 3 4
1 1 1 -
4 4 4 -
1 1 -
4 4 4 4 4
6 20 24 24 20
4 4 20 20 4
29
Annexure-1
30
DEWATERING CUM SILT EJECTION SYSTEM ARO: After receipt of Order ARAD: After receipt of approved drawings
Final (certified)
Without review
CD
12
3 3 3 -
4 3 3 4 3 4
1 1 1 -
4 4 4 -
1 1 -
4 4 4 4 4
6 20 24 24 20
4 4 20 20 4
30
Annexure-1
31
ERECTION AND COMMISSIONING ARO: After receipt of Order ARAD: After receipt of approved drawings
Final (certified)
Without review
CD
1. Master project schedule 2. Equipment wise erection schedule and method statements 3. Field quality check list of each equipment / system 4. List of tools and tackles at site 5. List of manpower at site 6. Commissioning procedures 7. As built drawings
3 3 -
3 3 3 4
1 1 1 -
2 12 6 20
4 4 4 4
1 1 1 -
4 4 4 4 As built drawings to be submitted for review within 30 days of the last machine commissioning and final drawings within 4 weeks after approval
31
Alaknanda Hydroelectric Project (300 MW) Schedule of Drawing Submission
Annexure-2
TABLE OF CONTENTS 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. TURBINE AND ACCESSORIES ....................................................................................... 1 GENERATOR.................................................................................................................... 1 STATIC EXCITATION SYSTEM ....................................................................................... 1 DIGITAL GOVERNING SYSTEM AND ACCESSORIES .................................................. 2 MAIN INLET VALVE.......................................................................................................... 2 PENSTOCK BUTTERFLY VALVE .................................................................................... 2 ISOLATED PHASE BUS DUCT, LAVT & NEUTRAL GROUNDING CUBICLE ................ 2 GENERATOR STEP UP TRANSFORMER ...................................................................... 3 220 KV GAS INSULATED SWITCHGEAR ....................................................................... 3 220 KV XLPE CABLES ..................................................................................................... 3 CONTROL, MONITORING AND DATA ACQUISITION SYSTEM (SCADA) .................... 3 PROTECTION SYSTEM ................................................................................................... 4 COMMUNICATION SYSTEM ........................................................................................... 4 415V STATION AUXILIARY SUPPLY SYSTEM............................................................... 4 STATION DC SUPPLY SYSTEM...................................................................................... 4 DIESEL GENERATING SET ............................................................................................. 5 ILLUMINATION SYSTEM ................................................................................................. 5 CABLES AND CABLE TRAYS .......................................................................................... 5 ELECTRICAL WORKSHOP .............................................................................................. 5 POT HEAD YARD EQUIPMENT....................................................................................... 6 GROUNDING SYSTEM .................................................................................................... 6 ELECTRIC OVERHEAD TRAVELLING CRANES ............................................................ 6 HEATING, VENTILATION AND AIR CONDITIONING SYSTEM (HVAC) ........................ 6 FIRE FIGHTING SYSTEM ................................................................................................ 7 COOLING WATER SYSTEM ............................................................................................ 7 LOW PRESSURE COMPRESSED AIR SYSTEM ............................................................ 7 OIL HANDLING SYSTEM ................................................................................................. 7 MECHANICAL WORKSHOP ............................................................................................ 8 ELEVATOR ....................................................................................................................... 8 DEWATERING CUM SILT EJECTION SYSTEM.............................................................. 8
Annexure-2
SCHEDULE OF DRAWING SUBMISSION (This document is to be filled by the contractor during pre-award stage.) The drawings pertaining to the components are as identified below and shall be submitted to the Employer by the dates indicated herein. (Additional sheets may be added to cover all the drawings.) 1. TURBINE AND ACCESSORIES Description Date of submission
Sl no.
2.
GENERATOR Description Date of submission
Sl no.
3.
STATIC EXCITATION SYSTEM Description Date of submission
Sl no.
Annexure-2
4.
DIGITAL GOVERNING SYSTEM AND ACCESSORIES Description Date of submission
Sl no.
5.
MAIN INLET VALVE Description Date of submission
Sl no.
6.
PENSTOCK BUTTERFLY VALVE Description Date of submission
Sl no.
7.
ISOLATED PHASE BUS DUCT, LAVT & NEUTRAL GROUNDING CUBICLE Description Date of submission
Sl no.
Annexure-2
8.
GENERATOR STEP UP TRANSFORMER Description Date of submission
Sl no.
9.
220 KV GAS INSULATED SWITCHGEAR Description Date of submission
Sl no.
10.
220 KV XLPE CABLES Description Date of submission
Sl no.
11.
CONTROL, MONITORING AND DATA ACQUISITION SYSTEM (SCADA) Description Date of submission
Sl no.
Annexure-2
12.
PROTECTION SYSTEM Description Date of submission
Sl no.
13.
COMMUNICATION SYSTEM Description Date of submission
Sl no.
14.
415V STATION AUXILIARY SUPPLY SYSTEM Description Date of submission
Sl no.
15. STATION DC SUPPLY SYSTEM Sl no. Description Date of submission
Annexure-2
16.
DIESEL GENERATING SET Description Date of submission
Sl no.
17.
ILLUMINATION SYSTEM Description Date of submission
Sl no.
18.
CABLES AND CABLE TRAYS Description Date of submission
Sl no.
19.
ELECTRICAL WORKSHOP Description Date of submission
Sl no.
Annexure-2
20. Sl no.
POT HEAD YARD EQUIPMENT Description Date of submission
21.
GROUNDING SYSTEM Description Date of submission
Sl no.
22.
ELECTRIC OVERHEAD TRAVELLING CRANES Description Date of submission
Sl no.
23.
HEATING, VENTILATION AND AIR CONDITIONING SYSTEM (HVAC) Description Date of submission
Sl no.
Annexure-2
24.
FIRE FIGHTING SYSTEM Description Date of submission
Sl no.
25.
COOLING WATER SYSTEM Description Date of submission
Sl no.
26.
LOW PRESSURE COMPRESSED AIR SYSTEM Description Date of submission
Sl no.
27.
OIL HANDLING SYSTEM Description Date of submission
Sl no.
Annexure-2
28.
MECHANICAL WORKSHOP Description Date of submission
Sl no.
29.
ELEVATOR Description Date of submission
Sl no.
30.
DEWATERING CUM SILT EJECTION SYSTEM Description Date of submission
Sl no.

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GMR (BADRINATH) HYDRO POWER GENERATION PVT. LTD.

Alaknanda Hydroelectric Project (300 MW) (UTTARAKHAND, INDIA)

(General Technical Specifications)

GENERAL TECHNICAL SPECIFICATIONS

Alaknanda Hydroelectric Project (300 MW) General Technical Specification

Alaknanda Hydroelectric Project (300 MW) General Technical Specification

GBHPL/LOT-5: Electro-mechanical works

Alaknanda Hydroelectric Project (300 MW) General Technical Specification

Alaknanda Hydroelectric Project (300 MW) General Technical Specification

GBHPL/LOT-5: Electro-mechanical works

Alaknanda Hydroelectric Project (300 MW) General Technical Specification

GBHPL/LOT-5: Electro-mechanical works

Alaknanda Hydroelectric Project (300 MW) General Technical Specification

GBHPL/LOT-5: Electro-mechanical works

Alaknanda Hydroelectric Project (300 MW) General Technical Specification

DG sets AC distribution system

GBHPL/LOT-5: Electro-mechanical works

Alaknanda Hydroelectric Project (300 MW) General Technical Specification

Alaknanda Hydroelectric Project (300 MW) General Technical Specification

GBHPL/LOT-5: Electro-mechanical works

Alaknanda Hydroelectric Project (300 MW) General Technical Specification

Volume 3A(GTS) Table 1

International Organization for Standardization

GBHPL/LOT-5: Electro-mechanical works

Alaknanda Hydroelectric Project (300 MW) General Technical Specification

Basic Design standards ISO/286-1988 ISO/1829-1975 ISO/2768-1973

ISO-68-1998 ISO-262-1998 ISO-724-1998

Manufacturing and Testing Standards ASTM-A370-2009

Standard test methods and definitions for mechanical

GBHPL/LOT-5: Electro-mechanical works

Alaknanda Hydroelectric Project (300 MW) General Technical Specification

GBHPL/LOT-5: Electro-mechanical works

Alaknanda Hydroelectric Project (300 MW) General Technical Specification

GBHPL/LOT-5: Electro-mechanical works

Alaknanda Hydroelectric Project (300 MW) General Technical Specification

Design Stress General

Cast Steel, Alloy Cast Steel and Steel Forgings

Plate Steel for Principal parts subject to hydraulic stresses

GBHPL/LOT-5: Electro-mechanical works

Alaknanda Hydroelectric Project (300 MW) General Technical Specification

GBHPL/LOT-5: Electro-mechanical works

Alaknanda Hydroelectric Project (300 MW) General Technical Specification

GBHPL/LOT-5: Electro-mechanical works

Alaknanda Hydroelectric Project (300 MW) General Technical Specification

Alaknanda Hydroelectric Project (300 MW) General Technical Specification

GBHPL/LOT-5: Electro-mechanical works

Alaknanda Hydroelectric Project (300 MW) General Technical Specification

GBHPL/LOT-5: Electro-mechanical works

Alaknanda Hydroelectric Project (300 MW) General Technical Specification

Steel castings shall conform to the following requirements: a) General

The costs incurred by such tests shall be at the Suppliers expense.

Alaknanda Hydroelectric Project (300 MW) General Technical Specification

Alaknanda Hydroelectric Project (300 MW) General Technical Specification

GBHPL/LOT-5: Electro-mechanical works

Alaknanda Hydroelectric Project (300 MW) General Technical Specification

products/instruments/control devices etc.

GBHPL/LOT-5: Electro-mechanical works

Alaknanda Hydroelectric Project (300 MW) General Technical Specification

GBHPL/LOT-5: Electro-mechanical works

Alaknanda Hydroelectric Project (300 MW) General Technical Specification

Alaknanda Hydroelectric Project (300 MW) General Technical Specification

GBHPL/LOT-5: Electro-mechanical works

Alaknanda Hydroelectric Project (300 MW) General Technical Specification

Structural Materials General