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Spec. No.
TCE.4857A-C510-01
TITLE
VOLUME II Part
-I
SECTION: C3a
SHEET 1 OF 1527
OF
GENERAL
a. The scope of Bidder shall comprise design, engineering, material selection,
manufacturing, testing at works, supply
CFR Chennai port , erection
supervision & commissioning supervision, , performance testing at site, and
other related items of work for the Steam generator and auxiliaries inclusive of
mechanical, electrical, instrumentation & control systems, furnishing input for
civil and structural works, necessary for putting into commercial operation a
highly reliable, safe, efficient and environmentally compliant Main Plant
equipment for 2 x 300 MW Malaxmi Thermal Power Project at Meramundali
and Kharagprasad villages, Denkanal District , Orissa state. India The systems
and equipment shall conform to the technical requirements specified in
separate sections of the specification.
b.
Contractor shall perform all the works specified or necessary to complete the
works in accordance with this specification. Further, SECs Contractors
performance of the works under the Contract shall be in accordance with good
engineering practices, notwithstanding the fact that every item involved may
not be specifically mentioned or the item mentioned may be inadequate for its
intended purpose. Details and items, which are not specifically mentioned
herein, shall also be adequately and properly performed by SECContractor
at no extra cost if such details and / or items are necessary to complete the
intent of this specification or otherwise to complete the Steam generator and
auxiliaries. The intent of this specification is to relieve the JSWEVLNPPL of
the necessity of engaging or supplying any labour, service, equipment or
material to complete the Steam generator in respect of the works furnished by
JSWEVL NPPL as specifically itemized under Clause 3.0 of this section.
1.1
MECHANICAL WORKS
1.1.1
Spec. No.
TCE.4857A-C510-01
TITLE
VOLUME II Part
-I
SECTION: C3a
SHEET 2 OF 1527
OF
Complete power cycle piping (main steam from Boiler outlet up to Turbine , cold
reheat from the HP turbine to Boiler and hot reheat from Boiler up to Turbine )
boiler feed discharge piping from last HP heater outlet to Boiler , auxiliary
system piping including the main header as well as all piping in SG island with
hangers and supports, valves, fasteners etc., as required for the boiler island
and connected systems.
j.
k. High Pressure (HP) dosing system for drum water with tanks, pumps, piping,
valves, and fittings.
l.
s. Mill reject hoppers and spouts and Mill reject handling system
t.
Spec. No.
TCE.4857A-C510-01
TITLE
VOLUME II Part
-I
SECTION: C3a
SHEET 3 OF 1527
OF
High Energy Arc (HEA) igniters shall be provided to ignite the fuel oil and shall
consist of transformers, control cabinets, cabling, etc.
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Spec. No.
TCE.4857A-C510-01
TITLE
1.2
VOLUME II Part
-I
SECTION: C3a
SHEET 4 OF 1527
OF
ELECTRICAL WORKS
1.2.1
1.2.2
Electrical system for ESP (ESP switchgear, Rectifier transformers and control
panels), power and control cables and cable trays
1.2.3
Soot Blower MCC and power and control cables for soot blowers
1.2.4
1.2.5
1.2.6
Note:
1.3
1.3.1
All the 6.6kV Switch gear, 415V MCC and 220V DC distribution boards, Power
cables up to motor terminal and Local Push Button Stations will be under the
JSWEVLs scope. However, MCC for ESP and Sootblower shall be in SECs
scope. For more details, please refer to DIVISION OF WORK (DOW)
BETWEEN MAIN PLANT SUPPLIER (SEC) & JINDAL (JSW) FOR 2X300MW
POWER ROJECT signed on March 24, 2006.
Spec. No.
TCE.4857A-C510-01
TITLE
VOLUME II Part
-I
SECTION: C3a
SHEET 5 OF 1527
OF
1.3.2
1.3.3
1.3.4
1.3.5
All final control elements like control valves, de-superheaters, control dampers
and actuators, de superheaters, etc.
1.3.6
1.3.7
The steam and water analysing system including sample conditioning and
Analyzers. This includes steam, condensate & feed water analysers
1.3.8
All Gas analysers including Carbon Monoxide analysers, Zirconia type Oxygen
Analysers, particulate analysers at Stack. (The numbers shall refer to I&C
section).
1.3.9
1.3.10
1.3.11
Cable
a) The I&C cables from sensor to JB or field equipment to JB will be in SECs
scope. , If any panels are provided by SEC then cable up to panel will be in
SECs scope(like flame scanner panel). Cabling/cable from JB/Panel to
DCS will be in JSWEVLs scope.
b) Compensating cable, special cable, pre-fabricated cable, Fibre optic cable
are in SECs scope.
1.3.1.12
JSWEVL will provide redundant bulk feeders of adequate rating for UPS and
DC requirements . JSWEVL will provide only 220VDC and 220 VAC UPS
control supply. Any other voltage level required will have to be derived by SEC.
.
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Spec. No.
TCE.4857A-C510-01
TITLE
VOLUME II Part
-I
SECTION: C3a
SHEET 6 OF 1527
OF
1.3.1.13
1.3.1.14
1.3.1.15
1.3.1.16
Furnace flue gas temperature probes, Electromatic relief valve controller, metal
Temperature measurements, local and remote Feeder control cabinets etc
1.3.2.18
1.3.2.19
1.3.2.20
1.3.2.21
Services shall include, testing , PG-Test , Guarantees etc., for all the
equipment supplied. Services
shall
also include all the required
documentation in soft and hard copies in JSWEVLs format , including As-Built
Document and preparation of Contract Document
1.3.2.22
Inspection, FAT (factory acceptance test) , SAT (site acceptance test) of critical
equipment as per JSWEVL approved procedures.
1.3.2.23
Spares, Special maintenance and erection tools and tackles required for
installation, operation and maintenance of C&I equipment & system.
1.3.2.24
1.4
Design and provision of Inertia block in RCC grade M25 over the
vibration isolation system for, Mills, , PA fFan, ID fFan and FD fFan ifas
required
ii)
Spec. No.
TCE.4857A-C510-01
TITLE
VOLUME II Part
-I
SECTION: C3a
SHEET 7 OF 1527
OF
iii)
iv)
1.5
1.5.1
1.5.2
Management Organisation
1.5.2.1
1.5.2.2
The SEC shall submit the names, qualifications and experience of the
proposed managerial and senior supervisory staff to be employed on the
Contract. The SEC shall indicate the number of staff, rating and seniority to
be employed to manage and supervise the Contract and list separately for
head office and site office based locations. In particular how staff are
planned to be deployed with respect to the Contract period timescale shall be
stated.
1.5.2.3
SEC shall inform the JSWEVL any proposed changes in the Senior Staff
category.
1.5.2.4
JSWEVL reserves the right to evaluate and audit the SECs management
systems and controls in the areas set forth in this section.
1.5.2.5
Spec. No.
TCE.4857A-C510-01
TITLE
VOLUME II Part
-I
SECTION: C3a
SHEET 8 OF 1527
OF
Engineering Services
1.5.3.1
SEC shall render complete engineering services for the project including
complete detailed engineering, design submission and documentation as
specified and as required for a good design and installation ensuring
efficiency, operability, availability, maintainability and reliability of the plant.
Prior to commencement of the engineering work all aspects of design, viz.,
criteria for selection and sizing of all equipment and systems, design margins,
analysis and design calculations, etc. shall be stated by the SEC in design
basis reports. As part of design submissions, the design basis reports shall
be submitted by the SEC for approval by the JSWEVL / Consultant. The
approved design basis reports
shall form the basis for the detailed
engineering work.
1.5.3.2
At any stage during the performance of the Contract, if the system warrants
improvements in the Contracted plant and consequent modification in the
equipment / system designs the SEC shall make the necessary design
modifications and carry out the / improvements in the plant with the approval
of JSWEVL/Consultant at no extra cost to the JSWEVL.
1.5.3.3
1.5.3.4
SEC shall cooperate with the JSWEVLs other Contractors and the
Consultant and freely exchange with them such technical information as are
necessary to obtain the most efficient and economical design and to avoid
unnecessary duplication of efforts. JSWEVL shall be provided with copies of
all correspondences addressed by SEC to other Contractors and the
Consultant in respect of such exchange of technical information.
1.5.3.5
For approval
For information / reference only
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TCE.4857A-C510-01
TITLE
VOLUME II Part
-I
SECTION: C3a
SHEET 9 OF 1527
OF
1.5.3.6
1.5.4
1.5.4.1
1.5.4.2
1.5.4.3
In addition, the SEC shall provide at least six (6) months before provisional
taking over of the first unit, a consolidated manual for the complete main plant
detailing out instructions for operation and maintenance.
1.5.4.4.
1.5.4.5
If after the commissioning and the initial operation of the plant, the instruction
manuals require modifications / additions, the same shall be incorporated by
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TCE.4857A-C510-01
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SECTION: C3a
SHEET 10 OF
OF
the SEC and the updated final version of the manuals shall be submitted to
JSWEVL.
1.5.4.6
1.5.5
Plant Handbook
SEC shall submit to JSWEVL, a preliminary main plant handbook
preferably in combination of A4 and A3 size sheets which shall contain
all approved design basis and design calculations, the design and
performance data of various plant, equipment and systems covering the
scope of his supply including single line flow diagrams, within twelve (12)
months from Notice to Proceed ( NTP) The final main plant handbook
complete in all respects shall be submitted by SEC three (3) months
before start-up and commissioning activities. The main plant handbook
shall be submitted in form of one (1) reproducible original and fifteen (15)
copies along with two (2) copy in Compact Disks (CDs).
(b)
As-built Documentation
SEC shall provide and keep up to date As built drawings of all
structures constructed and all equipment and accessories and
miscellaneous metal works erected or installed. These drawings shall
show all changes and revisions from the original drawings and
specifications, including the exact As-built locations, sizes and kind of
equipment and accessories, miscellaneous metal works, embedded
piping and electrical systems and other concealed items of work. These
drawings shall l be kept in SECs field office but shall l be made
available at all times for review of JSWEVL/Consultant. At the end of
every work, all entries, changes or revisions made in the drawings by the
SEC
shall be checked and approved by the Consultant. One
reproducible prints with fifteen (15) copies of all As-Built drawings shall
be progressively handed over to JSWEVL after taking over of the plant
by JSWEVL.
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TCE.4857A-C510-01
TITLE
VOLUME II Part
-I
SECTION: C3a
SHEET 11 OF
OF
1.5.6
Sub-Contractors
1.5.6.1
SEC shall submit to the JSWEVL a list of all major items/works that he
deems necessary to be sub-contracted for approval. The SEC shall not
change Sub-Contractor without prior approval of the JSWEVL.
1.5.6.2
1.5.6.3
1.5.6.4
1.5.6.5
JSWEVLs Contract reference and station name, shall l be added to all inter
works and sub-orders.
.
1.5.6.6
SECs shall ensure that their Sub-Contractors follow the requirement of the
specification and have adequate control over all aspects covered by the
specification.
1.5.7
Progress Reports
1.5.7.1
1.5.7.2
1.5.7.3
SEC shall also submit to JSWEVL monthly progress reports and any other
reports as required by JSWEVL / Lenders / Statutory authorities.
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Spec. No.
TCE.4857A-C510-01
TITLE
VOLUME II Part
-I
SECTION: C3a
SHEET 12 OF
OF
1.6
MISCELLANEOUS
a. Design and engineering
b. Consents, licenses and approvals from relevant statutory authorities other than
those obtained by the JSWEVL.
c. Packing & forwarding,inland transportation and shipping to Indian port.),
d. , Assessment of lost / damaged items in transit and helping JSWEVL to lodge
insurance claims and replacement of lost / damaged items in transit.
e. Taking custody of all the materials till the plant is officially taken over by the
JSWEVL after complete erection and successful trial run and commissioning.
f.
g. Supervising Trial run and commissioning of individual equipment/ sub-systems
and the plant as a whole to the satisfaction of the JSWEVL including supply of
temporary equipment and services for chemical cleaning, steam blowing, etc.
h. Provision for preservation of individual equipment after trial run and
commissioning (e.g. nitrogen blanketing) as necessary till take over of the
equipment.
i.
Supply of the paints on all the equipment to be erected under this specification
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TCE.4857A-C510-01
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VOLUME II Part
-I
SECTION: C3a
SHEET 13 OF
OF
k. Deployment of all erection tools & tackles, and all other implements in
adequate number, capacity and size
l.
m. Supply of necessary calibrated instruments for carrying out performance tests
of plant and equipment.
n. Taking approval of applicable statutory authorities by paying the requisite fee to
e.g., Boiler Inspector only , etc. for respective portions of work under the
jurisdiction of such statutes or laws, for which JSWEVL shall give all due
supports. In order to get approvals by Electrical and Factory inspectors, SEC
shall give all due supports (e.g. documentation) to JSWEVL.
o. Quality assurance and Quality Control of all work executed at site
p. Co-ordination and project management.
q. .
r.
Tools and tackles including all special tools and tackle, as required, for the
Main Plant equipment.
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SECTION: C3a
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OF
v. Conduct of shop and site tests as required. Conducting trial runs of the plant as
specified .
w. Conduct of performance tests for the entire main plant equipment and for the
individual equipments as required.
x. Conducting of various site acceptance tests on electrical, instrumentation and
control systems of generator, excitation system, bus ducts, field instruments
etc.
y. Supply of all cable termination / jointing kits, insulating materials, cable glands,
lugs, junction boxes, suitable sizes of cable boxes and insulating paints for
items in the scope of supply of SEC.
z. Furnishing of civil interface/loading, mechanical, electrical and instrumentation
coordination drawings indicating the details like providing of cut outs, Insert
plates, embedment of foundation bolts and providing of sleeves etc.
aa. Training of the plant JSWEVLs personnel on main plant operation and
maintenance.
bb. All other facilities/services as described in the section on 'Site Services' as per
DOW.
cc. Following documents to be submitted prior to six months start of erection to
the JSWEVL/Engineer for approval.
(a) All field quality plan for erection of complete equipment/system.
(b) Erection manual, NDT manual and welding procedure manual for all piping.
(c) .
dd. SEC should strictly submit monthly micro level equipment/material supply
programme to JSWEVL/ENGINEER before 2 nd of the particular month based
on their L1 network.
NOTE:
The above list of work is not exhaustive. The scope of work as detailed in DOW
and the above scope put together shall form the scope of supply. In addition all
other mutually agreed documents, letters,correspondences etc also shall
constitute part of Contract. Any additional works, whether or not specifically
described in this document and incidental to complete the power plant in all
respects shall be deemed to be in the scope of work of the Main Plant
Package Contractor SEC.
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OF
2.0 Terminal points and DOW- Please refer to appendix at the end of
C3.bTurbine Generator Section.
section
ii)
iii)
iv)
v)
Hot-well make-up lines from the terminal points provided by the NPPL
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SECTION: C3a
SHEET 16 OF
OF
k. Complete condensate cycle and feed water cycle piping, extraction steam &
heater drain piping, auxiliary system piping for turbine island, with hangers and
supports, valves, drains, vents, sampling points, instrument tapings, etc., as
required for steam turbine and generator auxiliaries and connected systems
l.
All consumables like oil for turbine oil system, lube oil for equipments, grease
and chemicals required up to completion of trial operation, performance test
and handing over to JSWEVL
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SECTION: C3a
SHEET 17 OF
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h. Circulation cooling water shall be closed type and its temp. shall not be more
than 38 deg. C.
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VOLUME II Part
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SECTION: C3a
SHEET 18 OF
OF
ELECTRICAL WORKS
1.2.7
1.2.8
1.2.9
1.3.1
1.3.1.1
Control system
State of the art Distributed Digital Control System (DCS) for turbine
integral controls including the following :
a)
b)
c)
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OF
Turbine protectionPLC
HP/LP Bypass system including HP/LP Bypass protection & interlock
Turbovisory system
Turbine analog controls including gland steam , Lube oil temperature
etc.,
Turbine Stress Evaluator/ Controller
DCS shall comprise data acquisition system, closed loop and open loop
controls, data highways / gateways for connecting packaged and other control
sub systems, operator stations with visual display units and control devices,
printers, engineering work stations, , etc.
In DCS, SEC shall ensure Sub Group Control based automated sequence
control for the Turbine start-up and shutdown. DCS shall have proper interfacing
withJSWELs BOP PLC
1.3.1.2 Control room mounted equipment like panels, consoles, stations, panels
cabinets, interposing relay cabinets , racks, etc.
1.3.1.3 All primary sensors like flow elements, temperature sensors.
1.3.1.4 All field instruments process switches, transmitters, local gauges etc.
All sensors related to Turbine protection, Governing system,shall be double/triple
and sensors for balance control loops will be single. However, the sensor for
turbine vibration and bearing temperature measurement shall be single.
1.3.1.5 All final control elements like control valves, de-superheaters, and actuators, etc.
All final control elements will be pneumatically operated except for Governing
valves and HP/LP Bypass valves which will be hydraulically operated.
1.3.1.6 All TG specific field instrumentation, and integral instrumentation.
1.3.1.8 All machinery monitoring instruments like bearing temperature, vibration
monitoring system in X-Y directions of all HT motors-driven equipment.
1.3.1.9 Turbovisory system including Turbine vibration measurements.
1.3.1.10
.
1.3.1.11
Spec. No.
TCE.4857A-C510-01
TITLE
VOLUME II Part
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SECTION: C3a
SHEET 20 OF
OF
JSWEVL will provide redundant bulk feeders of adequate rating for UPS/DC
supplies. JSWEVL will provide only 220VDC, 220 VAC UPS control supply.
Any other voltage level required will have to be derived by SEC.
1.3.1.13
Earthing system (separate electronic and frame earth) .For Terminal points
refer mutually agreed Terminal Points document
1.3.1.14
Emergency Fire protection push buttons and Emergency Turbine Trip push
Buttons.
1.3.1.15
1.3.1.16
1.3.1.17
1.3.1.18
1.3.1.19
Spares ,Special maintenance and erection tools and tackles required for
installation, operation and maintenance of C&I equipment & system.
1.3.1.20
1.4
Design and provision of Inertia block in RCC grade M25 over the
vibration isolation system for Steam Turbine Generator, BFP as required
vi)
Spec. No.
TCE.4857A-C510-01
TITLE
vii)
VOLUME II Part
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SECTION: C3a
SHEET 21 OF
OF
1.5
1.5.1
1.5.2
Management Organisation
1.5.2.1
1.5.2.2
The SEC shall submit the names, qualifications and experience of the
proposed managerial and senior supervisory staff to be employed on the
Contract. The SEC shall indicate the number of staff, rating and seniority to
be employed to manage and supervise the Contract and list separately for
head office and site office based locations. In particular how staff are
planned to be deployed with respect to the Contract period timescale shall be
stated.
1.5.2.3
SEC shall inform the JSWEVL any proposed changes in the Senior Staff
category.
1.5.2.4
JSWEVL reserves the right to evaluate and audit the SECs management
systems and controls in the areas set forth in this section.
1.5.2.5
Spec. No.
TCE.4857A-C510-01
TITLE
VOLUME II Part
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SECTION: C3a
SHEET 22 OF
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other system, etc. SEC shall have a separate planning and progress
monitoring team to enable timely completion of the project.
1.5.3
Engineering Services
1.5.3.1
SEC shall render complete engineering services for the project including
complete detailed engineering, design submission and documentation as
specified and as required for a good design and installation ensuring
efficiency, operability, availability, maintainability and reliability of the plant.
Prior to commencement of the engineering work all aspects of design, viz.,
criteria for selection and sizing of critical equipment and systems, design
margins, analysis and design calculations, etc. shall be stated by the SEC in
design basis reports. As part of design submissions, the design basis reports
shall be submitted by the SEC for approval by the JSWEVL / Consultant. The
approved design basis reports
shall form the basis for the detailed
engineering work.
1.5.3.2
At any stage during the performance of the Contract, if the system warrants
improvements in the Contracted plant and consequent modification in the
equipment / system designs the SEC shall make the necessary design
modifications and carry out the / improvements in the plant if applicable with
the approval of JSWEVL/Consultant at no extra cost to the JSWEVL.
1.5.3.3
1.5.3.4
SEC shall cooperate with the JSWEVLs other Contractors and the
Consultant and freely exchange with them such technical information as are
necessary to obtain the most efficient and economical design and to avoid
unnecessary duplication of efforts. JSWEVL shall be provided with copies of
all correspondences addressed by SEC to other Contractors and the
Consultant in respect of such exchange of technical information.
1.5.3.5
(b)
(a)
For approval
For information / reference only1.5.3.6 Documents submitted during bid stage,
shall be revalidated or revised as required and submitted as certified
document for approval / information of the JSWEVL/Consultant, after award of
Contract. Such documents shall include but not limited to the following:
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1.5.4
VOLUME II Part
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SHEET 23 OF
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(a)
System schematic drawings, pipeline and instrumentation diagrams
(b)
Design basis reports
(c)
Specification for major bought-out items
(d)
Equipment data sheets and general arrangement drawings
(e)
Materials for construction
(f)
Layout drawings
(g)
Operation logic diagrams
(h)
Typical control circuits
(i)
Protection schemes
(j)
Quality assurance plan (for works & erection etc)
(k)
Project engineering, procurement, supply, and commissioning schedule
(l)
Inputs required for Civil/Structural Design.
Operating Manuals and Maintenance Instructions
1.5.4.1
1.5.4.2
1.5.4.3
In addition, the SEC shall provide at least six (6) months before provisional
taking over of the first unit, a consolidated manual for the complete main plant
detailing out instructions for operation and maintenance.
1.5.4.4.
1.5.4.5
If after the commissioning and the initial operation of the plant, the instruction
manuals require modifications / additions, the same shall be incorporated by
the SEC and the updated final version of the manuals shall be submitted to
JSWEVL.
1.5.4.6
1.5.5
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(a)
VOLUME II Part
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SECTION: C3a
SHEET 24 OF
OF
Plant Handbook
SEC shall submit to JSWEVL, a preliminary main plant handbook
preferably in combination of A4 and A3 size sheets which shall contain
all approved design basis and design calculations, the design and
performance data of various plant, equipment and systems covering the
scope of his supply including single line flow diagrams, within twelve (12)
months from Notice to Proceed ( NTP) The final main plant handbook
complete in all respects shall be submitted by SEC three (3) months
before start-up and commissioning activities. The main plant handbook
shall be submitted in form of one (1) reproducible original and fifteen (15)
copies along with two (2) copy in Compact Disks (CDs).
(b)
As-built Documentation
SEC shall provide and keep up to date As built drawings of all
structures constructed and all equipment and accessories and
miscellaneous metal works erected or installed. These drawings shall
show all changes and revisions from the original drawings and
specifications, including the exact As-built locations, sizes and kind of
equipment and accessories, miscellaneous metal works, embedded
piping and electrical systems and other concealed items of work. These
drawings shall l be kept in SECs field office but shall l be made
available at all times for review of JSWEVL/Consultant. At the end of
every work, all entries, changes or revisions made in the drawings by the
SEC
shall be checked and approved by the Consultant. One
reproducible prints with fifteen (15) copies of all As-Built drawings shall
be progressively handed over to JSWEVL after taking over of the plant
by JSWEVL.
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SHEET 25 OF
OF
1.5.6
Sub-Contractors
1.5.6.1
SEC shall submit to the JSWEVL a list of all major items/works that he
deems necessary to be sub-contracted for approval. The SEC shall not
change Sub-Contractor without prior approval of the JSWEVL.
1.5.6.2
1.5.6.3
1.5.6.4
1.5.6.5
JSWEVLs Contract reference and station name, shall l be added to all inter
works and sub-orders.
1.5.6.6
SECs shall ensure that their Sub-Contractors follow the requirement of the
specification and have adequate control over all aspects covered by the
specification.
1.5.7
Progress Reports
1.5.7.1
1.5.7.2
1.5.7.3
SEC shall also submit to JSWEVL monthly progress reports and any other
reports as required by JSWEVL / Lenders / Statutory authorities.
ISSUE
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Consultants: TCE CONSULTING ENGINEERS LIMITED
Spec. No.
TCE.4857A-C510-01
TITLE
VOLUME II Part
-I
SECTION: C3a
SHEET 26 OF
OF
1.6
MISCELLANEOUS
a. Design and engineering
b. Consents, licenses and approvals from relevant statutory authorities other than
those obtained by the JSWEVL.
c. Packing & forwarding,shipping to Indian port.
d. Assessment of lost / damaged items in transit and helping JSWEVL to lodge
insurance claims and replacement of lost / damaged items in transit.
e. Taking custody of all the materials till the plant is officially taken over by the
JSWEVL after complete erection and successful trial run and commissioning.
f.
ISSUE
R0
Consultants: TCE CONSULTING ENGINEERS LIMITED
Spec. No.
TCE.4857A-C510-01
TITLE
VOLUME II Part
-I
SECTION: C3a
SHEET 27 OF
OF
ISSUE
R0
Consultants: TCE CONSULTING ENGINEERS LIMITED