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Bharat Heavy Electricals Limited

Piping Centre, Chennai-600017


ENGINEERING DEPARTMENT

SPECIFICATION NO. REV NO SHEET NO


PC: TELANGANA-AUX-BLR:DOS 00 1 OF 11

TITLE: SPECIFICATION FOR LP & HP DOSING SYSTEM (SKID-MOUNTED)

PROJECT: TELANGANA STPP AUXILIARY BOILER(1X60t/hr)

CUSTOMER: NTPC LIMITED

CONTENTS

1. Scope of Work and Supply


2. Equipment Specification (LP & HP Dosing)
3. General technical requirement
4. Spares
5. Dosing pumps –HP / LP
6. Tank constructional requirements
7. Inspection and Testing
8. Documents to be furnished along with offer
9. Contract documentation and final documentation.
Encl:
1.) Data sheets A,B,C and D
2.) Technical Specification of HT & LT Motor. ( PC:TSP:81059, REV-04 )
3.) HP & LP Dosing - C&I checklist
4.) List of signal exchange between LCP and DCS C&I
5.) LT motor datasheet
6.) Technical Specification For Supervisory Control Panel For HP & LP Dosing System
7.) HP and LP Dosing Scheme No 1-00-302-32884 and Valve Schedule
Drg. no. 4-00-306-40934.
8.) List of Mandatory spare – Annexure 5C

00 15-06-17 FRESH ISSUE MATHANGI.D C.SARAVANAN R.PRABHA


Rev Date Alteration Prepared Approved(Mech.) Approved(C&I)
Bharat Heavy Electricals Limited
Piping Centre, Chennai-600017
ENGINEERING DEPARTMENT

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TECHNICAL SPECIFICATION FOR LP & HP DOSING SYSTEM

1.0 SCOPE OF WORK AND SUPPLY

1.1. SCOPE OF WORK:


The scope of work of this specification shall include design, manufacturing and supply
of LP and HP dosing system as detailed in the various sections of this specification.

1.2. SCOPE OF SUPPLY :


Complete assembly (skid mounted) of LP & HP Dosing system as detailed in various
clauses of this specification. HP dosing equipments and LP dosing equipments shall be
kept in separate skids.

2.0 EQUIPMENT SPECIFICATION

2.1 LP DOSING
2.1.1 One low pressure chemical dosing plant / system, comprising of the following
are under the scope of supply of the bidder.

2.1.1.1 One no. of hydrazine mixing cum metering tank as specified in Data
Sheet-B

2.1.1.2 Tanks shall be provided with motorized agitator and breather tank, as
indicated in scheme.

2.1.1.3 Two hydrazine dosing pumps (one working and one standby) for normal
operation, as specified in data sheet-A. All the pumps are motor
operated and are to be provided with safety relief valve, suction strainer.

2.1.1.4 All necessary structural support for all equipment including foundation
anchor bolts & nuts and ladders. All structures shall be designed as per
IS800. The dimensions of the structures shall be as per IS808 and the
fillet weld size for structure welding shall be minimum as per IS816.

2.1.1.5 All valves within the skid boundary and as specified in Scheme no. 1-00-
302-32884. All valves of material and class rating as per enclosed Valve
Schedule Drg No. 4-00-306-40934 and designed as per API602. Valves
shall be of OS&Y type with bolted bonnet having back seat arrangement.

2.1.2 All piping and fittings as per Scheme no. 1-00-302-32884 and pipe
supports within the skid/ trolley boundary (refer scheme). The
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specification for pipes and fittings are SA312TP304 & SA182F304 and
of seamless quality.

2.1.3 All fasteners within the skid boundary

2.1.4 Tank level gauges & level switches with isolating, drain valves.

2.1.5 All other instrument stubs within the skid boundary along with root valves etc.

2.2 HP DOSING

2.2.1 One high pressure chemical dosing plant /system, comprising of the
following are under the scope of supply of the bidder.

2.2.2 One phosphate mixing cum metering tank, as specified in Data Sheet-D,
Tank shall be provided with motorized agitator.

2.2.3 Two phosphate dosing pumps (one working and one standby), as specified in
Data Sheet C. All the pumps are motor operated and are to be provided with
safety relief valve, suction strainer.

2.2.4 All necessary structural support for all the equipment including foundation
anchor bolts & nuts and ladder. All structures shall be designed as per
IS800. The dimensions of the structures shall be as per IS808 as the fillet
weld size for structure welding shall be minimum as per IS816.

2.2.5 All valves of material and class rating as per enclosed Valve Schedule Drg
No. 4-00-306-40934 and designed as per API602 within the skid boundary
and as specified in Scheme No. 1-00-302-32884. Valves shall be of OS&Y
type with bolted bonnet having back seat arrangement.

2.2.6 All piping and fittings of material (SA312TP304 & SA182F304) as per
scheme no. 1-00-302-32884 and piping supports within the skid boundary.
Pipes shall be of seamless quality.

2.2.7 All fasteners within the skid boundary.

2.2.8 Level gauges & level transmitter along with root valves, drain valves.

2.2.9 All other instrument stubs within the skid boundary along with root valves
etc.
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2.3 NOTE

2.3.1 Each LP/HP chemical dosing plant shall be completely skid mounted and
packed before dispatching.

2.3.2 Suitable lifting lugs are to be provided for lifting of the skid mounted LP/HP
dosing plant.

2.3.3 Hydrazine and Phosphate dosing pumps shall be suitable for manual
adjustment.

2.3.4 Each dosing pump shall be capable to be operated under flooded suction
condition. On the hydraulic side each dosing pump shall have a relief valve to
prevent over pressure.

2.3.5 Pumps and motors shall be mounted rigidly on a steel box plate.

2.3.6 Pipe to pipe connection shall be done by socket-welded couplings as per


ASME B16.11 of suitable class rating not less than class 3000.

2.3.7 Pipe hangers and supports shall be designed and fabricated in accordance with
ASME B31.1.

3.0 GENERAL TECHNICAL REQUIREMENT

3.1 All equipment shall be completely assembled in a skid and supplied as a single
piece.

3.2 The foundation dimensions of the skid/trolley shall be submitted along with
offer.

3.3 All drains from the skid shall be interconnected and only one drain shall be let
out of the skid to Trench Ladders, if required, for feeding solution and
operating valves shall be provided on the Skid/trolley.

3.4 All instruments enclosure class shall be IP-65 & Motor enclosure class shall be
IP-55. All equipment shall be completely assembled in a skid and supplied as a
single unit.

3.5 All instruments pressure gauges, D.P. switches, DP transmitters, level gauges,
pressure transmitters, level transmitters shall be supplied as per enclosed
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ENGINEERING DEPARTMENT

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specification and data sheet. All transmitters shall be SMART type with
HART protocol, 24 V DC, 2 wire, Micro Processor based.

3.6 A local control panel (LCP) shall be supplied with housing starters for all
drives, START/STOP press buttons and indicating lamps. One feeder of
10.kW, 415 V, 3 Phase, 50 HZ will be made available to the panel. Interlocks
are built in DCS. All field instruments shall be wired up to LCP. Potential free
(PF) contacts shall be available for DCS use. Signals from DCS will be 24V
DC. Suitable relay for processing 24 V DC signals (from DCS to Local control
panel) to be provided in LCP. Please refer standard list of signal exchange
between Local Control Panel and DCS.

3.7 Supervision of dosing skid commissioning by vendor at site is required for


minimum of 2-3 days

3.8 MOTOR FOR DOSING PUMP & AGITATOR:

3.8.1 Motor shall be rated for 415 V, 3ϕ, 50 Hz and shall comply with enclosed
specification (PC: TSP: 81059 R04). All motors shall be of Energy Efficient
type, Either High Efficiency (IE2) as per IEC:60034-30 or Premium
Efficiency (IE3) as per IEC:60034-30. & Motor enclosure class shall be IP-55.
Refer project specific “C&I checklist” made available as part of Enquiry
Documents.

4.0 SPARES

4.1 Commissioning spares if any for all items:


Commissioning spares are those spares which may be required during start up
and Commissioning of the unit. Bidder must supply these spares.

4.2 Recommended spares for all the items shall be indicated as applicable.

4.3 Mandatory Spares


Price of Mandatory spares shall be quoted separately as per list furnished by
BHEL as per annexure 5C enclosed
Bharat Heavy Electricals Limited
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ENGINEERING DEPARTMENT

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5.0 DOSING PUMP – HP/LP

5.1 Basic Design

5.1.1 The pumps shall be designed fabricated tested and supplied strictly in
accordance with Hydraulic Institute standards/ API 675 Positive
displacement pump – controlled volume 2012 edition.

5.1.2 Pumps shall have positive return stroke mechanism.

5.1.3 Unless otherwise specified, equipment will be made suitable for


outdoor installation without a roof.

5.1.4 Unless otherwise specified, pipe flow rate shall be adjustable over the
range of 0% to 100% of rated capacity while the pump is running.

5.1.5 Pump rated capacity shall be at least 10% more than the maximum
capacity specified by the purchaser.

5.1.6 For operation of pump without loss of accuracy the pump speed shall
not exceed 100 strokes per minute.

5.1.7 The flow repeatability shall be within ±3% over the entire range of
pump for full stroke variation.

5.1.8 All pump suction valves shall be with Limit Switch Open Contact

5.2 Connections
Inlet outlet connections shall be flanged and shall be suitable for design
pressure. Flanges shall be forged and conform to ASME B16.5 rating to suit
design parameters.

5.3 Packed Plungers

5.3.1 Requirement of jacketed housing shall be recommended by the vendor


for the fluid being pumped.

5.3.2 The cylinder supporting assembly, stuffing box and plunger assembly
shall be designed and machined in such a manner, so as to ensure
concentricity of plunger movement and stuffing box bore. This is to
ensure perfect seating and minimum leakage with prolonged life of
packing.
Bharat Heavy Electricals Limited
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5.4 Pulsation Suppression Devices

5.4.1 Pulsation suppression device shall be furnished when indicated in data


sheet.

5.4.2 Unless otherwise specified elsewhere, pulsation suppression device,


when specified, shall be designed in such a way as to give amplitude of
pulsation within the limit of ±3% of mean.

5.4.3 Selection of material of pulsation dampener and bladder shall be


suitable for the liquid being handled.

5.4.4 When bladder type suppression device is specified, gas changing


assembly kit shall be supplied by the vendor along with necessary
instruction for use.

5.4.5 Relief Valve


Unless otherwise specified relief valve, for packed plunger pump shall
be furnished by the vendor and shall be mounted on pump discharge
flange or on purchaser’s piping. The relief valve setting pressure shall
be 10% over the rated discharge pressure or 1 kg/cm2 over the rated
discharge pressure whichever is lower. Relief valve shall be single coil
type and shall be procured from a reputed manufacturer. Material of
construction of relief valve shall be equal or better than that of main
pump wetted parts, however, shall be AISI 304 or superior. End
connections of relief valve shall be flanged type and shall be connected
to suction source by the Purchaser. Relief valve shall be selected to
pass 100% rated capacity of pump when fully open to limit
accumulation pressure to 110% of rated discharge pressure.

5.4.6 Capacity Adjustment


Capacity control shall be local manual as specified on data sheet.

6.0 TANK CONSTRUCTIONAL REQUIREMENTS

6.1 Tank
6.1.1 The tank shall be of stainless steel material (SA240 type 304) of
thickness not less than 4 mm.

6.1.2 The tank shall have minimum 3 supporting legs (non-despatchable)


made of MS of minimum 6 mm thickness. Access platform along with
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ladder for charging chemicals, inspection and maintenance of tank,


agitator etc. to be provided for each skid.

6.1.3 Foundation bolt and nuts shall be supplied for fixing the tank to the
floor pedestal.

6.1.4 A drain connection shall be provided at the bottom most point of the
tank and the size shall be as mentioned in the data sheet.

6.1.5 The solution outlet shall be above the bottom end cover (hemispherical
or torispherical cover) and the size shall be as mentioned in the data
sheet.

6.1.6 The vent, observation hole and solution inlet shall be on the top portion
of the vessel. The vent pipe shall be bent to 180 Degree (so that no rain
water enters the tank). The vent size shall be as mentioned in the data
sheet.

6.1.7 The size of the water inlet connection shall be a mentioned in the data
sheet.

6.1.8 All connection pipes shall be flanged as per ASME B16.5.

6.1.9 Necessary lugs for handling the tank shall be provided on the tank.

6.1.10 Necessary stubs for connecting level switches & level gauges shall be
indicated.

6.1.11 Values of normal level, low level & high level shall be furnished with
back up calculations.

6.1.12 The tank shall be designed as per ASME Sec VIII.

6.1.13 HP dosing tank shall be provided with a removable dissolving basket


having sufficient volume for dissolving phosphate in the water. The
basket material shall be stainless steel AISI 316 and shall have opening
of 4 mesh.

6.1.2 The hydrazine dosing tank shall be provided with a breather complete with plugged
drain, plugged filling, air inlet and outlet connection. The breather shall be
supported from the tank shell by means of a bracket. The inlet water connection
shall preferably have tangential entry to the tank.
Bharat Heavy Electricals Limited
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ENGINEERING DEPARTMENT

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6.2 AGITATOR

6.2.1 The tank shall be provided with one top entry motor operated agitator
with suitable gear box and coupling. The rated speed of the agitator
shall be furnished.

6.2.2 The material of the impeller and the shaft carrying the impeller shall be
of SS316.

6.2.3 The motor for the agitator shall conform to LT motor specification
enclosed.

6.2.4 The motor details are to be furnished as per the enclosed ‘Proforma on
Motor Information’.

6.3 GENERAL

6.3.1 The trial assembly and test run shall be carried out at the
manufacturer’s works for the satisfactory working of the equipment.
The time of carrying out the test shall be informed to the Purchaser in
advance. Purchaser has the right of witnessing the test.

7.0 INSPECTION AND TESTING

Quality requirements shall be inline with BHEL Standard Quality Plan

8.0 DOCUMENTS TO BE FURNISHED ALONG WITH THE OFFER

8.1 General arrangement drawing of the skid mounted LP/HP dosing system,
showing the following:
8.1.1 8.1.1 Overall dimension (l*b*h)
8.1.2 Shipping dimension (l*b*h*)
8.1.3 Total weight of the LP/HP dosing system
8.1.3.1 -without liquid
8.1.3.2 - with liquid
8.1.4 No. of foundation pockets with details of foundation showing the
following as minimum.
8.1.4.1 Finished floor level
8.1.4.2 All dimensions of foundation bolt and nut
8.1.4.3 All dimensions of foundation pocket
8.1.4.4 Load acting on each foundation pocket
8.1.4.5 Location of all equipment in the skid
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8.1.4.6 Structural detail

8.2 Separate general arrangement drawing with overall dimensions is required for
the following equipment :

8.2.1 Hydrazine and phosphate dosing pumps with drive motor fixed on
common base plate.
8.2.2 Hydrazine and phosphate measuring tank with nozzle orientation.

8.3 Complete scheme of LP/HP dosing system (to be prepared based on the
scheme enclosed with this specification) containing minimum the following:

8.3.1 Legend showing all symbols used in the scheme (no symbol shall be
left in the tabulation)
8.3.2 All pipe sizes (OD x Thk)

8.4 Manufacturing Quality Plan for BHEL’s approval.

8.5 Complete valve schedule indicating size, class, material, connecting pipe size,
type of connection, quantity etc.

8.6 Drawings of relief valve, strainer, level gauges, level switches, valves
indicating end connection details, material specification, parameters, testing
standards, weight etc.

9.0 CONTRACT DOCUMENTATION AND FINAL DOCUMENTATION


(15 copies each unless marked otherwise)

9.1 Drawings in Section 8.0


9.2 Performance testing curves for the pump and motor
9.3 Filled up data sheets A, B, C and D.
9.4 Catalogue for pump, motor, valves etc.
9.5 Erection, commissioning, operation and maintenance manual containing the
following:
9.5.1 Relevant drawings
9.5.2 Filled up data sheets
9.5.3 List of special tools and quantity
9.5.4 List of lubrication oil schedule
9.5.5 Erection, commissioning procedure and precautions to be taken.
9.5.6 Operating and maintenance instruction and precaution to be taken.
9.5.7 Wiring diagram, if any.
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9.5.8 Instrument data sheets.


9.5.9 Motor data sheets.
9.5.10 Panel drawings.
9.5.11 Foundation drawing for HP dosing System
9.5.12 Foundation drawing for LP dosing System
9.5.13 Fabrication details of Phosphate tanks
9.5.14 Fabrication details of Hydrazine tanks
9.5.15 Fabrication details of Breather tanks
9.5.16 GA details of motorized Stirrer fixing Details for hydrazine tanks
9.5.17 Details of agitator for phosphate tanks
9.5.18 Details of level switch chamber and mounting
9.5.19 Datasheet for level gauge
9.5.20 Datasheet for level switch
9.5.21 Datasheet for metering pumps
9.5.22 Datasheet for Pressure relief valve
9.5.23 GA of Pressure relief valve
9.5.24 Datasheet for Pressure switch
9.5.25 Datasheet for Diff Pressure switch
9.5.26 Datasheet for Pressure Gauge
9.5.27 Datasheet for Diff Pressure Gauge
9.5.28 Datasheet for Y type strainer
9.5.29 Datasheet for Valves
9.5.30 Datasheet for 3 Way Valve
9.5.31 General assembly of pump
9.5.32 Drawing for LP Dosing system
9.5.33 GA drawing for HP Dosing system
9.5.34 PID for LP Dosing system
9.5.35 PID for HP Dosing system