Sample power plant specification

7/24/2019 Sample power plant specification

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FACOR ALLOYS LIMITED45 MW CAPTIVE POWER PLANT AT GARIVIDI, ANDHRA PRADESH.

EPC TENDER SPECIFICATION

TABLE OF CONTENTS

S. No. Description No. of

pages

EPC Main Specification 1 to 22

Annexure-1 Specification for Boiler & Auxiliaries 1 to 20

Annexure-2 Specification for Turbogenerator & Auxiliaries 1 to 22

Annexure-3 Specification for Air Cooled Condenser 1 to 4

Annexure-4 Specification for Fuel Handling System 1 to 10

Annexure-5 Specification for Electrical System 1 to 26

Annexure-6 Specification for Ash Handling System 1 to 4

Annexure-7 Specification for DM Plant, Auxiliary Cooling Tower,

Ventilation and Fire Fighting System

1 to 4

Annexure-8 Specification for Instrumentation & Automation

System

1 to 23

Annexure-9 Scope Matrix 1 to 82

Annexure-10 Questionnaire 1 to 103

Annexure 11 Vendors List 1 to 11





1.0 GENERAL

M/s.Facor Alloys Limited (FAL ) are proposing to install a CPP, a TG set of

rating 45 mw along with a CFBC boiler of capacity 195 TPH with steam

parameters of 110 ata and 545 deg c.

This specification is issued for implementation of the 45 MW CPP and its

auxiliaries through the EPC mode. This specification covers the design,

engineering, manufacture, assembly / re-assembly, tests at manufacturer’s works,

packing, ocean shipment and clearance through Indian Port of entry in case ofimported plant & equipment, inland transportation, in-land delivery to the site,

unloading, storage and in-plant transportation within site, complete civil and

structural design and construction work as required for the plant and facilities

covered by this specification, complete services of erection, testing, successful

commissioning, carrying out PG test, handing over and training of Purchaser’s

personnel, for the power plant complete with all accessories, auxiliaries and

ancillaries as specified hereinafter and elsewhere of this specification and as

required for safe and trouble free operation of the facilities.

The scope shall broadly include the equipment / systems, described in the

subsequent sections of this specification, but shall not be necessarily restricted to

these only. Whatever additional items necessary for safe and efficient operation

of the equipment / systems described elsewhere in this specification, shall also be

included as a part of the total services to be offered by the bidder



FACOR ALLOYS LIMITED45 MW CAPTIVE POER PLANT AT GARIVIDI, ANDHRA PRADESH.


EPC Spec (Cont’d)

132 KV and vice versa. The power plant will have an HTpower distribution system

at 3.3 KV and an LT power system at 415 V.

1.1.2 Water: Source of Raw water for cooling and other uses in the plant will be from

the nearby abandoned rivers bunta and bore wells in the area. The approximate

analysis of the raw water from the 2 sources is given below:

Constituent

in

PPM

Abandoned

Bore

well

Mines Bunta

Total

Hardness

140

380

TDS

200

500

PH 8 8

Phenolphthalein Alkalinity 12 NIL

Methyl

Orange

Alkalinity

120

270

The raw water will have to be suitably treated and supplied as make up to the

auxiliary cooling water system and DM plant of the power plant as well as other

uses such as fire fighting, drinking etc. EPC bidder shall include for a raw water

storage tank of capacity 2000 cum in his scope. All necessary treatment facilities

for raw water shall be included in their scope by the EPC bidder.

1.2 PLANT LAYOUT

1 2 1 The proposed plant general layout of the existing facilities indicating the





EPC Spec (Cont’d)

information required for bidding, before submitting the Bids. No claim on account

of any ambiguity due to variations/changes in above conditions will be entertained

by purchaser subsequent to finalisation of contract.

Location : Garividi, Vijanagaram Dt, Andhra

Pradesh.

Max. dry bulb temp. : 45oC

Site altitude above MSL : 125 mt

Design dry bulb temp. for

Electrical equipment

: 50oC

Relative humidity for de sign : 80%

Design wet bulb temperature : 28 deg C

Wind Velocity at 10M

elevation

: 8 m/s as per IS 875 (Part 3)-

1987

Susceptibility to earthquake : Zone III as per IS 1893-20





EPC Spec (Cont’d)

International Electric technical commission (IEC) Publication and also within the

statutory requirements of the Government of India and Government of Orissa as

regards safety, ear thing and other provisions specified therein for installation and

operation of electrical equipment.

1.4.5 The Bidder shall be responsible for obtaining necessary approval and clearance

and making whatever additions / modifications considered necessary by CEIG /

Electricity Company and other Statutory Authorities to bring the installation in

conformity with the above Rules / Regulations at various stages during executionof this contract.

1.4.6 All Environmental / Pollution Control measures and Monitoring devices are to be

incorporated as per the requirement of relevant standards under Environmental &

Safety Act and as per the stipulations of Pollution Control Board of the state in

which plant is located.

1.4.7 Internationally accepted standards which ensure equal or higher performance

than those specified shall also be accepted.

1.5 STANDARDISATION

1.5.1 Contractor shall standardise various types and make of equipment and

accessories in order to reduce diversity, convenience of operation and

maintenance and minimise inventory.





EPC Spec (Cont’d)

1.5.5 Systems shall be designed incorporating the latest technology and maximum

flexibility in operation with sufficient stand-by provision. All system design shall be

subjected to the approval of Purchaser.

1.5.6 Equipment furnished by the Bidder shall be complete in every respect with all

mountings, fittings, fixtures and standard accessories which are normally supplied

even though not specifically detailed in the specification. The Purchaser shall not

be called for any extra payment in respect of such mountings, fittings, fixtures and

accessories which are needed for the safe operation of the equipment as requiredby applicable codes within Indian Territory though they may not have been

included in this contract.

1.5.7 All equipment shall have suitable approach ladder and platform for repair and

maintenance wherever necessary.

1.5.8 The Bidder shall endeavour to utilise and adopt same codes, standards, and

norms keeping in mind the minimum variation & comprehensive standardisation of

the different spare parts for similar / identical basic component / equipment,

machinery and for the plant as a whole.

1.6 DOCUMENTS FORMING PART OF THIS TENDER

1.6.1 The following documents enclosed to this specification shall be considered as a

part of this tender Document:





EPC Spec (Cont’d)

1.6.2 Bidder shall note that the layout drawings and schematic diagrams furnished with

this specification are for the specific purpose of clarifying purchaser’s

requirements, which are to be considered for preparing the bid. The schematic

diagrams and layout drawings enclosed with this specification are not valid for

interpretation of scope of work during contract execution stage. Successful bidder

shall prepare drawings and schematic diagrams as required for equipment offered

taking also into consideration the technical specification and typical schematic

diagram for manufacturing, supply and erection. Drawings and schemes whichare finally approved by purchaser shall determine the respective scope of supply

& erection and responsibility of supplier.

1.7 COMPLETE SERVICES TILL COMMISSIONING

1.7.1 The scope of service under this specification has been elaborated in above

clauses. It is stressed that all responsibility from design, manufacture to

successful commissioning and performance acceptance test at site rests totally onthe successful Bidder. Purchaser shall not, in any way, be responsible for any

delay in transportation and clearance through Indian Port of entry.

1.7.2 In case bidder offers equipment from foreign sources, it is suggested that bidder

shall employ reputable Indian agents who will furnish necessary helps to ensure

speedy clearance through port, handling and transportation. Bidder / Indian agent

h ld k i it t th it b f b i i f ff i d t th





EPC Spec (Cont’d)

attended to and the entire trial run repeated for another 15 days. On successful

completion of the trial run and reliability test the boiler will be taken over by the

Purchaser and a Provisional Acceptance Certificate (PAC) issued.

1.8.2 All equipment shall be guaranteed for workmanship and materials, and

satisfactory performance. The guarantee for performance shall cover individual

items and systems including electrics for their ratings/outputs, as required in the

specification. On issue of the PAC as mentioned in para 1.8.1 above supplier shall

conduct the performance guarantee tests within 1 month of issue of PAC toestablish the various parameters guaranteed by him in the contract.

1.8.3 Instruments, gauges and flow meters installed for the normal operation of the

equipment shall be made use of during the acceptance tests as far as practicable.

However, if there is no panel-mounted instrument for measurement, separate

calibrated instruments shall be hooked up for the performance test purpose.

Temporary meters required for PG test shall be arranged by the contractor. ThePerformance test on the unit shall be conducted within one month from the date of

Provisional taking over. Upon successful completion of the Performance tests,

and compliance of all contractual conditions by the contractor such as submission

of all final drawings and documents, as built drawings and operation &

maintenance manuals etc. as well as fulfilment of all other obligations, Purchaser

will issue to contractor a final acceptance certificate.





EPC Spec (Cont’d)

to be mutually agreed upon. A maximum of two chances will be given for repair

and retest to bring the parameters within the guaranteed values and the total time

period for such retests shall be a maximum of 4 months from the date of

commissioning. However, if the performance guarantees are not proved within the

above attempts or time period Liquidity Damages (LD) / price reduction as defined

in following clause will be applied in the case of some of the parameters

1.9 LD CLAUSE / PRICE REDUCTION:

1.9.1 Price reduction for Non performance:

The following LD/price reduction shall be applicable in case of non-achievement of

guarantee parameters as per Para 1.8.4 above:

Nature of

Shortfall

LD/price reduction rate Limit of non acceptability

Maximum

continuous rating

of boiler

0.5% of contract price for

every 1% deficiency or part

thereof.

Deficiency up to 2% will be

accepted with LD. Beyond

2% equipment will have to

be rectified by supplier to

bring it within the

acceptable limit.

Steam pressure

d t t

Not applicable No tolerance is acceptable

th t





EPC Spec (Cont’d)

efficiency or part thereof. 2 % equipment will have to

be rectified by supplier to

bring it within the

acceptable limit at no extra

cost to Purchaser.

Guaranteed

Auxiliary power

consumption

Rs. 1.5 lakhs for every 1 KW

additional power

consumption over theguaranteed value

Increase in auxiliary power

consumption upto 3% will

be accepted with LD.Beyond 3% equipment will

have to be rectified by

supplier to bring it within

the acceptable limit at no

extra cost to Purchaser.

If the total value of the penalties for shortfall in performance exceed ten percent

(10 %) of Total Contract price, and the supplier has expressed his inability to rectify the

defects & bring the equipment performance to the guaranteed value, then the purchaser

retains the option to reject the equipment, and in case of such option the supplier shall,

jointly and severally, replace the equipment with one, which shall meet the guaranteed

values. The replacement shall be done within a reasonable period mutually agreed and

with no extra cost to the purchaser.

F th it f hi h h tf ll i f i t t bl b d th





EPC Spec (Cont’d)

1.9.2 Price reduction for Delay in Delivery:

Time is the crux of the project. The supplier shall endeavour to deliver, install &

commission the plant within time period specified in contract. If the supplier fails to

deliver, install & commission any or all the goods within time period, specified in contract

the Purchaser shall, without prejudice to his other remedies, under contract, deduct from

the contract price, as liquidated damages, a sum equivalent to 0.5% of the total contract

price for each week of delay up to maximum 5 % of contract price. Once the maximum is

reached the purchaser may consider termination of the contract.

1.9.3 Total LD / price reduction

The total price reduction on account of both clause 1.15.1 and 1.15.2 above shall

be applicable independently subject to an overall ceiling (considering an aggregate of all

items) of 10% of the total contract price.

1.10 INSPECTION AT WORKS FOR IBR CLEARANCE:

Equipment shall be offered for inspection prior to despatch. The test shall be

conducted as per the procedure laid down by the concerned Indian Boiler Regulations

(IBR) and got cleared by Boiler Inspectorate for pressure parts as per IBR. Third party

inspection by internationally reputed testing agencies like Lloyds inspection, BVQI shall

be arranged by supplier as per requirement of Indian Boiler Inspectorate. All necessary

cost for getting the IBR clearance shall be included by the bidders in their offers.





EPC Spec (Cont’d)

inspection clearance for that stage. Items shall not be despatched without

obtaining inspection clearance.

1.11.3 If any defect / deviation are observed, the same shall be recorded in the report

and corrective measure that will be taken shall be discussed and mutually agreed.

If the correction is not accepted by the testing engineer, the same shall be

referred to the designer / consultant for review and approval. In due course of

inspection, if any additional tests are required to be carried out, the same shall be

done without any additional cost to the purchaser.

1.11.4 Items will be categorised as A, B and C. Major items whose testing is to be

witnessed are categorised as “A” and those items, which are not to be witness

tested, shall be categorised as “B”. All other items like foundation bolts, support

structures and similar items shall be categorised as “C”. Itemised categorisation

will be done at the time of finalisation of order. All routine tests for category A as

per applicable standards will be witnessed by the inspection Engineer. Materialtests certificates and internal inspection test certificates shall be submitted for

category B. Items categorised as category C may be despatched by suppliers

after ensuring the quality themselves.

1.11.5 Even though inspection is conducted, if any defect is found at site, the same shall

be corrected / replaced by supplier without any additional cost to the purchaser.

1 11 6 F ll i d h ll b b i d d b i d f h





EPC Spec (Cont’d)

/ FHS / AHS test

2Bought outs like boiler feed

pumps etcX, T, W -

3 Control Panels X, T,D -

4 Instruments & control X, T -

5 Motors X, T -

6 MCC X, T, W, D

X –Routine tests to be conducted

T – Type test Certificates to be submitted for review

W – Factory tests will be witnessed by purchaser

D – Dimensional, general arrangement, workmanship, finish checks

The modalities & the QA plan proposed will be discussed & mutually agreed.

1.12 BOILER REGISTRATION

The boiler shall be manufactured as per Indian Boiler Regulations with latest

amendments. One set of relevant documents and certificates signed by the Chief

Inspector of Boilers of concerned state shall be forwarded to the customer. Boiler

registration formalities, IBR approval and approval by other statutory bodies shall be done

by tenderer. However, Purchaser shall pay only the statutory fees to the concerning





EPC Spec (Cont’d)

1.15 SUPERVISION FOR ERECTION AND COMMISSIONING

Experienced engineers shall be posted at site for erection supervision by the

contractor who shall interact with consultant and client on a day-to-day basis and

reporting shall be on daily basis. For major bought out items like boiler feed pumps etc.

erection & commissioning engineer from OEM shall be made available by contractor.

1.16 TRAINING

All system shall be operated by O&M group of the client from the day of start ofcommissioning under the direct supervision of the commissioning team deployed by

contractor. Commissioning engineers of contractors shall operate for at least 6 months

from the date of reaching 60% of full power operation. During the 6 months O&M team

shall be trained and gain confidence for independent operation.

1.17 SUBLETTING OF CONTRACT

Bought out items shall be procured from approved vendors only. List of suggestedvendors is enclosed as Appendix to this specification. The Contractor shall not without the

consent in writing of the Purchaser/Consultant, which shall not be unreasonably withheld,

assign or sublet his Contract or any substantial part thereof other than for raw materials,

for minor details, or for any part of the works of which the makers are named in the

Contract, provided that any such consent shall not relieve the Contractor from any

obligation, duty or responsibility under the Contract.





EPC Spec (Cont’d)

1.21 DRAWINGS AND DOCUMENTS

1.21.1 Information to be furnished with the tender

Bidders shall submit following drawings along with the bid for review before

finalisation of the tender.

General layout of Boiler and Auxiliaries proposed by the bidder.

Scheme diagrams of Boiler steam system, Feed water system, Auxiliary

system steam, Deaerator etc.,

1.21.2 Drawings to be submitted after award of contract

Bidders shall submit following drawings after award of contract.

a) Approval category

Basic design drawings, general arrangement drawings, P&I diagrams,

procurement data sheets for bought out items, pipe routings, electrical single line

diagrams, electrical relays schedules shall be included in the approval category of

drawings. List of drawings, which will be in approved category, will be finalised at the time

of placement of order.

b) Certified data /Drawings for purchaser’s input

Contractor shall submit following drawings for purchaser’s design inputs.





EPC Spec (Cont’d)

Instructions showing pre-requisites and procedure for erection

Erection drawings for proper erection and assembly of all equipment.

Pre commissioning check list for erection completion which will be signed

as protocol for erection completion

Commissioning procedures

Check list for completion of commissioning as part of protocol for

commissioning

Handing over protocol

e) Inspection and Test reports

Purchaser shall submit all factory test reports and inspection reports, minutes of

meeting during inspection etc. and protocol for erection completion, commissioning

protocol etc. at the end of contract for purchaser and plant records.

f) Operation and maintenance manuals

Contractor shall supply of the following documents & drawings with the delivery of

equipment.

Operation and maintenance manuals.

List of recommended spare parts with specification and supplier reference.





EPC Spec (Cont’d)

All design drawings shall be oriented to match the plant arrangement drawings

and shall have a key plan identifying the plant area to which they apply. All layoutdrawings shall be made with the NORTH arrow pointing to the TOP of the sheet.

1.22 MISCELLANEOUS

1.22.1 Painting

All items of equipment shall be thoroughly cleaned and painted with two coats of

approved primer and two coats of approved alkyd based finish paint as per

standard practise of the equipment supplier. The successful bidder shall furnish

painting procedure for equipment, piping, structural and other items before start of

erection or before fabrication of the items.

1.28.2 Lubrication

All equipment shall have adequate lubrication arrangements for smooth and

efficient operation. Sufficient lubrication points shall be provided wherevernecessary and all such points shall be easily accessible. Grease guns shall be

provided wherever necessary.

1.23 SPARES, TOOLS AND TACKLES & CONSUMABLES

1.23.1 Commissioning Spares

Provision for all spares required for commissioning of the equipment and for its





EPC Spec (Cont’d)

1.23.5 Consumables, etc.

All consumables for erection, testing and commissioning including first fill of all

items such as oil, grease, etc till handing over of the plant and equipment to purchaser

shall be in the scope of the supplier.

2.0 SCOPE OF THE SPECIFICATION

2.1 The scope of supply of equipment and services covered by this specification are

detailed in various sections of this specification. Any item, though not specificallymentioned but required to make the power plant and auxiliaries complete in all

respects and for its reliable and safe operation and guaranteed performance shall

be included by the tenderer in his offer. Obtaining statutory approvals and

clearances at appropriate stages from various authorities shall also be treated as

though included and the bidder shall include the same, unless otherwise

specifically excluded elsewhere.

2.2 Basic and detailed engineering services including but not limited to the following

for the proposed CPP are covered by this specification:

• Basic engineering for the complete Power Plant covering complete process

design, process calculations, material and heat balance, complete system

design for plant and equipment including utilities, electrics, and

instrumentation and automation systems.





EPC Spec (Cont’d)

2.3 Supply, erection, testing and commissioning of the following equipment, systems

and services for the power plant are included in this specification:

• One (1) Boiler of CFBC design capable of using coal washery rejects,

Indian coal G grade,and Indonesian coal as fuel.However the boiler should

be designed for 100% coal washery rejects. The capacity of the boiler shall

be 195 TPH at required pressure of temperature. The boiler and auxiliaries

shall be as per enclosed specification.

• One (1) Turbo generator set of capacity 45 MW at the designed inlet steam

and temperature. The TG and auxiliaries shall be as per enclosed

specification.

• One (1) Air cooled condenser with air extraction equipment and other

auxiliaries for the turbine and a set of condensate extraction pumps with

drive motors and other accessories. The ACC and auxiliaries shall be as

per enclosed specification.• Complete piping, auxiliary piping, and interconnecting main steam, feed

water, condensate, auxiliary steam etc. complete with hangers, supports,

valves, specialties, etc. for each TG unit

• Raw Water Treatment and auxiliary cooling water system with pumps &

accessories DM plant etc. as per specification enclosed.





EPC Spec (Cont’d)

• Fire detection and protection systems & accessories complete with

detectors, electrics, pumps & associated accessories, pipe work etc andportable C02 extinguishers and sand filled buckets for electrical rooms,

transformer area, control room, cable vaults, etc. as per requirements

• HVAC System & its accessories for turbine building operating and ground

floor, electrical room, battery charger room, control room, office room etc.

including air conditioning & ventilation systems with package and split type

air conditioners, air handling units for washed air supply systems supplyand exhaust fans & associated ducting, piping etc.

• Mono rails with electric hoists for ESP, boiler, pump houses and other

areas as required for maintenance.

• Inspection at Factory, Quality control at manufacturing works, testing of all

the equipment as specified and as per the requirement of Indian Boiler act.

• Commissioning spares as required for all equipment / plant / systems asrecommended by the respective manufacturers for successful

commissioning and operation of the plant till the system is handed over

after successful performance guarantee tests.

• Packing and forwarding, arranging transport inland or sea transportation,

port handling and clearance of imported equipment safe transportation





EPC Spec (Cont’d)

means shall be provided for lifting and handling of each item of plant and

equipment.

• All statutory permits license from competent authority approvals from Boiler

Inspectorate, Electrical & Factory Inspector, and TAC/ NFPA, labour etc.

as required for the project.

• Carrying out all pre-commissioning and commissioning tests in

consultation with Purchaser’s Engineer at site and commissioning of the

systems.

• Performance Guarantee tests for all the equipment as per mutually agreed

procedure and as per Indian and International Standards.

• Submission of all drawings and documents to Purchaser’s consultants and

obtaining approvals before start of manufacturing or construction.

• Preparation of monthly reports in the agreed formats and attending

monthly review meetings, design coordination meetings etc.

• Arrange permission for Purchaser’s / Purchaser representative’s entry to

different stage and final inspection / testing of equipment at manufacturers

works.

• Receiving and unloading of all equipment, plant and materials at site,

checking with shipment list / consignment note and reporting for missing or





EPC Spec (Cont’d)

• Carrying out commissioning testing, starting up checks, performance

testing, and handing over of the complete plant / equipment / system / sub-systems.

• Supply of all drawings, data, test certificates, O & M manuals, etc., as

necessary.

• Supply and compilation of different manufacturers operating and instruction

manuals in a comprehensive manner prepared for use by operating and /

or maintenance personnel.

• Submit complete “As-Built” drawings for the plant / system / sub-system /

equipment / material as erected and installed at site incorporating each

change or modifications in the executed works from the approved

construction drawings.

• Project engineering and management and periodic reporting till handing

over the plant.

2.4 The successful bidder shall provide the following manpower at site during

erection, testing and commissioning:

• One experienced Site In charge having at least 15 years of experience in

erection and commissioning of similar projects

• Engineers with experience in similar job as Supervisory staff, inspectors,





EPC Spec (Cont’d)

• Furnace oil/LDO at the inlet of storage tank.

• Raw water supply lines at inlet to raw water storage reservoir.

• Vents to be taken outside building limit wherever necessary with suitable

bird net, rain protecting hood etc., fitted at the outlet with suitable

approaches for servicing & maintenance.

• Drains and blow downs to be taken up to a collection sump through drain

header or drain trench. All above ground drain piping inside the plant shall

also be included by bidder in his scope.

• Electrical 132 KV transmission line for power export at gantry of existing

132 KV bus.

2.7 Following items of work are excluded from the scope of work covered by this

specification:

•

Site levelling, soil investigation etc.



FACOR ALLOYS LIMITED45 MW CAPTIVE POWER PLANT AT GARVIDI, ANDHRA PRADESH.


ANNEXURE-1 – BOILER & AUXILIARIES

1.0 DESIGN BASIS

1.1 BOILER

1. Type Single or bi-drum, vertical, semi-

outdoor, natural circulation

2. Normal Continuous rating

(NCR), Steam pressure and

Temperature at MSSV outlet

195 TPH, 110 ata, 545 +/- 5° C

3. Number One

4. FW inlet temperature 219° C ( min)

5. Steam purity Total Dissolved Solids: 0.1 ppm

(max)

Silica (max): 0.02 ppm

6. Steam system Steam line from CFBC boiler to be

connected to main steam header in

the TG building which has to be

extended as required. Auxiliary

steam header to be provided as

required.





Annexure-1 Boiler & Auxiliaries (contd.)

Combination – 3:

Imported coal : 25%

Washery reject : 25 %

Indian Coal ‘G’ : 50 % .

1.2.2 Analysis of Fuels:

Approximate indicative analysis of different fuels is given below:

Ultimate Analysis:

S.No PARTICULARSCoal washery

rejects

Indian coal

G - grade

Indonesian

coal

1 Carbon % 23.0 17.10 59.38

2 Hydrogen % 01.3 0.22 3.15

3 Nitrogen % 00.6 0.10 01.04

4 Sulphur % 01.50 0.57 0.38

5 Moisture % 08.00 06.32 06.00

6 Ash % 60.50 75.48 25.19

7 Oxygen % 05.10 0.20 04.86






The control of the CPP will be based on a DCS system to be

procured by the purchaser separately. All instruments and controls

provided by the boiler supplier shall be compatible to the DCS and

necessary outputs for feeding the signals to purchasers DCS shall

be provided by the boiler supplier.

1.4 ELECTRICAL SYSTEM

All drive motors up to 200 KW shall be suitable for operation on 415 V, 50

Hz, 3 / 4-wire systems. All the motor shall meet the following conditions. All the AC motors for various auxiliaries should be designed to

operate in humid air with the maximum ambient temperature up to

45 deg. C

All the motors shall be of squirrel cage type

The degree of protection of motors shall be IP 54 & shall confirm to

IS: 325 / IEC – 60034. Motors for outdoor application shall be IP 55 degree of protection

with sheet Steel canopy

The motor winding shall be provided with class F insulation

The motors shall be suitable for + 10 % voltage variation on rated

Voltage and + 5 % frequency variation on 50Hz. Subject to






Fuel Feeders shall be provided with VFD’s. VFD’s shall be meet the

following requirements:

Rated for 415 V

Suitable for the selected IGBT based variable frequency drive, and

shall match with the drive in respect of over voltage / spike

generated by drives.

Winding shall be VPI treated and two coat enamelled. These motors

shall be sized to operate satisfactorily under the lowest speed

conditions. Operating speed requirement shall be as follows –

Boiler Feed Pump - 30 % to 100 %

Fans - 30 % to 100 %

Fuel Feeder - 10 % to 100 %

Motors of rating above 30 KW shall be provided with thermisters in

the windings and higher capacity motors shall be provided with

RTDs

Motor terminals to be rotatable for 4 X 90 Deg. Higher rating motors

shall be provided with extension terminal box to receive the

aluminium cables. The terminal box shall be capable of

withstanding the maximum system fault current for duration of at






they will have a minimum clearance of 6.0 metres between bottom

of supporting structures and road crown/ railway track.

All shop headers, except for gravity return fluids, shall be generally

routed along columns in multiple rows at a height 4 to 6 metres

above floor level. The connections to equipment shall be taken

through suitable covered floor trenches for shops at ground floor

and for basements and for elevated operating floors, the equipment

pipe work connections may be taken below the floor level. Allgravity pipes shall also be preferably routed along the same route.

Isolated single pipe connections to equipment may be buried in the

flooring/ equipment foundations. All pipe trenches shall be covered

by chequered plate or by concrete slabs.

The outlet pipes for purging lines and other exhaust pipe work shall

be routed upward along columns / gable ends and / or walls to a

height of 4,000 mm above the roof level.

Platforms, access ladders, hand railing etc shall be provided for

operation and maintenance of valves, instruments and controls. In

case the units and electric drives for the valves are to be located at

a height of more than 1.4 m from the maintenance level, the

platform with stairs shall be envisaged (either stationary or light-






For condensate (upto 8Kscg & 60 deg. C) velocity shall not exceed

2 m/s

For drain & cooling water (upto 6Kscg & 200 deg. C) velocity shall

not exceed 2 m/s

1.5.3 Valves & Fittings

Valves of DN 100 and above shall be provided with by-pass.

Pipes, fittings and valves shall be supplied with IBR certificates.

Valves shall be provided on pipe work for isolation of pipe sections

and equipment, control of pressure, flow and level of fluids, venting,

draining, pressure relief etc. They shall be suitable for the service

conditions in all respects and located suitably considering ease of

operation and maintenance.

The valves provided shall include but not be limited to the

followings:

On all pipelines both at the sources and consumers.

On all branch pipes from main header to consumers.

Isolating and bypass valves for flow meters, filters, trap assembly

etc.

Check valve on all pipelines requiring unidirectional flow.






Relief & safety valves of adequate capacity shall be provided at

required location for ensuring the safe operation of the system.These shall be of spring-loaded type and shall automatically open

when the pressure and the pipelines, on which they are mounted,

exceed preset values. The valves shall have end connections and

materials specified for throttling valves. Relief/Safety valves for

steam service shall have IBR certification. Relief valves shall have

hand wheel / wrench for adjustment of preset value of relief

pressure.

1.5.4 Expansion and flexibility

Piping stress analysis using suitable software package to comply

with the requirements of ANSI B31.1 power piping code and IBR

All pipe work shall be designed to provide suff icient flexibil ity to

prevent development of undesirable forces or moments at points of

connection to equipment, at anchorages or at guide points due to

thermal expansion.

Flexibility shall be provided by changes of direction or by the use of

bends, loops or offsets. Wherever no self-compensation can be

used to cater for the expansion deformation of the pipelines, special

expansion joints shall be provided. In general, expansion loops






details might be omitted on the drawings. Supporting shall ensure

freedom for expansion and absence of movement as well as restrictsagging to reasonable limits.

1.5.5 Supports

Pipe supports, anchors, hangers, guides, sway bracings, vibration

dampers etc shall be according to ANSI B 31.1 or equivalent.

Design, material and workmanship for structural steelwork used for

pipe supports shall conform to relevant Indian Standards forStructural Steelwork and Civil Engineering Work.

1.5.6 Welding

The Tenderer shall provide all tools, plant, instruments and

consumable including welding electrodes for carrying out the

welding at site.

The Tenderer shall arrange at his own cost for all tests outlined

below and any other test indicated by the Equipment Manufacturer /

FAL from time to time during the progress of work.

Visual examination.

X-ray and Gamma-ray examination.

Ultrasonic test.






1.5.7 Thermal insulation

Thermal insulation shall be provided for all surfaces substantiallyhotter than ambient conditions. The data regarding ambient

conditions given shall be used for selection of thermal insulation.

The thermal insulation provided shall ensure that the temperature of

outside surface of insulation (Cladding) shall not exceed 60 deg C.

Mineral wool (made from rock, slag & glass) insulation materials

shall be used for hot services. The insulation material shall be oneof the following types.

For pipe work up to DN 350, pipe-sections of light resin-bonded

mineral wool (rock/slag wool) as per IS: 9842 shall be used. In

addition to the compulsory requirements indicated in clauses 4.1 to

4.11 of the IS code, optional requirements laid down in clauses

4.12.1 to 4.12.4 of the IS code shall be fulfilled in all cases.

For pipe sizes above DN 350 and for flat surfaces and equipment,

resin bonded mineral wool (rock wool) mattress as per IS:8183, with

factory stitched G.I. Wire netting on outer surface. In addition to the

compulsory requirements indicated in clauses 4.1 to 4.9 of the IS

code, optional requirements laid down in clauses 4.10.1 to 4.10.7 of

the IS code shall be fulfilled in all cases.






Preparation of detailed GA drawings, Foundation load data

requirements, for main boiler, auxiliaries, piping within the scopeetc.

2.1.2 Manufacture, supply erection & commissioning

Complete manufacture and supply of all the equipment, electrics

and piping covered in the scope including shop testing.

Providing engineering drawings, data, and operation manuals to the

Purchaser. Supply of all equipment, materials, spares and special tools and

tackles, which are required for achieving the specified performance

parameters of the plant. Any special instruments etc. required for

proving the performance of the boilers after the installation at site

shall also be included in the scope.

Testing of the equipment after manufacture at works including

inspection by an approved third party inspection agency as per Para

1.6 above.

Obtaining approval from Indian Boiler Inspectorate for the

equipment supplied, steam and feed water piping and wherever

required by IBR.

Packing forwarding and arranging transportation / shipment from






Fin welded water wall furnace enclosure with refractory in bed zone.

Down comers and risers.

Drainable super heater assembly with inlet and outlet header.

Spray type inter stage de super heater assembly.

Necessary piping connecting super heaters and de super heater.

Economiser with plain tubes with casings & hoppers.

Multi tubular air pre heater with tubes, tube sheets, casing and

hoppers.

2.2.2 Furnace

Fluidised bed furnace of suitable sizes enclosed by water wall etc.

Firing arrangement

Bed ash drain arrangement

Inspection arrangement

Fuel and air nozzles

2.2.3 Air and Gas ducting

Integral Air and Gas ducting of boiler.

Air headers for primary air and secondary air and suitable

distribution in the furnace






2.2.8 Boiler Integral Piping

Feed piping from NRV, Feed water control station to feed waterheader.

Feed piping feed water header to economizer.

Feed water piping from economiser outlet to steam drum.

Spray water piping for desuperheater.

Saturated steam line from steam drum to inlet header of primary

super heater.

Steam line from primary super heater outlet to inlet header of

secondary super heater.

Main steam piping from secondary superheater outlet header up to

outlet of main steam stop valve.

Soot blower steam piping as necessary.

HP dosing unit to feed water line.

Boiler blow down up to boiler blow down tank.

Boiler blow down tank (common for continuous and intermittent

blow down and its associated piping)

Drain piping up to common drain header/ nearest trench.






Four no of sample coolers for feed water, saturated steam,

superheated steam and blow down water of boiler.

Flow nozzle, transmitters, Drain valves etc.,

HP dosing system with pumping unit and its drives, supporting,

fittings, valves, agitators etc.,

Feed water control station

Isolation valve at boiler filling line.

Instrument air piping.

Two no. of Safety valve at drum and one no. of safety relief valve at

Main steam header.

Motorised main steam valve and motorised bypass valve

Motorised start up vent valve

2.2.10 Supports and Platforms All steel supporting structure for the boiler over the concrete

platform to be provided.

Minimum & essential operating platforms with approach stairs/

ladders and canopy and side sheeting up to bunker level and side

covering as required to avoid rain beating.

2 2 11 Electrostatic precipitator






Steel supporting structure for the bunker.

2.2.14 Chemical Dosing System

Skid mounted LP dosing system including pump set (1W + 1S) with

their motors of required capacity.

Skid mounted HP dosing system including pump set (1W + 1S) with

their motors of required capacity.

LP dosing piping including supports upto feed pump suction.

HP dosing piping including supports upto steam drum.

Minimum & essential valves and fittings.

2.2.15 Deaerator and Boiler Feed Pumps

One Deaerator of capacity 220 tons/hour complete with deaerated water

storage tank of capacity 70 cum complete with all necessary accessories,

safety valves, Insulations, supporting structures, foundation bolts, fittings

etc.

Three boiler feed pumps (1W+1S) each of approximate capacity 240

cum/hr and head to suit the pressure requirement of the boilers and the

pressure drop in the pipe work complete with drive motors, recirculation

valves, balancing valves, strainers, isolation valves, check valves,

foundation bolts and accessories etc.,

FACOR ALLOYS LIMITED






Shut off Head – The shut off head should be at least 1.1 times the

duty point head (at boiler MCR) and should not be more than 1.2times the duty point head (at boiler MCR).

Power Characteristics – The power curve should be of non-

overloading type with the maximum power occurring at or near duty

point or towards maximum run out flow. Deeply formed “S” shaped

power curve should as for as possible be avoided.

NPSHR Characteristics – At rated capacity, margin betweenrequired and available NPSH shall be at least 1.0 M

NPSHR curve should be a continuous rising one in the range of

operation, from the minimum flow in the range to the maximum flow

in the range. A bowl shaped NPSHR curve in the operating range is

unacceptable. Required NPSH values shall not exceed available

values over the entire range from minimum to rated flow.

Efficiency Vs Flow Characteristics – The efficiency curve should be

fairly flat in the range of +(-) 1% of the BEP flow. The duty point of

the equipment should preferably lie in this flat region, but not a flow

higher than the BEP flow.

Pumps operating in parallel shall have equal head rises from

normal capacity to shut off of at least 10 %.







2.2.16 Complete feed water pipework between the Deaerator and feed water pumps,

feed water pumps and individual boilers complete with necessary valves, fittingsand accessories.

2.2.17 Complete main steam pipe work from the MSSV of CFBC boiler up to the existing

common steam header in the TG building including extension of the main steam

header, necessary isolation valve at the header and the steam line from the

common stream header up to inlet flange of TG complete with valves, fittings,

supports and accessories.

2.2.18 Complete steam piping from main steam header to PRDSs , to Auxiliary steam

headers, to Deaerator, to Ejector inlet nozzle, to Sealing steam inlet of TG,

Extraction line from TG extraction steam nozzle to Deaerator and other branching

steam pipelines with valves, accessories, fittings etc.,

2.2.19 Basic Field Instruments for the boiler

Thermocouple & RTD (PT100Ω) compatible with DCS for the

following

- Water temperature at the inlet of economiser.

- Water temperature at the outlet of economiser.

- Water temperature at the inlet to primary SH

- Water temperature at the inlet to secondary SH

- Water temperature at the outlet to Primary SH







Draught gauges for CFBC boiler with transmitters to measure

- Air box pressure, secondary air pressure

- Furnace pressure

- Flue gas pressure before economiser

- Flue gas pressure before & after multi tubular air heater

- Air pressure before & after multi tubular air heater

- Air pressure at primary air header and secondary air header.

- Compensating cables and impulse piping wherever necessary for the

items, which are under THE CONTRACTOR scope of supply.

- Instrument panel to mount draught gauges supplied by The Contractor.

Boiler Controls:

Following minimum controls are required for the boiler. All field

instruments, switches, level measurements sensors etc shall be provided by the

boiler supplier to enable purchaser’s DCS control system

- Automatic Three element drum level control- Automatic Attemperator control to maintain constant temperature for

60 to 100% flow within +/- 5 Deg C

- Automatic Combustion control for CFBC boiler

- Automatic Furnace draught control for CFBC boiler

- Fuel feeders with variable speed drives

Alarms and annunciation sensors for purchaser’s DCS system







Deaerator shell SA 515 Gr.70/SA 516 Gr.70

Deaerator storage tank SA 515 Gr.70/SA 516 Gr.70

Non pressure parts

Steam drum drier / mesh SA 478 Type 304

Air heater corten steel tubes SA 423 Gr.1 ERW

Fuel bunker conical portion AISI 304

Fuel distributor exposed to

radiation

AISI 304

Ducting IS 226 / IS 2062

Bank area baffles AISI 304

Structural steel IS 226 / IS 2062

High tensile steel IS 961

Hand rails IS 1239 – 32 NB Medium

Structural fasteners IS 1363 /1364

Grating BS 4952 Part 1

LP dozing piping SA312 TP 304







Piping

Main steam line ASTM A 335 P11/12

Auxiliary steam of low pressure &

low temperature

SA 106 Gr.B

Feed pump SA 106 Gr.B

Spray water piping to

desuperheater

SA 106 Gr.B

Fitting & flanges As per IBR code

Water piping up to NB 150 IS 1239 black medium

Water piping NB 200 & above IS 3589 ERW

Service air piping AISI 304 black medium

Instrument air piping IS 1239 G I

Fittings for Non IBR IS 1239 II /ASTM B16.9

Insulation & refractory

Insulation Bricks IS 2042







Economiser

Stop valve at inlet 1Check valve at inlet 1

Drain valve 1

Vent valve 2

Pressure gauge isolation valve 1

Steam Drum

Spring loaded safety valve 2Isolation valves for level gauges 8

Drain valves for level gauges 2

Air vent valve 1

Isolation valve for pressure gauge 2

Aux. steam stop valve 1

Isolation valve for level transmitter & level switches 4Continuous blow down valve 1

Bypass for CBD 1

Mud Drum & WH Bottom HDRS

Blow down valve 1

Drain Valves 5




45 MW CAPTIVE POWER PLANT AT GARIVIDI, ANDHRA PRADESH.EPC TENDER SPECIFICATION

ANNEXURE-2 – TURBO GENERATOR & AUXILIARIES

1.0 DESIGN BASIS

1.1 THE TURBO GENERATOR AS PER THIS SPECIFICATION SHALL MEET THEFOLLOWING REQUIREMENTS:

NO. DESCRIPTION TURBO-GENERATOR

1. Type Low or High speed, condensing steam with one bleed

for Deaerator and bleed for HP, LP heaters as per

standard design of supplier.

2. Type of

condenser

Air cooled condenser

3. Number One

4. Max. Contin.

Rating

45 MW

5. Press & Temp at

I/L

108 Ksca, 540 deg. C

6





Annexure-2 Turbo Generator & Auxiliaries (Contd.)

and uncontrolled bleed for feed water heating in the deaerator. The output capacity of the

turbine will be 45 MW as measured at generator terminals. Turbo generator set shall be

designed for the fluctuations and transients so that the system as a total will sustain

without any adverse effect on the life of the equipment.

1.3 GENERATOR

Generator of voltage rating 11.0KV suitable for 0.8PF, 57 MVA is envisaged.

Generator shall be complete with exciter, brush less excitation system, automatic voltage

control etc. adequately designed for the requirement of generator. Bidders shall furnish a

write up along with the tender indicating the technical consideration for review and to

convince that they will take care of this fluctuating load requirement in their basic design.

1.4 CONDENSING PLANT

Air-cooled condensing system is envisaged for the turbine (TG). However the

condenser with all necessary standard auxiliaries such as condensate storage tanks,

condensate extraction pumps, flash tanks, two-stage steam jet ejectors, start-up ejector,

hot well level control system, bellows etc. is not included in the scope of this specification.

Gland steam system with steam pressure regulators, de-superheater, Gland Vent

Condenser (GVC), all piping and valves and associated instruments shall be provided.

Auxiliary steam for gland sealing will be supplied at 10kg/cm2 and 300 deg C. The leak






1.7 ELECTRICAL SYSTEM

1.7.1 Generator protection

The generator shall be provided with following minimum protections:

Phase & ground Inverse time O/C relay.

Phase & ground Instantaneous time O/C relay.

Generator stator E/F and Backup earth fault relay.

Differential protection with CTs on phase and neutral sides.

Loss of excitation.

Negative Phase sequence.

Forward power relay for Low Forward trip.

Reverse Power relay for trip with timer.

Over Voltage relay having 2 stages on generator side.

Under voltage relay having 2 stages on generator side.

Low frequency relay having 2 stages on generator side with timer.

Rotor earth fault relay I stage.

Trip circuit supervision.

Lock out relay for hand reset for generator.






1.9 INSTRUMENTATION AND CONTROL

The system envisaged is DCS for the entire CPP having the operator and

Engineering stations in main control room. Auxiliary units like ash handling, fuel handling,

DM Plant will be provided with PC based PLC and the important parameters will be

communicated to DCS for the information of the shift in-charge.

All logics and controls will be provided only in DCS with redundant processors andhot standby units. Minimum controls shall be

Split type hot well level control with re-circulation control valves.

Gland steam pressure control system.

LP heater condensate level control system if opted.

Deaerator pressure control for bleed steam.

1.10 MISCELLANEOUS

1.10.1 Insulation

All exposed portions of the Turbine, auxiliaries and interconnecting piping which

operate at temperature of above 65ºC during normal operation shall be thermally

insulated so that the outer surface temperature of the insulating material before cladding

shall not exceed 65ºC at the ambient temperature of 45ºC at a Wind velocity of 5 m/sec at






Complete turbine integral piping and other piping including all valves

(isolating, regulating, non-return, hand operated and / or pneumatic,

motorized) actuators, air vents, safety valves, drains, hangers, supports,

anchors and other fittings. Emergency gravity lube oil system with SS

overhead tank, SS piping, SS valves & Instrumentation as per the design

requirement.

Turbine supervisory, protective and governing systems including safetygovernors, load limit device, low vacuum tripping device, thrust bearing

protective device, solenoid trip etc., as specified hereinafter and all

equipment mounted/local instruments, pressure, temperature, level switch,

primary sensing device etc., as required. Governing system shall be

electro hydraulic type.

Oil purifier of suitable capacity.

HP heaters with accessories and auxiliaries.

LP heater with accessories and auxiliaries.

Electrical motor operated or Hydraulic turning gear equipment and

provision for hand barring.

Gland steam sealing system with steam pressure regulators, de-

superheater gland steam condenser all piping and valves and associated






2.4 ACCESSORIES

Motorized barring gear arrangement with auto engage and auto disengage

facility. In case of turbine trip, the barring gear automatically cuts in when

the rotor speed falls below a preset value and it keeps the rotor rotating at

slow speed to avoid bending of rotor.

QCNRV, FFRV and Isolation valve for all bleed steam lines.

Common base plate for turbine and gearbox

Insulation for Turbine hot parts (lagging & cladding)

Mating flanges for all the equipment connections in the bidders scope of

supply

Base frame, Sole plate for embedment in the concrete, Bottom plate for

foundation bolts.

Set of foundation bolts.

Set of special tools & tackles for maintenance

2.5 AC GENERATOR

AC Generator shall be complete with following:

Four pole, cylindrical rotor type alternator

Brush-less exciter







All control gears for turbine and generator whether specifically indicated or

not.

All sensors, field instruments, junction boxes etc for local and remote

monitoring instruments including transmitters, sensing elements,

connecting pipes/tubes and local gauge board.

HP heaters level control valves

LP heater level control valves.

Dial type Pressure gauges as required. List to be furnished with offer.

Temperature gauge as required. List to be furnished

Pressure switches as required. List to be furnished.

Pneumatic and impulse piping with fittings for interconnection within

battery limits.

RTDs (PT 100 type), Thermowells for all the temperature measuring points

for purchaser’s DCS system.

Provision for level transmitters for purchaser’s DCS controls and

instrumentation

2.9 MISCELLANEOUS ITEMS






Spares, tools and tackles for operation, repair and maintenance for two

years of trouble free operation (Optional) List of items recommended and

their price valid for 6 months shall be submitted.

Insurance Spares like Generator coils etc. as per mutually agreed basis

(Price shall be furnished along with offer).

2.11 SERVICES TO BE RENDERED FOR VARIOUS STAGES OF CONTRACT

2.11.1 Design and Engineering

Complete system design and layout.

Basic design, Preparation of P&I, Schemes, Flow sheets etc.

Preparation of detailed GA drawings, Foundation requirements, details of

auxiliaries etc.

Detailed design of equipment, preparation of drawings for internals,

interfacing details etc.

Preparation of input data for civil and structural design by purchaser.

Sizing of pipe and pipe works preparation of piping layout, routing etc for

interconnection of equipment within the scope of supply as per this

specification.

2 11 2 Manufacturing and supply:






I & C Engineer for all open loop and closed loop controls to commission

the TG controls along with DCS commissioning group

TG commissioning engineer for checking the completion of erection and

commissioning engineer

Performance test group.

2.11.4 Erection and commissioning:

Receipt and unloading at site of all equipment including pipes, valves,

structural steel materials, etc.

Opening of crates and packing cases, thorough cleaning and checking of

completeness of equipment in relation to Equipment Manufacturer’s

drawings, packing defect. Damages or missing items, if any, shall be

rectified or made good by the successful bidder.

Providing storage and safe custody of the equipment, etc. at site

Supply of erection consumables like weld rods, cleaning agents,

lubricants, grease, and shims, small bolts etc.

Supply of items like pipe, valves, gaskets, bolts, and flanges etc., which

are required during the course of erection at a mutually agreed rate at the

request of purchaser.






Any other work connected with erection and commissioning of the

equipment that is customarily rendered by the successful bidder to

complete the works.

3.0 EQUIPMENT DETAILS

3.1 TURBINE

3.1.1 Casing

The casings shall be designed for hydrostatic test pressure of not less than 50%

in excess of the working pressure. Each turbine casing shall be efficiently drained. The

parts of the turbine, which are expected to be in contact with wet steam in normal

operation or during start-up, shall be provided with a system of inter-stage drainage

whereby extracted water will be prevented from re-entry to the blading and will be

admitted to either a convenient heater extraction branch or the condenser. The casing

drains shall be provided with temperature sensing devices to help ensure proper

evacuation of drains. Bolts, nuts and studs used for the turbine casing flanges and main

turbine valve bonnets etc. shall be with milled threads and of special alloy steel properly

treated. Provision shall be made for electrically heating the bolts to facilitate setting and

loosening. In addition, the supplier shall indicate the design features incorporated to

prevent the seizure of nuts and studs and features, which will facilitate their easy removal






all load conditions of operation. The peak-to-peak value of vibrations measured on the

bearing housing shall be within 25 microns.

The critical speed/speeds of the combined turbine and generator rotor shall not lie

within a range of + 20% or 40% to 60% of the rated operating speed.

3.1.3 Nozzle & Blading

All nozzles and blading shall be of hard, corrosion and erosion resisting alloy steelsuitable for the specified steam. In the low pressure stages where the moisture

percentage and the blade peripheral speeds are high, additional protection against

erosion by way of hardened surface of blades or strips of erosion and corrosion resistant

material such as stellite, secured to the leading edge, shall be provided.

The method of fixture of the blades to the rotor shall have been satisfactorily

proved by long use of operation. Care shall be taken to ensure that the natural frequency

of the rotor blades is compatible with the rotational frequency of the machine.

3.1.4 Exhausts

The turbine exhaust shall be designed for velocity recovery and shall be suitable

for connecting to the condenser preferably through expansion joints. The unit shall be

provided with turbine exhaust water spray system. The system shall be provided

complete with spray nozzles a controller an automatic spray water control valve and all






The rotor axial position shall be maintained by a thrust bearing assembly of

adequate capacity. Proper arrangement shall be made to maintain oil pressure under all

load conditions of operation. The design shall incorporate arrangements for monitoring

thrust bearing metal temperatures. Devices shall be provided for annunciation of an

impending failure of the turbine thrust bearing. Additional switches shall be provided for

alarm and trip of the unit in case of a thrust bearing failure.

The metal temperature of all bearing shells shall be monitored by thermocouples,

which extend right into the white metal layer. Provision shall also be made for reading the

oil temperature leaving the bearings. Suitable direct reading type thermometers and

separate switches each with two `High’ signalling contacts for all bearings shall be

provided. Arrangement shall be incorporated in all the bearings for measuring vibrations.

The proposal shall include necessary accessories for remote monitoring of all bearing

metal temperatures, oil temperatures and vibrations.

3.2 TURBINE ACCESSORIES

3.2.1 Coupling

The rotors shall be coupled by means of flanges of aerofoil type of proven make

for ensuring long life. Fitted bolts shall be provided to prevent slippage under abnormal

operating conditions. They shall be such as to facilitate easy alignment during erection.






hydraulic pressure etc. The extraction line valves shall close positively on turbine trip and

at pre-set high heater level. The non-return valves shall be located as close to the turbine

as possible, to reduce entrapped steam.

3.2.4 Governing System

To govern the turbine speed during varying load demand and fluctuating steam

supply conditions, a speed governor of suitable type shall be provided.

Turbine governing system shall be Woodward 505 electronic type. The governing

system shall be an electronic type with an electric signal being transmitted to a hydraulic

actuator for amplification by the turbine throttle valve relay system. Turbine shall operate

as an independent unit, in parallel with other generating sets of known governing

characteristics or in parallel with the main grid supply, in which case inlet pressure control

shall be utilised.

The speed governing system shall limit the over speed of the TG set on loss of full

load so as to avoid tripping by the emergency over speed device. Emergency governor

shall be provided to keep the turbine well below the safety limit and shall come into

operation when the speed sensitive governor fails to operate. The turbine governor shall

also contain electrical and mechanical trips to shutdown the turbine generator during

abnormal conditions, to prevent damage to the unit.






Steam temperature

Metal temperatures

Turning gear status

Seal interference monitoring device, if applicable

Pressure indicator for Curtis stage of the H.P. stage

The above list gives the minimum requirement, any other supervisory instrument

as required by the unit offered shall be included in the scope of supply.

The turbine protection system shall put the turbine out of operation by closing the

turbine emergency stop and control valves as soon as any of the following conditions

occur and admissible limits are exceeded:

Condenser pressure very high

Turbine lube oil pressure very low

Trip oil pressure very low

Control oil pressure very low

Turbine shaft vibrations high

Turbine speed very high

Steam temperature very low






An oil purification system shall be provided complete with centrifuge, pipe work

etc. to continuously operate as a bypass system handling around 20% per hour of the

total oil in circulation in the oil system. The purifier shall be a separate complete package,

mounted on a skid, complete by itself with drive motor, piping, valves & fittings. Feed to

purifier shall be from the drain end of the reservoir and its operation shall be independent

of the oil system.

3.2.8 HP/LP heaters

HP/ LP heaters shall be provided with inlet steam valves and outlet drain valves

with level controls. Valves are also provided in water lines at both inlet and outlet. All

necessary instrumentation with inter locks are to be provided.

3.2.9 Turbine Gauge Panel

TG Gauge Panel shall house the pressure and temperature gauges for various

operating parameters. Impulse piping with fittings shall be supplied loose for

interconnection between field tap-off points and gauge panel.

3.3 GENERATOR

3.3.1 Stator

Stator body shall be a totally enclosed gas tight, explosion proof fabricated

structure suitably ribbed internally to ensure high rigidity The stator shall be designed to






Strength test, material analysis and ultrasonic tests shall be performed during the

manufacture of the rotor. The rotor shall be balanced in various planes at different speed

and shall be subjected to over speed test. Individual turns of the rotor coil shall be

insulated against each other.

3.3.3 Fan

The rotor shall have fans mounted on it for the circulation of air inside the

machine. The fixing bolts, pins, nuts, etc. shall be made of non-magnetic material.

3.3.4 Shaft Seals

The shaft seals should be of adequate design to be provided on either side of the

rotor to prevent escape of air from the generator casing along the rotor shaft. The design

should be such that minimum oil should come in contact with the air during the course of

sealing. The shaft seal body on the exciter side shall be suitably insulated from the stator

end shields current.

3.3.5 Bearings

The generator shall be provided with sleeve bearings. The bearings shall be

spherically seated, self-aligning, cylindrical bore type. The liner shall be lined with at least

two-resistance thermometer in each liner for continuous sensing and recording of white

metal temperature The bearing and the oil pipes of the generator on exciter side shall be






3.3.7 Temperature Measurement

Temperature of various active parts shall be measured. The stator winding

temperature shall be sensed by at least one embedded resistance thermometer for each

coil placed at the bottom of the slots out of which at least six shall be in the end zone.

Temperature of cooling water to the (in case of water cooled machines), air

coolers, hot and cold gas and lubricating oil to the bearings and shaft seals shall also be

sensed by resistance thermometers. The rotor winding temperature shall be measured

by resistance method and shall be continuously recorded. Duplicate sensor shall be

supplied for all the above temperature measurements.

3.3.8 Generator Excitation System

The excitation system shall be brushless type with diodes mounted on the shaft at

location where maintenance access is available without opening the generator cover. The

brushless exciter shall consist of a permanent magnet generator, AC exciter and rotating

rectifier with silicon diodes and indicating fuses. The whole system should be enclosed to

avoid dusty air ingress from outside with adequate cooling arrangement of the closed

circuit air inside.

The excitation system shall be complete with switchgear, control equipment and

automatic voltage regulators It shall be capable for operating the generator at full range






3.3.10 Surge protection and voltage transformer (SPVT)

A Surge Protection and voltage transformer (SPVT) cubicle for the generator shall

be provided in the turbo generator building at ground floor level. Surge protection shall

comprise lightning arrestors and surge capacitors and shall protect the generator against

high voltage / high frequency surges occurring in the system. The generator neutral shall

be earthed through a resistor to restrict the earth fault current to within limits. An isolator

and a CT shall be provided in the neutral circuit along with a resistor bank, all housed in acubicle. This cubicle shall be located in the turbine hall at the ground floor level close to

the generator.

4.0 ELECTRICAL AND INSTRUMENTATION

4.1 AC MOTORS

All AC motors for driving the various auxiliaries of Turbo generator set shall be

rated for 415V, 3-phase and 50 Hz supply. The motors shall be capable of delivering

rated output at rated power factor with a variation in voltage equal to +10% and a

variation in frequency equal to +5% with any combination of these two variations.

The motors shall meet with the requirements of IS: 325. The stator coils of all

motors shall have class ‘F’ insulation. The temperature of the insulation shall be limited to

class ‘B’ over an ambient temperature of 50 oC






The instruments, meters and other devices to be provided in the panel

shall include but not be limited to the following:

Spring return to neutral type Raise / Lower control switches for voltage and

speed raise for TG5.

Synchroscope and synchronising lamps

Double voltmeter and frequency meters

Four position synchronising selector switch for breaker selection for

Incomer to Bus, Generator to bus, DG to LT bus and LT bus to incomer

(DG and LT bus not in the scope of this contract. Only synchronising

provision is required).

Synchronising circuit ON/OFF switch.

Synchronising check relay

Voltmeter 0-15KV range with voltmeter selector switch for Bus, Generatorand incomer

Frequency meter 45 to 55Hz for TG, Grid, and DG frequency

measurement. Signal for DG and grid will be provided from the purchaser’s

panel for contractor’s termination at existing panel.

Digital multiple display meter with RS485 Modbus port for export / import







4-20 ma DC output signal for Speed, Power. Turbine inlet pressure for

logging in the DCS. These signals shall be made available in the Turbine

panel.

4.4 VIBRATION MONITORING SYSTEM

Vibration monitoring system consisting of X-Y probes, signal conditioning unit,

display unit, junction boxes, interconnecting cables for measurement of bearing

vibrations, shaft vibrations, axial shift position, casing expansion, differential expansion,eccentricity shall be provided. The Vibration monitoring system shall be provided with

isolated 4-20 mA dc output for the above measurements to connect it to customer’s

distributed computer system (DCS)

Temperature detectors (RTD) associated with bearing temperature, motor winding

temperature measurements shall be connected to DCS. The temperature scanner shall

have communication link facility conforming to MODBUS RTU Protocol RS-485 interfaceto provide connectivity to DCS.

4.5 PROTECTION & INTERLOCKING SYSTEMS

The operation of protections shall be accompanied by annunciation, which

will provide definite indication of the primary cause or causes of operation

of the protection. The following basic interlocks and protection







• Energisation of generator lockout relay

• Master trip lockout relay energized

• Low lubricating oil pressure for bearings

• Any other protection as envisaged in design

• Generator electrical protection trip

Turbine protection interlock system shall be based on hard-wired logic and

shall be carried out in the Turbine control panel. One set of potential free

contacts shall be provided in the turbine panel for the above faults to wire it

to DCS.

The turbine governing system shall be based on Electro hydraulic type

consisting Woodward electronic unit, E-H converters, Hydraulic unit etc.,

the governing system shall be configured to meet the following operating

requirements./Parallel with the 132 KV Grid and existing DG/Island modewhen both existing TG and grid trip./Along with the Woodward speed

governing system necessary load control module required for the turbine

shall also be supplied so that following functions are done:

• Dead bus closing

• Tie breaker closing







supplier during detailed engineering and commissioning shall be included

in the scope of work of this tender.

All outdoor electronic instruments shall be provided with IP-65 enclosure.

Pressure gauges shall be provided with snubber for pump discharge

pressure measurements. Bourdon / movement material of all gauges shall

be of SS. Diaphragm of diaphragm sealed pressure gauges in dosing lines

shall be of SS with Teflon lining. Dial sizes of gauges shall be 150 mm.Gauge cocks with drain plugs shall be provided for all gauges. For steam

services, syphons shall be provided.

RTD type temperature elements shall be of Pt-100 three-wire type, duplex

RTDs.All thermocouples shall be provided with compensating cables upto

the field mounted transmitter. SMART type temperature transmitters

having 4-20 mA DC output shall be provided for all thermocouples based

temperature measurements.

Generally instruments tubing, isolation valves etc. shall be of the same

material as specified for main piping/tanks. The specification details for the

instrument cables shall be Inter connecting cables between individual

instruments to junction boxes; Single twisted pair cables having 1.0 sq mm

stranded annealed tinned copper conductor insulated with PVC, inner

FACOR ALLOYS LIMITED45 MW CAPTIVE POWER PLANT AT GARIVIDI, ANDHRA PRADESH





ANNEXURE-3 – AIR COOLED CONDENSER & AUXILIARIES

1.0 DESIGN BASIS

1.1 PROCESS DESCRIPTION

1.1.1 The ACC shall condense the exhaust steam from the turbine, which is at a

pressure of 0.18 ata. The steam is drawn from the turbine to the condenser

through steam ejectors. The outlet temperature of hot well water is estimated as

57deg.C. The ambient dry bulb temperature condition for design shall be

considered as 40deg.C. The hot well water is continuously pumped to deaeratorthrough condensate extraction pumps with control valves. The condenser shall be

provided with exhaust water spray system to operate when exhaust temp exceeds

65 deg. C, rupture disc and necessary instruments to control the system.

1.2 TECHNICAL PARTICULARS OF AIR COOLED CONDENSER SYSTEM

1.2.1 Design of the ACC shall be suitable for the following conditions.

Type of Air CooledCondenser

: Aluminium fin type forced draughtwater to air coolers constructed in

dismountable modules with hot &

cold water headers.

Design ambient temperature

for ACC

: 40 deg. C





Annexure-3 - Air Cooled Condenser & Auxiliaries (Contd.)

1.3.2 Bidder shall provide water cleaning arrangement for the aluminium fins with spray

nozzles having a water jet pressure of at least 3.5 Kg/cm2 which will be provided

from auxiliary cooling water system of the plant.

1.4 CIVIL AND STRUCTURAL

1.4.1 The successful bidder shall supply civil construction drawings for the foundation.

1.4.2 All civil and structural steel work shall be in the scope of the work of this tender.

For design of structure, wind load conditions and Seismic conditions as specified

in this specification shall be considered. While designing the Air Cooled

Condenser structures, either effect of seismic force or wind loads, whichever

produces the worst effect, will be considered along with the usual load conditions.

2.0 SCOPE OF WORK, EQUIPMENT SUPPLY AND SERVICES

2.1 The scope of work of successful Bidder shall include and not be limited to design,

fabrication, manufacture, assembly, testing, packing, Transport, Supply at site,

Erection, start-up, commissioning, and testing for performance.

2.2 Air Cooled condenser unit shall be complete and shall include but not limited to

the following equipment, accessories and services.

2.2.1 Condensing System






2.2.3 Condensate extraction system

Horizontal/ vertical Condensate extraction pumps (CEP) with motors (2 x

100%) along with isolation and recirculation valves and NRVs.

Condensate piping from hot well through CEPs & ejector condensers and

up to inlet of Deaerator.

Split range control valves for Condensate re-circulation along with controls

Pipe supports, strainers, steam traps, drains, vents and isolation Valves as

required.

Drain lines with isolation valves for ejector condenser drains etc.

Dry air/vapour line to ejector with isolation valve.

All high pressure drains lines to flash tank.

2.2.4 Condenser air evacuation system

Steam jet air ejector system complete with:

Twin stage main ejectors (1 working + 1 standby)

Start up ejector (hogging) with silencer

Inter and after condensers individually for each service ejector

2.2.5 Condensing system C&I






Pneumatic and impulse piping with fittings for interconnection within

battery limits.

Instruments cables up to junction boxes for connecting to purchaser’s DCS

system

RTDs, Thermo wells for all the temperature measuring points for

purchaser’s DCS system.

Provision for level transmitters for purchaser’s DCS controls and

instrumentation

Vibration switches for high and Very high for each fan for connecting to

DCS logic.

2.2.6 Electrics:

One (1) lot of drive motors for pumps like CEP, CDP, fans and any

electrical drives Space heaters, its cables up to junction box

Vibration, RTDs etc. as required

2.2.7 Electrical Equipment

One (1) lot of complete interconnecting power and control cables from the

field switches motor heaters to the nearest junction boxes





ANNEXURE – 4 – FUEL HANDLING SYSTEM & AUXILIARIES

1.0 DESIGN BASIS

1.1 MATERIAL TO BE HANDLED

Coal washery rejects, Indian coal and Indonesian coal is proposed to be used as fuel

for the boiler. The characteristics of the material to be handled are given below:

TABLE-1: CHARACTERISTICS OF IMPORTED COAL/ INDIAN COAL

Top size, mm (max) – Indian coal

- Imported coal

- Washery rejects

250 mm

50 mm

50 mm

Average bulk density, kg/ m3 800

The coal will be received and stored in the coal yard of the plant and stacked in

separate heaps / stockpiles.

1.2 SYSTEM CAPACITY

The plant capacity and specification for equipments are given below in Table –2. The

system diagram is shown on drawing No.HIQ-4036-H-01 R0

TABLE – 2: SPECIFICATION OF EQUIPMENTS

Sl.



& ( )



Annexure – 4 Fuel handling system & auxiliaries (contd.)

2.3 Hopper size (min.), m 6 m x 4 m with 2 bottom openings

2.4 Grid size, mm Grizzly 200 mm square opening or as required.

2.5 Hopper material RCC

3.0VIBRATING FEEDER

(VF)V F

3.1 Quantity One

3.2 Capacity (each) To be indicated by bidder.

3.3 Type Electromagnetic vibration

3.4 Location Below ground hopper (CLH)

3.5 Material of construction Mild steel

3.6 Vibration frequency 3000 cpm

3.7 Vibration swing 1.6 mm (max)

4.0BELT CONVEYORS

(BC)

BC

– 1

BC –

2BC-3

BC –

4BC-5 BC – 6

BC-7

tripper

4.1 Type 3 roll 30 deg. Trough

4.2 Profile Inclined



A 4 F l h dli t & ili i ( td )




5.3 Location CH 1 & CH 2

5.4 Feed size Less than 250/75 mm

5.5 Product screened size Less than 75/6 mm

5.6 Rated capacity As per the design requirement

5.7 Duty Continuous

6.0 CRUSHER (CR)

6.1 Quantity Two ( primary/Secondary)

6.2 Design Capacity (each) As per the design requirement

6.3 Type Impact type

6.4 Location Crusher House-I & II

6.5 Fuel to be handled Coal washery rejects, Indian coal & Indonesian coal

6.6 Feed size (max.) Primary crusher - < 250 mmSecondary crusher - < 50 mm

6.7 Crushed fuel size (max.)Primary crusher - < 50 mm

Secondary crusher - < 6 mm

6.8Permissible fuel over size

from crusher

Shall be less than 10% of input coal through the

crusher.



Annexure 4 Fuel handling system & auxiliaries (contd )




8.7 Weighing accuracy ± 0.5%

9.0 GATE, CHUTE, ETC As required

9.1 Location GH, CHs,THs & Bunker

10.0 DUST EXTRACTION

SYSTEM (DE)

10.1 No. of dust extraction

pointsThree

10.2 Location CH-I, CH-II & BB

10.3Supply to cover

Blowers, bag filters, hoppers, chimney etc to control

dust at all transfer points in various conveyers.

10.4 Max. air / filter bag cloth

ratio1.5 m3 / min / m2

10.5 Filter cloth To be selected considering proximate analysis of coal.

10.6 Dust load in exhaust gas Within 50 mg / Nm3

10.7 Pressure drop across

system125 mm WC (Max)

11.0 DUST SUPPRESSION

SYSTEM (DS)

11 1 N f d t i O



Annexure 4 Fuel handling system & auxiliaries (contd )




considering the interconnectivity and interchange ability of equipment such that the

availability of major equipment is ensured at any point of time.

Coal from the coal yard stockpiles will be reclaimed by tractor dozers and fed into

ground hoppers in the Coal Loading House (CLH) where from it will be conveyed through

Belt Conveyer (BC- 1) to the Vibroscreening and crushing plant at Crusher House-I (CH) to

size the coal as per design requirement. Vibratory Feeders (VF) are used below the ground

hopper outlet, which feeds to BC 1. The screened fuel will be crushed in the crusher-I, the

crushed fuel will be taken to BC-1 through Coal Transfer House- 1 (CTH- 1) by Belt

Conveyor (BC- 3) from where it is fed to BC-I by gravity. The accepted coal from vibro

screen is fed to BC-2.The BC-2 belt conveyer feed the coal to the crusher house -2.vibro

screen. The screened fuel will be taken to BC-2 by BC-5 through TH-2.The accepted coal

will be taken to TH-3 by BC-4 then by BC-6 to bunker. BC- 7 through a boiler hopper a tipper

transfers the coal to the each compartment of Boiler Bunker (BB).

On-line magnetic separators are provided at upstream of crushers and boiler bunker

house to prevent damage to the crusher by tramp iron present in the raw coal. Non-ferrousmetals and other objects like stones etc. are detected by metal detectors, provided at

upstream of crushers and boiler bunker house. Belt scales are also provided to measure the

weight of the fuel conveyed by the belts.

Dust Extraction systems (DES) is provided at all transfer points to minimize dust

nuisance. Dust Suppression System (DSS) is provided at coal loading house. For dust



Annexure – 4 Fuel handling system & auxiliaries (contd )



Annexure 4 Fuel handling system & auxiliaries (contd.)

condition, through ability of the belt and the suitability for supporting the load. The cover

grade and thickness shall be selected to give maximum life of the belting giving due

consideration on the lump size, abrasiveness of the material and the loading cycle. The

permanent splicing of the belt shall be within the scope of work and shall be done by

vulcanising after removing the initial stress.

3.1.3 Belt carriers (idlers)

All belt conveyor idler assemblies shall be suitable for continuous operation under full

load conditions. Idler rollers shall be provided with wear resistant deep groove ball bearings

only. The minimum life of the bearing assembly shall be 40,000 working hours. Idlers shall

be self- lubricated and life sealed. The idler rolls shall be made of ERW pipes of medium

shell thickness. The carrying and return idlers shall confirm to the requirements of IS: 8598

and IS: 11592.

3.1.4 Idler spacing

Maximum spacing of toughing rollers shall be in accordance with the nature of

loading, weight of the materials carried and maximum belt tension. The spacing shall not

exceed 1000mm and shall be such that the centenary sag is within two (2) percent.

3.1.5 Take-up

Take-up shall be sufficient to cope up with a maximum elongation of belt during

operation. Counter weighted vertical gravity take-up shall be used for conveyor length about






Annexure 4 Fuel handling system & auxiliaries (contd.)

3.1.8 Belt cleaner / scraper

Suitable cleaning device shall be installed at the discharge end of the conveyor onthe return run of the belt so that the carrying side is properly cleaned before it comes in

contact with the return idlers. The belt cleaners shall be preferably be double bladed type

with spring and /or counter weight arrangement for maintaining constant contact with belt at

adequate pressure.

3.1.9 Deck plate

Mild steel deck plate shall be used between the upper and the lower belt of theconveyor. The decking shall preferably be self-cleaning type.

3.1.10 Conveyor hood

Conveyor hood of 2 mm thick GI sheeting shall be provided for the exposed, Short

Support, portion of the belt conveyor etc.

3.1.11 Stringer, short support, etc

The belt conveyor shall be complete with channel stringer angle or channel, short

support of about 800mm height for support, bracing, suitable head, tail and take-up frame

fabricated from structural steel sections. The supports shall be spaced approximately 3m

apart and shall be designed to withstand fluctuating loads during starting and stopping of

conveyor.

3 2 SHUTTLE CONVEYOR/TRIPPER






g y ( )

tensioning screws, dust covers and foundation bolts etc. Bearing used in the screen shall be

vibration duty spherical roller bearing.

3.6 CRUSHERS

The coal crusher (two) receives the coal of sizes less than 250/50 mm and crushes it

to the required size of less than 50/6 mm. It is of impact type and driven by motor.

3.7 BELT SCALE

Belt scale shall be of multi idler–load cell type suitable of indication accurate

conveyor rate flow. The operating accuracy of the belt scale shall be ± 0.5 % on actualconveying rate.

3.8 METAL DETECTOR

Metal detector shall be capable of detecting up to minimum 25 mm aluminium sphere

at a maximum working belt speed. Sensitivity to other materials such as stainless steel and

copper shall be proportional to their electrical characteristics.

3.9 TRAMP IRON SEPARATOR (MAGNETIC SEPARATOR)

The suspended magnet shall be able to pick-up tramp iron from the bottom of the

material being carried by the conveyor over which the equipment is fitted. The equipment

shall be complete in all respects, including electro magnet hanging support necessary

fasteners, electrically operated travelling block. Necessary electrics with AC to DC

conversion system & control necessary sensors for the equipment shall be supplied along






3.13 BRAKES

Separate electromagnetic brakes, operated through direct current shall be providedfor each motor driven mechanism. Brakes shall be of approved make and shall be

connected so as to apply automatically when power supply fails or when the stop push

button is pressed or stop command is signalled from PLC. The release of the brake shall be

with adjustable time delay proceeded by electronic command for start of push button is

released. Brakes shall be designed as per IS 3938.

3.14 INSTRUMETNATION AND CONTROL

Complete instrumentation and control for all the equipment provided in this

package shall be covered under the scope of this tender. All field instruments shall be wired

up to the junction box where from the same shall be connected to the PLC as per the

requirement.

3.14.1 Controls

Fuel handling system shall be provided with controls for material flow metering, belt

scale electrical drives, conveyor systems, crusher, dust handling, dust suppression system

and other equipment covered under the scope of this contract.

Field warning sound before starting the conveyors, crusher etc by hooters for one

minute in crusher house, ground hopper, and bunker top shall be provided in every

sequence of operation during start up.






operation. Pull chord switches shall be placed at an every interval of 25

metres on both sides of the conveyor.

Belt sway switches at every 10M to 15M distances as required in each side of

the belt. It shall be industrial, heavy duty, housed in a dust and vermin proof

cast iron / cast aluminium box with indirect arrangement for operation.

Zero speed switches / belt slip switches shall be non-contact induction type

with associated electronic unit. Necessary potentiometer for adjustment of

speed setting shall be provided in the electronic unit in each conveyor.

Material flow metering like belt scale shall be of load cell type hermetically

sealed with IP-67 protection class suitable for remote indication of rate of flow

as well as totalised amount material conveyed at any point of time. The

operating accuracy of belt scale shall be + 0.5% on actual conveying rate.

The weighing scale transmitter shall be installed in a safe location.

3.15 SAFETY DEVICES

All equipment shall be complete with approved safety device wherever a potential

hazard to personal exists and with provision for safe access of personnel to and around the

equipment for carrying out operational and maintenance function. The offer shall include the

entire safety item such as coupling guard, conveyor tail pulley guards, gearing and chain

guard, guard deflector, protection and/or shield etc., shall be supplied.

3 16 CIVIL AND STRUCTURAL





ANNEXURE-5 ELECTRICAL EQUIPMENT AND SYSTEMS

1.0 INTRODUCTION

The plant consists of one number Steam Turbine Generator of 45 MW rating, the

generation voltage level 11KV. The plant electrics have been designed for the power

evacuation 11 KV power distribution system and auxiliary power for the boiler, TG, BOP

auxiliary loads. The power evacuation, auxiliary distribution system shall be in 132 KV and

415 V voltage level. For steel plant loads like steel plant, inter connection of existing plant,

connection with generator, input to the auxiliary transformer, power evacuation inter

connection from the generator switch board shall be in 11 KV voltage level.The power distribution for plant electrics is envisaged at 3.3 kV and 415 V level. The

plant outline design is detailed in drawing nos. HIQ-4036-E-01/R-00.

1.1 GENERAL PRINCIPLES OF DESIGN CONCEPT

The design concept of the electrical system as a whole is based on the requirements

for the safe and reliable performance of steam turbine generator sets and the interconnected

electrical system with provision for easy maintenance and overhauling.The design principles and standards delineated herein is generally in compliance

with latest IEC / IS Standards and the Code of Practice already established in the country.

Indian Electricity Rules wherever applicable have also been complied with.

1.1.1 SYSTEM DESCRIPTION

1 Rated Frequency 50 Hz



Annexure-5 – Electrical System (contd….)



2.10 Control Supply Voltages 110 V AC

110 V DC

3.0 Fault Levels

3.1 132 kV 31.5kA for 1 sec

3.2 11KV 40kA for 3 sec

3.3 3.3 kV 31.5 kA for 1sec

3.4 415 V 50 kA for 1 sec

4 DC System 110 V DC

5 Grounding

5.1 Generator neutral Neutral Grounding Secondary Resistor

5.2 132 kV System Solidly Grounded

5.3 3.3 kV System Medium Resistance Grounded

5.4 415 V System Solidly Grounded

5.6 DC System Ungrounded

6 One minute power frequency

withstand voltage




N t



Note:

1. Continuous duty 415V motors will be controlled by contactors.

2. HT motors will be controlled by Vacuum circuit breakers. Coal handling systemmotors (HT) will be controlled by fused vacuum contactors, considering frequent

starting.

1.2 GENERATORS

The generator coupled with steam turbine will have the following salient technical

features.

Type Synchronous generator

Rated capacity

45 MW (56.25 MVA) to suit the Turbine

rating

Rated power factor 0.8 lag

Rated Voltage

Rated terminal voltage 11 kV

Voltage variation ± 10%

Rated Frequency

Rated frequency 50 Hz




Q titi d ti f th t t f id d f t ti h ll b



Quantities and ratios of the current transformer provided for protection shall be

decided by the bidder and shall be generally in accordance with standard requirements. The

current transformer ratings shall be such as to provide proper accuracy’s for excitationcontrol, relaying, voltage regulation and metering under all normal and fault conditions.

1.2.2 Rotor

The rotor shall be of cylindrical type, the shaft and body being forged in one piece

from nickel chromium molybdenum vanadium steel. The fully assembled rotor shall be

balanced to a high degree of accuracy and subjected to 20% over speeding for two minutes

as per International Standards to ensure mechanical strength.

The field winding shall consist of coils made up of copper with bonded insulation and

shall be held in position against centrifugal forces in wedges in the slot portion and by high

tensile non-magnetic alloy steel retaining rings in the overhang portion.

Strength test, material analysis and ultrasonic tests shall be performed during the

manufacture of the rotor. The rotor shall be balanced in various planes at different speed

and shall be subjected to over speed test. Individual turns of the rotor coil shall be insulated

against each other.

1.2.3 Fan

The rotor shall have fans mounted on it for the circulation of air inside the machine.

The fixing bolts, pins, nuts, etc. shall be made of non-magnetic material.

1.2.4 Shaft Seals




The rotor windings shall be directly cooled by air The stator core shall be cooled by air



The rotor windings shall be directly cooled by air. The stator core shall be cooled by air

flowing through the radial ventilating ducts. The shaft mounted propeller type fans on each

side shall facilitate circulation of air inside the machine. The air inside the generator shall bemaintained clean and dry by continuously circulating the air through a suitable air drier and

filter arrangement. There should be 100% standby arrangement for the same.

1.2.7 Temperature Measurement

Temperature of various active parts shall be measured. The stator winding

temperature shall be sensed by at least one embedded resistance thermometer for each coil

placed at the bottom of the slots out of which at least six shall be in the end zone.

Temperature of cooling water to the (in case of water cooled machines), air coolers,

hot and cold gas and lubricating oil to the bearings and shaft seals shall also be sensed by

resistance thermometers. The rotor winding temperature shall be measured by resistance

method and shall be continuously recorded. Duplicate sensor shall be supplied for all the

above temperature measurements.

1.2.8 Generator Excitation System

The excitation system shall be brushless type. The brushless exciter shall consist of a

permanent magnet generator, AC exciter and rotating rectifier with silicon diodes and

indicating fuses. The whole system should be enclosed to avoid dusty air ingress from

outside with adequate cooling arrangement of the closed circuit air inside.

The excitation system shall be complete with switchgear, control equipment and

a tomatic oltage reg lators It shall be capable for operating the generator at f ll range of




Generator will conform to IEC 34 The generator will be capable of withstanding short



Generator will conform to IEC-34. The generator will be capable of withstanding short

circuit level as per IEC. Short circuit ratio will not be less than 0.5. Generator will be suitable

to operate continuously with a negative sequence current of 8% of the rated value, and I2Twill not be less than 8.

The generator withstands capability for 3-phase short circuit at the generator terminals

when operating at rated MVA and p.f. with 5% over voltage will be for a period of not less

than 3 seconds. The generator will be capable of delivering 100 % of the rated output with

one cooler out of service.

Line charging capability (MVAR) of generator will be not be less than 40% rated MVA

at zero p.f. leading.

The generator winding will be star connected and all the six leads of the generator

phase and neutral side will be brought out of the stator frame for connection to busduct. The

neutral of the generator will be earthed through distribution transformer and secondary

resistor to limit the ground fault current to above 10 amps.

Surge diverters and protective capacitors will be provided near STG to protect the

insulation of the generators from the onslaught of surges, both from steepness of wave front

and magnitude of surge level.

The generator will be provided with either brush less excitation system consisting of

exciter with rotating diode assembly along with Permanent Magnet Generator (PMG) or

static excitation achieving high degree of operational reliability and minimum maintenance.

The e citation s stem ill ha e fast response time to meet the s stem req irement




Electrical equipment and its systems that will be provided for the proposed Power Plant



Electrical equipment and its systems that will be provided for the proposed Power Plant

(PP) as shown in the SLD No: HIQ-4036-E-01/R-00.

1.3.1 132 KV switchyard bays : The existing switchyard main bus (one bay) shall be extended for

interconnection of proposed 45MW power plant. The synchronization system

to be provided in existing switchyard in both outgoing breaker and alteration

of the existing metering system shall be done in the same the accounting of

both input and output of power. The extended switchyard bay in existing

132KV switchyard shall be connected to the proposed power plant switchyard

through HT cable. The cable length is approximately 600mtrs. Bidders to visit

the existing switchyard in the Ferro alloy plant and satisfy themselves

regarding availability of space and flexibility for existence of the existing

132KV facilities.

Single bus system with suitable post insulators, Bus Potential transformer

with isolators etc.

One section breaker for main bus with CTs on either side

Three sets of Potential transformers one set on each of the sections of main

bus and one on transfer bus.




7 Cooling ONAN / ONAF ONAN / ONAF / ONAN / ONAF



7 Cooling ONAN / ONAF ONAN / ONAF /

OFAF

ONAN / ONAF

8 Tap Changer

& Range

OCTC, ± 5 % in

steps of 2.5%

OLTC, ± 10 % in

steps of1.25%

OCTC, ± 5 % in

steps of2.5%

9 Impedance 12.5 % 6.25% 5 % / 6.25 %

10 Basic Insulation level

HT 650kVp 75 kVp 75 kVp

LT 75 kVp 60 kVp 2.5 kVp

11 Sizing Criteria To match the

generator MCR

rating and shall be

design ambient

temperature of 50c

Rated to

meet the unit

HT loads

For supplying the

unit LT loads ans

stations LT loads.

The transformers

are sized on the

basis of 2 x 100%rating.

1.3.3 Generator Electrics:

Generator protections




1.3.5 Switchgears



1.3.5 Switchgears

S.

No.

Description 11KV switchgear 3.3 kV Switchgear 415V Switchgear

1 Type Metal clad /metal

enclosed, cubical

type, free floor

standing, dust &

vermin proof, draw

out type

Metal clad /metal

enclosed, cubical

type, free floor

standing, dust &

vermin proof, draw

out type

Metal clad /metal

enclosed, cubical

type, free floor

standing, dust &

vermin proof, draw

out type

2 Constru-

ctionSingle front Single front Single front

3 Design Sectionalized

single bus bar with

tie breakers

Sectionalized

single bus bar with

tie breakers

Sectionalized

single bus bar with

tie breakers

4 IP

protectionIP-42 IP-42 IP-42

5 Fault level 40KA for 3 sec 31.5KA for 1 sec 50KA for 1 sec

6 Incomers VCB breakers VCB breakers ACB breakers






13 Max.

Panel

height

from FFL

2400mm 2400mm 2400mm

14 Control

Supply110V DC 110V DC 110V AC

15 Incomer

Cable

Entry

Bottom Bottom Top entry

16 Outgoing

Cable

Entry

Bottom Bottom Bottom

The High Tension and Low Tension switchboards shall generally comprise of

adequately rated circuit breakers for tiebreaker and outgoing circuits. The switch boards

shall be complete with draw-out type circuit – breakers, earthing switches, bus– bars, draw-

out type voltage transformers, CTs, cable connections etc. Earthing trucks of approved

design shall be provided in case inbuilt earth switch is not standard feature in the design.




The potential transformers (PTs) shall be mounted on independent draw-out type



p ( ) p yp

carriages in HT board and fixed chassy in LT board in separate panels. In HT board the PT

shall be arranged such that in the draw-out position the PTs together with the protective

HRC fuses shall be disconnected from the high voltage circuit and automatic shutters shall

isolate bus side / line side contacts. The PTs shall be cast resin insulated.

The racking mechanism of the circuit breaker truck shall permit smooth operation

without jerk. It shall be possible to engage and lock the circuit breaker truck in “Service“, i.e.

fully drawn–in and “isolated’ i.e. fully drawn out positions. In the “Test” position, the circuit –

breaker shall be drawn out with low voltage circuit connected to permit testing. All these

positions shall be achieved with the front door closed. Suitable earthing connections

between the circuit breaker truck and the cubicle shall be provided so that the earth

continuity is maintained in ‘ Service ‘ and Test ‘ positions. All necessary connections

between the fixed and the moving portions of the equipment shall be made with positive

pressure contacts without any possibility of loose connections. Flexible jumper connections

with plugs and sockets shall be provided with the equipment so that it will be possible to

operate the breaker for testing when in ‘test’ position. All standard interlocks of switchgears

shall be provided.

Micro switches shall also be provided for the circuit breakers for incorporating

positional interlocks in the control scheme.

Cable box for incoming and outgoing cables shall be suitable for terminating heat

shrinkable type indoor cable terminations. Terminations shall be fully contained within the




Strip type space heaters shall be provided in the cable chambers and front breaker



chambers. The space heaters shall be rated for 240V SPN supply and controlled through

thermostat and a switch shall be provided on the front panel on individual cubicles.

1.3.6 Circuit-breakers

Circuit breaker shall be tested and proven design and robust construction. The

minimum rating of the circuit breakers of LBDS shall be 630A for 11KV outgoing and 1200A

for grid & generator breaker. The breaker capacity shall be minimum of 1250A for MCC

feeders and 4000A for Generator, grid and tie breakers. No part of the circuit breaker or any

other part of the equipment carrying the fault current or any supporting structure shall be

unduly strained or damaged when making or breaking the specified fault current. Circuit

breakers should be provided with necessary auxiliary switches for indication, control,

interlocking, protection and other purposes. Four spare sets of auxiliary contacts, two

normally closed and two normally open shall be left free in each unit wired up to the control

cable terminal board. The auxiliary contacts shall be mounted in an accessible position. If

contact multiplication is required, CB normally open (NO) auxiliary contacts shall only be

used along with relays.Each circuit breaker shall have shunt trip device suitable for operation at a voltage of

110V DC and shall be provided with ON and OFF position indicators and operation counter.

Spring charging motor shall be designed to operate at a voltage of 240VAC.

Rated current of all secondary windings of CTs shall be 1A unless otherwise specified.

For differential protection, CTs matching ratio shall be provided. The accuracy limit factor for




The cable terminal arrangement for all outgoing circuit-breaker and SFU units shall be



housed in separate cable compartments and shall be suitable for multi-core aluminium

conductor PVC insulated armoured/un-armoured cables of number, types and sizes as

specified. The termination arrangement of multiple cables shall permit easy connection and

disconnection of individual cables without disturbing the other cables. For termination of

cables suitable bus-bar extension of proper size shall be provided.

1.3.7 Circuit-breaker Handling Truck

A suitable universal type truck shall be provided for withdrawing the breakers from the

board. The trucks shall have platforms of adequate mechanical strength for bearing the

weight of the largest circuit-breaker unit and shall be provided with necessary guide rails and

stops. The height of the platform shall be adjustable to suit the levels at which the different

circuit breakers are mounted on the switchboard.

1.3.8 Motor Control Centres:

MCCs will be provided for TG, Water treatment plant, DM Plant, Cooling tower and

pump house, AHS, FHS, Boiler, ESP, capacitor panel with APFC relay, PDB, LDB , etc. The

source of power will be from PCC provided in the LT side of distribution transformer.Feeders shall be selected such that the LT loads above 1KW and below 50KW are

connected to DOL Starter. Above 50KW motor shall be provided with star delta starter. All

valves and conveyors wherever required shall have Reverse DOL starter.

1.3.9 Motors:

All LT motors ill be sq irrel cage ind ction t pe machines and ill operate on 415V 3




be provided with space heaters.



The speed-torque characteristics of the motors shall be matched with those of the

coupled machines so that smooth acceleration is obtained without over-heating the motorand over-stressing the mechanical parts of the driven equipment. The terminal boxes shall

be of adequate size for terminating the required number and size of PVC insulated,

armoured, aluminum conductor cables after considering the required derating factors. The

motor shall be dynamically balanced to comply with the requirements of IS: 12075 including

the amplitude of vibration specified therein. The motor feet shall be integrally cast with the

stator and shall be of such a design as to prevent breakage or other failures due to vibration

normally encountered in power plants. The motor body shall have two separate earthingterminals. Motors shall be provided with lifting hooks / lugs for frame sizes 100 and above.

1.3.10 Capacitors

Capacitors shall be provided at the load end or in each MCC end which is the source of

the low power factor. However, Capacitors of adequate KVA shall be provided in MCCs to

correct the power factor to 0.9 so that the rating of electrical equipment will be economical

and operation will be optimum. The capacitors shall be equally provided on either side ofeach bus. The power factor correction in bulk loaded MCC (say above 200KVA) shall have

automatic cutting in and cutting out of capacitors and the control requirement shall be

programmed in DCS system.

1.4 CONTROL AND PROTECTION

Central Control Room (CCR) shall have free floor standing vertical panels to provide




For protection of equipment against abnormal system conditions, adequate protective



devices will be installed in the respective switchgear and / or relay panels. A group of such

protective devices will be necessary to protect the equipment under different abnormal

conditions arising in the system. In all cases, proper discrimination shall be achieved to

isolate the faulty elements only keeping the healthy part of the system in service.

All protective relay panels will be of free standing, floor mounting, sheet steel

enclosed with a degree of protection of not less than IP 40. The panels will be located in air

conditioned rooms.

All protective relays will be comprehensive numerical type capable of measuring all

electrical parameters like voltage, current, power, power factor, frequency etc. The relays will

be capable of communicating all analogue and digital signals with plant DCS system, as

applicable.

All protective relays will be of draw out type with built in testing facilities. Small auxiliary

relays may be of non-draw-out type and mounted within the cubicle. All relays will have

hand-reset and means for visual indication of their operation.

Fully graded protection system with requisite speed, sensitivity and selectivity will beprovided for the entire power station. Critical equipments / systems will be provided with

duplicate protection.

The unit protection relays will be divided into two independent groups including

separate power supply so that in case of failure of one group, the protection system shall be

still functioning and protection of the unit is guaranteed




The protection has two over currents and one earth fault current check elements and



a timer with a continuously adjustable setting of 0.5 sec. This protection shall be provided for

each breaker separately.

1.5.3 Generator Protection

Differential protection - generator winding

Over voltage protection

Stator Earth fault protection

Reverse power protection

Negative phase sequence current protection

Field failure protection

Rotor Earth fault protection

Generator overload protection

Overall differential protection for generator, GT and UAT.

Generator under frequency protection

Local breaker back up protection

Diode failure relay

Backup Impedance Protection

Low forward Power protection

Pole slipping protection




1.5.5 LT Service Transformers



Over current protection (IDMTL & instantaneous)

Earth fault Protection LV side Backup Earth fault protection

Buchholz protection

Oil winding temperature protection

1.5.6 HT Auxiliary Transformers

Differential protection

Restricted Earth Fault protection for LV winding

Over current protection on 1IkV side & LV side

Backup Earth fault protection

Bucholtz protection

Oil/winding temperature protection

Pressure Relief valve OLTC surge relay protection.

1.5.7 3.3 kV Motors

Multifunction Numerical motor protection relay having flexibility to

accommodate following protections

I t t t d d fi it ti t t ti




1.6.2 Telephone System



The Power plant and housing colony will be provided with microprocessor based

intercom telephone system to facilitate inter-communication for operation/administrative

purposes. This consists of an Electronic Private Automatic Branch Exchange (EPABX) of

suitable capacity. All the instruments for subscribers will also have the provision for hooking

up with P&T lines.

The telephone sets will be installed in various areas of power plant and colony. The

EPABX at Power plant and EPABX at colony will be interconnected.

In hazard areas such as oil storage, wall telephone sets with explosion proof and

corrosion resistant metal cases will be provided.

1.7 ILLUMINATION SYSTEM

The plant lighting system includes the normal AC lighting and emergency Lighting

which contributes together 100% lighting as well as emergency DC lighting in selected areas

of the plant during plant emergency conditions. The emergency AC lighting will provide

about 20% of the total AC lighting.

The plant lighting (illumination level) is varying at different locations of the Plant

depending on the utility and nature of work expected to be carried out at that area.

1.7.1 Normal A.C. Lighting of the Plant

Lighting feeders will be provided with lighting transformers of voltage ratio 1:1 for

reducing fault level. For general illumination, fluorescent fixtures are taken into




portable tools and other services. Flush type 5 A and 15 A single phase receptacles shall

l b id d f ffi t l d f l ili



also be provided for office rooms, control rooms and false ceiling areas.

1.7.5 Illumination Levels

Illumination levels proposed at various places are listed below:

Location

Illumination

level (lux)

Control room, control equipment room, testing

laboratories 400

Switchgear rooms, MCC room 200

Turbine hall 200

Air compressor house, pump house, water treatment

plant. 150

Basement floors, boiler house including platforms,

crusher house, 100

Cable galleries, passages, stairs, toilets

Coal conveyors (outdoor), fuel oil delivery header, oil

storage tanks 50

O td T f d & it h d 30 t 50




cables will be suitable for unearthed system.

/



LT power cables will be 1100 V grade with stranded aluminium/copper conductor,

XLPE/PVC insulated, extruded PVC inner sheathed, armoured and overall FRLS PVC

sheathed.

Control cables will be multicore 1100 V grade, PVC insulated, PVC inner sheathed

armoured and overall FRLS PVC sheathed with 2.5 mm stranded copper conductors.

Main factors which will be taken into consideration for selection of cable sizes are as

follows:

System short circuit current

Derating factors due to higher ambient temperature and grouping of cables

Continuous current rating.

Voltage drop during starting and continuous operation

Standardization of the cable size to minimize too many sizes of cables.

The cables will conform to the relevant Indian / IEC standards in general with the

following special, FRLS properties for the outer sheath. BOQ of cables shall be submittedwith design basis for approval.

1.9 PLANT DC SYSTEM

The DC power system provides DC power to protection and control requirements and

h i l l d h i d f i l f AC Th DC




compensation factors.

B tt ill b f t t l d id ith l t t b l iti l t T (2)



Battery will be of storage type lead acid with plate or tubular positive plates. Two (2)

nos. redundant battery set at Main Power, Plant has been considered. Separate batteries for

switchyard, telephone, fire fighting system and other systems, and remote areas like coal

handling plant to be provided.

1.9.2 Battery Chargers

One (1) No. Battery charger for each battery set (float cum boost) of suitable

capacity will be provided for quick boost and trickle charging.

The battery charger will be of solid-state control rectifier type, completely

automatic and self-regulating.

The float charger will be capable of floating the battery and at the same time

supply the continuous DC load of the unit.

The boost charger will be capable of boost charging the battery a fully

discharged battery to a state of full charge in 12 hours.

1.9.3 BATTERY AND BATTERY CHARGER LOAD DETAILS:

The following minimum requirement loads shall be considered for the battery and

battery charger system design.

415V PCC and MCC panel (trip coil, closing coil, shunt trip coil, protection

relays, indications)

3 3KV & 11KV switchgear (trip coil closing coil shunt trip coil protection




The earth mat of the station will be designed such that the total ground impedance

does not exceed 1 0 ohm The plant grounding will utilize GI flat /mild steel rods Equipment



does not exceed 1.0 ohm. The plant grounding will utilize GI flat /mild steel rods. Equipment

grounding conductor will be of galvanized steel flats / GI wire.

Each large structure and building complex will have a ground loop around its

perimeter. The ground loops around each structure will be connected to the ground grid.

The fence within the ground grid will be bonded to the plant ground system. The

power plant ground grid will be tied together with the switchyard ground grid.

The grounding system will be connected to all metallic equipment, electrical as well

as non-electrical (except underground pipelines), located at the plant site. All these will be

connected at two distinct points. This will include all structures, buildings, towers, etc.

The chimney and powerhouse building will be equipped with lightning protection.

Lightning protection conductors located on the top of the structures will be connected to the

ground loop surrounding the structures with down comers as per the provisions contained in

the latest issues of Indian Electricity Rules and IS 2309.

1.11 EMERGENCY POWER SUPPLY SYSTEM

A separate emergency power supply for safe shut down of power plant shall be

provided.

One (1) No. of 625 kVA DG sets will deliver power at 415V, 3 phase, 50 Hz, 4 wire.

The estimated capacity of the set will take care of the following loads:

Barring Gears.




Two (2) UPS units (2x100%) will be furnished for the Power Plant sized to feed

essential AC loads like DCS and other C&I equipment The UPS system will be provided



essential AC loads like DCS and other C&I equipment. The UPS system will be provided

with two (2) nos. 100% capacity inverter.

An alternative 110 V A.C. single-phase source through by pass transformer and

stabilizer is provided through a static transfer switch to feed the vital A.C. loads during the

failure of both the inverters.

1.12.1 TECHNICAL DATA SHEET FOR – UPS SYSTEM

SL.NO GENERAL DATA DESCRIPTION

1.Continuous rating : Suitable rating

2.Quantity : Two Sets.

3.Location : Indoor.

4.

Input supply : 110 V +/- 10%

5.Output supply : 110 V +/- 10%

6.Input frequency : 50 +/- 5%

7.Overall efficiency : 80 ~ 85 %




18.Transfer time on manual transfer : Synchronous - Break free



19.Charger Type :

FCBC, Constant Voltage with

Charging current Limit.

20.Charger Efficiency : >90%

21.Discharging time : 60 minutes

22.Type of battery : Nickle Cadmium

23.Type of electrolyte in the battery :

Potassium Hydroxide (KOH)

Density: 1.19

24.

Type of Cell container in the

battery : Translucent Polypropylene

25. Permissible overload :

120% for 10 Min. 150 % for 1

Min

26.Degree of protection : IP 42

27.Paint shade : RAL 7035




protection shall be provided which will protect the inverter against overloads and short

circuits at the output. The current limit shall be adjustable. Once the overload is removed,



p j ,

the inverter shall automatically resume normal operation.

The inverter output shall have spike / surge suppression filters to protect the loads

By-pass transformer shall be natural air-cooled type suitable for indoor location. Links shall

be provided on 415 V windings to give offload tapings of +/- 2.5% & +/- 5% of normal

voltage.

A manual Bypass switch, make before break type, shall be provided to take the

system out for maintenance without interrupting power to the load. The switch shall be

mounted in the inverter section. The enclosure to be of IP 3X or better The SUPPLIER shallensure that neutral of the all transformers are solidly connected to earth to ensure that the

potential between earth and neutral is zero at all conditions.

1.12.3 PRINCIPLE OF OPERATION:

The uninterrupted power supply system shall be complete with chargers, inverters,

static switches, by pass transformer with Automatic voltage regulator and manual bypass

switch. Normally the system will supply the load in UPS mode. In case of any trouble withone of the Inverter Sections, the load shall be catered by the redundant system if both the

inverters fail, loads shall be transferred to the bypass transformer without any interruption.

A manual by pass switch (make before break) shall be provided to isolate the

inverters and static switches for maintenance. When it becomes necessary to boost charge

the battery (i e when the battery has discharged during mains failure) the charger shall be




Switchyard control panel

Transformer control panel



Transformer control panel

SWAS system panel Field instruments

CEMS panel

Annunciator panel

AHS PLC control panel

FHS PLC control panel

DM plant control panel

1.13 CABLE TRAY:

Prefabricated ladder type/ perforated type cable trays shall be used for laying of

cables in cable trenches while routing cables along technological structures etc. Cable trays

shall be galvanized after fabrication.

Ladder type cable trays shall be fabricated by means of 2.5mm thick hot rolled sheet

for longitudinal members and cross members. The cross members shall be placed at an

interval of 250 mm along the length of the rack with 30mm slotted holes for cable clamping

purpose. Width of the rung shall be 50mm and above. Cable tray ends shall be suitable for

connecting the jointing plates. The cable trays shall be of widths 300mm, 450 mm, 600 mm

and 900mm. The ladder type racks shall be used for power and control cables.


45 MW CAPTIVE POWER PLANT AT GARIVIDI, ANDHRA PRADESH.EPC TENDER SPECIFICATION

ANNEXURE -6 ASH HANDLING SYSTEM & AUXILIARIES



1.0 DESIGN BASIS FOR SYSTEM

1.1 BASIC DETAILS OF DRY DENSE PHASE SYSTEM:

Following are the basic details of the proposed ash handling system for CFBC.

Description Details

No of boilers and

capacity

1 Nos of CFBC boiler of capacity 195TPH

Fuel combinations

used in boiler

1. 50% Washery rejects, plus 50% Indian coal

2. 50%Washery rejects, 25% Indian coal, 25%

Indonesian coal

3. 25% Washery rejects 50% Indian coal, 25%

Indonesian coal.

Ash collection points Furnace, Cyclones, Eco/APH and hopper below the

ESP fields.

2.0 THE SCOPE OF SUPPLY FOR THE ASH HANDLING SYSTEM SHALL

INCLUDE BUT NOT BE LIMITED TO THE FOLLOWING:



Annexure – 6 Ash Handling System & Auxiliaries (Contd.)

For APH / Economiser one ash pipe line from the APH / Economiser



hopper to the respective fly ash silo.

ESP – all lines from the ESP ash hopper to the respective fly ash silo.

Abrasion resistant type Pipe fittings like Lateral, Elbow or Tee as

required changing direction or diameter.

Pneumatic piping interconnecting the compressor, air receiver, receiver

outlet to the required points complete with supports, accessories, various

traps, strainers, etc., as required.

Ash storage silos of RCC construction one no for boiler bottom ash and

one number for fly ash. Capacity of bed ash silo – 150 m3 and Capacity of

fly ash silo – 600 m3.

All ash conveying lines, vent fans, dust collectors aeration blowers and

level indicating instrumentation etc.,

Pocket feeder below the silo to transport ash to dust unloaders.

Dry dust unloaders or pug mill unloaders on the silo at elevated level

above ground to allow access to ash transport vehicles below with water

spray arrangements.

Lubricated screw type air compressors with oil and moisture separators of

required capacity complete with required number of air receivers of





Annexure – 6 Ash Handling System & Auxiliaries (Contd.)

incoming air sources. Typically, the filter bags shall be "jet-pulse" cleaned. Silo

t filt b l i h ll b ti



vent filter bag cleaning shall be continuous.

3.10 Pipe line support structure shall be as per the standard.

3.11 Valve access door shall be provided in each chamber for ease of maintenance

and inspection.

3.12 Flapper style gates shall swing completely out of material flow path to minimise

component wear.

3.13 Wear back fittings shall be provided to have plain-end and shall be removable forpipeline inspection.

3.14 Bellows Expansion Joints shall be inserted in long pipe runs and before ash

collection vessels to accommodate thermal expansion.

3.15 Velocity in ash conveying pipelines shall be less than 2 m/sec.





Anneuxre-7 DM Plant, Auxiliary cooling water system, Ventilation system, Fire fighting system (contd.)

9 Total CO2 NIL



10 Free chlorine NIL

11 Oil NIL

1.4 DEMINERALISING PLANT SHALL CONSIST OF BUT NOT BE LIMITED TOTHE FOLLOWING:

One of raw water tank with accessories.

Two nos. of chlorination dosing system.

Two (1W+1S) nos. of raw water pump with accessories.

One (1) Multi Grade Filter (MGF) with back flush, fast flush recirculation

etc.

One (1) Activated Carbon Filter (ACF) with back flush, fast flush /

recirculation / CIP arrangement, tanks, dosing system etc as required.

One set of RO membrane with back flush, chemical cleaning,

arrangements , high pressure pumps, chemical dosing pump etc.,

Permeate tank and pump with accessories.

One set of conventional DM plant with cation exchanger and anion

exchanger complete with resins and accessories along with degasser

tower with tower packing and necessary accessories





Anneuxre-7 DM Plant, Auxiliary cooling water system, Ventilation system, Fire fighting system (contd.)

Window model split or package air conditioners shall be of standard reputed

make suitable to meet the requirement as per the standard shall be provided.



q p p

Integrated air ventilation system for electrical room with AHU adequate fancapacity & suitable ducting shall be recommended. The maximum positive pressure shall

be +5 mmWC.

Ventilation system of having throw fans and exhaust fans for required capacity

shall be considered for TG hall. Required quantity of roof exhausters with required

capacity of air flow shall be selected for TG hall.

Man cooler shall be provide in TG hall in ground floor, 5 mtrs Floor and TG hallto maintain good ventilation with required air changes.

4.0 FIRE FIGHTING SYSTEM

The system covers protection, alarm, and detection fire fighting system required

for various units of the power plant.

Water based fire hydrant system with pipe work, hydrants, hose, and hose reels,

hose cabinet branch pipe coupling hydrant valves and other accessories and auxiliaries.

One AC pump (270 m3/hr), Two (2) jockey pumps each of 10 cum/hr and one diesel

pump of capacity 270 cum/hr shall be provided with valves auto start and stop control to

pump, the water where ever required from the pump house near raw water tank. Hydro

pneumatic tank and compressor shall be provided as required. The water hydrant

system covers complete power plant area.



ANNEXURE – 8

INSTRUMENTATION & AUTOMATION SYSTEM



1.0 DESIGN BASIS OF DCS

1.1 The following shall be basis for design of the instrumentation and control

systems for the CPP

Steam Generator System (CFBC)

All field Instruments from the different locations will be wired & terminated

up to the local junction box by the boiler supplier. The supplier will furnish the JB

internal wiring details. The junction boxes shall be located at floor wise in the

boiler area depending on the requirement.

From the local junction boxes multi core cable will be laid through the

cable tray to the DCS marshalling cabinet. Scope of laying cable from JB to DCS

including detailing will be under the DCS Supplier scope.

Operating & controlling the system will be from the DCS station located at

CCR. Initial start-up of the system with all protection interlocks/permissive shall be

from the DCS located at CCR.

Steam Turbine Generator (STG)

All field Instruments from the different locations will be wired & terminated

up to the local junction box by the equipment STG supplier The supplier will



ANNEXURE – 8 INSTRUMENTATION AND AUTOMATION SYSTEM(CONTD.)

Ash Handling System (AHS)

Controlling the System will be from the dedicated redundant PLC located



Controlling the System will be from the dedicated redundant PLC located

in the field control panel. Supply of PLC including cabling from field instruments up

to the PLC shall be in the AHS supplier scope. The control of AHS shall be

selected through Manual or Auto mode switch which will be located in the Local

Control Panel. Brief write-up on entire AHS operational & control sequence shall

be furnished by supplier.

Communication with the DCS for monitoring the sequence & other

parameters will be through the built-in Communication port available in the PLC.The Data Communication to the DCS will be through special Cable (Modbus

Communication Cable).Memory mapping details to be furnished by the PLC

supplier to interface the PLC with DCS. Scope of engineering, detailing & laying

of cable from PLC to the DCS shall be carried out by DCS Supplier.

DM Plant

Controlling the System will be from the dedicated PLC located in the field

control panel. Supply of PLC including cabling from field instruments up to the

PLC shall be in the DM Plant supplier scope. The control of DM Plant shall be

selected in Manual or Auto mode switch which will be located in the local control

panel.




Start-up / Controlling / Sequencing the System will be from the dedicated

micro-processor based controller at the local controller console. The supply of



controller will be under compressor supplier scope.

For monitoring the critical process parameters, communication to the DCS

will be through modbus communication port available in the controller itself. Scope

of supply engineering & laying cable from local controller to the DCS shall be

carried out by DCS Supplier.

Water System

The entire cooling water pump, auxiliary cooling water, CT make up pump

and DM transfer pumps shall be controlled through the DCS from the CCR.

Auto/Manual selection & the corresponding trip Interlock shall be wired in the DCS

panel itself.

For monitoring the process parameters like level, pressure, flow,

temperature, pH, conductivity, pump running status etc shall be hardwired from

the field Instruments to the DCS marshalling panel by the DCS Supplier. Scope ofsupply, engineering & laying cable from local controller to the DCS shall be carried

out by DCS Supplier.

Cooling Tower Monitoring

Control of cooling tower fans shall be from the local control panel in the




Emission Monitoring System

Monitoring the emission of CO SO2 Nox & other important parameters



Monitoring the emission of CO, SO2, Nox, & other important parameters

in the combustion gas & volatile emission will be from the analyzer mounted at

critical location.

The Emission Monitoring System shall be supplied by the boiler supplier.

All critical parameters from these analyzers shall be hardwired to the DCS for

monitoring. In addition to that these analyzers shall also be provided with built-in

modbus communication port.

Scope of supply, engineering & laying cable from MCC/PCC to the DCS

shall be carried out by DCS Supplier. .

SWAS System

Separate analyzing & measurement unit will be mounted in the field for

measuring the parameters like pH, silica, conductivity, dissolved oxygen, in steam

& Feed water.

The SWAS System shall be supplied by the boiler supplier. All the critical

parameters from these analyzers shall be hardwired to the DCS for monitoring. In

addition to that these analyzers shall be provided with built-in modbus

communication port.




DCS analog input module.

Compensating cables shall be



T/C Thermocouple Input AI –T

Compensating cables shall be

provided as part of the field cabling up

to the marshalling cabinet.

RTD – 3 Wire AI – R For Pt-100Ω 3Wire RTD inputs

All the analog outputs shall be of 4-20mA DC capable of driving a load of

700 Ω.

All the digital inputs wired to the DCS from the field limit switches,

proximity switches, process switches and MCC contacts will be potential

free and suitable for 24V DC interrogation voltage.

The digital output transmitted from the DCS to the field solenoid valves

and the MCC shall be through potential free relay contacts. Necessary

interposing relays and contactors shall be provided for all the digital

outputs. Modules with built-in relays are preferred and the specification of

the relay contacts shall meet the duty cycle ratings.

Separate marshalling cabinets along with terminal blocks shall be provided

to terminate cable from the field as well as from MCC. The terminal blocks

shall be arranged as per the field cable schedule, which shall be furnished

during detail engineering




Control/Communication facility to Turbine Governing System, Energy

Meter, OPC Server MIS, SCADA Terminal with RS-485 Link



Controller & IO subsystem capable of performing the following functions

• CLCS

• OLCS (Sequential / Protection & Interlocking)

• Data Acquisition

• SOE with 1 m sec resolution

• Third Party Integration using standard protocol like Modbus Master-

Slave/Modbus RTU or through Ethernet to the Data Highway

The system configuration shall be as per the drawing no. HIQ-4036-I&C-01 titled “System

Configuration Diagram” enclosed to this specification.

This power plant has been unit wise classified in to the following for the purpose of

DCS.

SECTION: CFBC ,STG & BOP

The DCS has been configured in the functional distribution concept having

separate field control sub-system section wise (FCS – 1 ~ 3) for section respectively to

perform the monitoring, closed loop and sequential, protection and interlocking logics as




v) NX- 1 &2 :

High speed, redundant fast Ethernet data

highway network consisting of Ethernet



switches.

The system offered shall be from latest series introduced to the market by the

tenderer in the last 2 years and systems that are old by more than 5 years are not

acceptable even though improvements/up gradations are made to the system.

The system offered shall be from the same nativity of Processor, I/O’s and

Software packages developed exclusively as a total system. Configuration with hybrid

components or software packages is not to be offered.

The Tenderer to configure the system, based on the I/O List. While configuring the

system, the following design aspects are to be considered.

The system components shall be identical as far as possible with high degree of

inter changeability and flexibility.

System with minimum types of modules shall be preferred. The Tenderer should

list out all the types of modules envisaged in the configuration diagram separately in the

offer.

The system offered shall be suitable for upward expandability for future

expansions and additions. This expandability should be ensured with respect to Operator

t ti FCS d l f th ft d l t h dl th i t t Th






10 % spare slots or 1 slot in each rack whichever is higher is to be

provided as slot spare.



The racks shall be exclusive for each unit and mixing of I/O channels in theracks is to be avoided.

3.4 CONTROLLER UNIT

The processor shall be of high speed, 32 Bit, latest state-of-the art technology with

powerful instruction set. The processor shall have advanced features for high speed

processing, power and flexibility to perform application and communication oriented task.

The processor shall be provided with memory of flash RAM type with minimum

capacity of 64 MB. However the memory of the system shall be sized such that the

loading of the memory is only to the tune of 60 to 70% after loading all the programmes.

The system shall have standard features like automatic error detection and

correction, watchdog timers, Status indications, self-diagnostic routines for fault finding

and reporting up to I/O level.

The processor & memory loading on the main controller, I/O cards, and

communication processor shall not exceed 60% under the worst loaded condition &

taking 10% I/O requirement of the future.

The Controller shall be able to operate in manual, auto, cascade mode.




The change over from the primary processor to the secondary processor in

case of failure of the primary processor shall be bump less and balance



less. The failure of the primary processor shall have to be diagnosed andreported in the system.

The redundant data link provided in the processor shall work

independently in redundant configuration and failure of any one link will not

initiate the hot stand by change over process.

The failure of any of the data link connection shall be diagnosed by the

processor and reported to the system.

When the Secondary processor takes over on the failure of the primary

processor, the status of the secondary processor shall automatically

change from secondary to primary without any operator initiation. Once the

failed primary processor gets rectified and replaced, this new processor

will get assigned as secondary processor without disturbing the continuous

functioning of the working processor

The hot stand-by redundancy offered for the field control station shall have

the feature of segmental redundancy concept considering the processors,

communication links, power supplies etc as a redundant pair. With the

segmental redundancy concept failure of any component in a pair will

k th th t t t k f th f il ith t th h




The scan time includes the time for scanning the input, A/D conversion, signal

processing and control and outputting as followed



Protection & Interlock for Digital Signals 250 msec.

Digital Signals 100 msec.

Analog Signal (Std Closed Loops) 100 msec

Analog Signal (Critical Closed Loops) 250 msec

Analog Signal (Open Loops) 500 msec ~ 1 sec

Digital Inputs (SOE) 1msec with time stamping

3.5 Self Diagnosis

The System shall have an extensive set of self diagnostic features such that

any failure detected shall be displayed on the operator screen.

At local level, failure mode in any subsystem shall be monitored by an

individual LED.

Diagnostic software shall have the capability to provide information about the

failed module.

Diagnostics feature to display the sensor condition.




On line replacement of IO modules shall be possible without influencing

other logic function.



All modules shall have self diagnostic feature with LED indication

Analog Input modules shall be capable of accepting 4 ~ 20mA DC & shall

provide 24 Vdc power to the field transmitter. However when 4-wire

transmitters are used the modules shall be capable of accepting

4 ~ 20mA DC isolated signal.

RTD modules shall be capable of accepting RTD, Pt-100Ω signal that shall

be individually configured.

Thermo-couple modules shall be compatible for various types of Thermo-

couples like J, K, R, S, T, E, B or N with cold junction compensation.

AO Modules shall have following default option upon failure of the card to

receive fresh output like Hold last value / predefined value from processor

module.

AO Modules shall be capable of driving up to 700Ω total loop resistance at

4 ~ 20mA DC.

DI Modules shall accept the input voltages at 24 Vdc.

DI signal shall be through fused TB with LED indication.




Core 2 Duo Processor or higher family with 32 bit processor having

minimum speed of 3.0 GHz with working memory (RAM) capacity of

min 2 GB



min 2 GB.

High-resolution 22” digital LCD colour monitor (Flat Screen) with minimum

pixel resolution of 1024 x 780.

Bulk memory units (HDD) of not less than 160GB.

One no CD ROM- Drive unit for Operator Station

One no CD Read/Write unit for Engineering Station

Dual ETHERNET 100 MBPS interface modules for connecting the data

highway network and one no ETHERNET interface module for connecting

to the higher-level information network in future.

Console type sheet steel enclosures for mounting the monitors, keyboard,

mouse and the CPU unit of the PC stations.

Engineering and operating workstation console desk shall have furniturearrangements with ergonomic chairs, considering safety and comfort.

The workstations shall be operating using the latest Windows XP platform.

Tenderer shall furnish details of the workstation along with the operating system, in his

offer clearly.




Graphics shall be dynamic & interactive.

3.9 Engineering Station Display



The Engineering Station offered shall provide following functions both on-

line & off-line.

• System Configuration

• Controller Configuration

• Fault diagnostics

• Modification / Addition of Control Loops

• Generation / Modification of Graphics/displays/logs & reports

• Programming of controllers

• Database configuration including configuration of all displays

•

Automatic downloading of the configurations.

• Configuration of various control functions / Alarm settings/Tuning

• Defining the key lock functions

• On-line Compilation of all types of dynamic graphic displays






After successful commissioning of the system consumables shall be provided for a

minimum of three months operation.



3.13 FAST ETHERNET DATA HIGHWAY NETWORK

The PC based workstations and the Field control sub systems (FCS) are networked with

a redundant fault tolerant high-speed control data highway network as shown in the

configuration diagram. The control data highway shall be of high speed Ethernet open

network and systems with proprietary type network are not acceptable. The data highway

network shall have the following main features:

Bus topology of network architecture with high speed Ethernet Backbonethrough redundant fast Ethernet manageable L2 type switches .The

network shall have cross-link independent connections to each node on

the network.

Communication medium shall be of high quality data cable with speed

transmission not less than 100 MBPS.

Communication method shall be of Ethernet conforming to IEEE 802.3

standard

The redundant buses shall concurrently share the traffic load and in case of failure

of one bus, the other shall cater to the full traffic demand. The transfer shall bump less.






shall elaborate in his offer the various performance calculations available

as part of the system with supporting catalogues for the same.



3.17 Software at FCS

The Field Control station shall have powerful instructions and function

blocks for complex control loops facilitating effective analog signal processing. The

software shall have the following features:

On-line editing and down loading of the programme.

On –line upload of the programme from the FCS processor for review and

editing.

3.18 SOFTWARE DEVELOPMENT

The Tenderer shall be required to develop job specific application software

modules using the utility packages. This shall include but not limited to the following:

i)

Database generation (for each work

station)

:

As required

ii)

Process graphic mimic displays with

dynamic graphic definitions

:

Approximate 25no’s

Alarm monitoring, trending and :




3.19 Environment Condition

All Control Panel, Operator/Engineering Stations, Printers shall be located in the



Central Control Room with ambient temperature of 23°C ±2°C with 50% relative humidity.However upon failure of air conditioning system the equipment shall be capable of

withstanding 50°C with relative humidity of 95%.

4.0 SYSTEM, I/O AND MARSHALLING CABINETS

4.1 MARSHALLING CABINETS

The system, I/O and marshalling cabinets shall be of free standing, vertical closed

cubicle type with front and rear opening single doors. Separate cabinets shall be provided

for power distribution arrangement. The width, depth and height of the individual cabinets

shall not exceed 800mm (W) x 800mm (D) x 2200mm (H) respectively for the purpose of

easy handling and installation. The make of the cabinet shall be preferably of RITTAL or

HOFFMAN.

The cabinets shall be fabricated out of cold rolled sheet steel (CRCA)

enclosure of thickness 2.5 mm on front & sides and 2mm for Top & Doors

with welded/bolted construction. All welds shall be smooth and all the

corners to be rounded and the weld spatters shall be cleaned.

Mounting angle, flush with bottom shall be provided. All panels shall be

supported on suitably sized vibration rubber pads designed for bolting to




No.of terminations on one side of the DCS IO cabinet shall not

exceed 300.

C bi t l d i ti



Cabinet colour and painting.

All the panels and cabinets shall be pre-treated and powder coated as per

the following colour coding.

i) Exterior : Pebble grey as per shade RAL 7035

ii) Interior : Milky White

4.2 Wiring Termination & Ferruling

a. All incoming and outgoing wires except the thermocouple lead wires shall

be routed through suitable sizes of clip-on type terminal blocks of minimum

size of 2.5mm². Special terminal blocks such as double ducker, fused TB

with LED indication, disconnecting type etc., shall be used wherever

applicable. The preferable make of the terminal block shall be of

WAGO/PHEONIX.

b. Terminal blocks shall be provided for external wiring with proper

identification strips.

c. Terminal blocks shall have laminated plastic engraved tag in white letters

with black back ground fixed on each Terminal Block.




• All Power cables → 2.5 mm²

• All Signal Cables→ 1.0 mm²



• All Alarm Cable → 1.0 mm²

i. All terminal block shall include at least 20 % spare terminals.

Wires shall run in PVC cable trough s inside the panel. All wires shall be

plainly and durably labelled at both ends for easy identification and must

conform to the wiring-labelling scheme shown in the interconnection

drawing. All spare cores shall be terminated with terminal blocks with

proper identity.

j. Separate safety and signal earthing shall be provided in each system

cabinet. The system earth shall be insulated from the body and shall be

connected to a separate earth pit.

4.3 CONTROL DESK

The following cabinets/control desks shall be provided.

i) Power distribution cabinet for DCS : One (1) no.

ii) System cabinets for FCS : As required.

iii) I/O cabinets for the I/O racks : As required




Ferrules shall fit tightly on the wires & shall not fall off when the wire is

disconnected form terminal blocks

Th hil h f + di t f li h ll b f ll d f ll i t l &



The philosophy of cross + direct ferruling shall be followed for all internal &external wiring in the Control Panel, MCC, Junction Boxes etc..

5.3 EARTHING

The Tendered shall include in his scope of supply all necessary items required for

the isolated special earthing arrangement called as system earth exclusively for the DCS.

Details of this arrangement shall be indicated in the offer. However, earthing

arrangement (safety earthing) throughout the plant including earth mat in the control roomshall be provided by the Purchaser. All the panel and the cabinet bodies shall be

connected to this safety earth and the system shall be connected to the system earthing

arrangement.

Exclusive earthing pits (power earth & system earth) for the DCS as per the

requirements of the vendor shall be provided by the purchaser and rest of all the work

related to earthing shall be in the scope of work of the tenderer.

6.0 MANDATORY SPARE REQUIREMENTS

Following Mandatory spares shall be supplied

10 % of the Input / Output connected to each I/O Card shall be supplied as




Powering up / loading the system system configuration & carryout internal

loop checks.

8 0 PERFORMANCE GUARANTEE



8.0 PERFORMANCE GUARANTEE

8.1 Demonstration of guarantee & performance test shall be with the

Acceptability as follows.

Redundant System → 100 %

8.2 Performance Guarantee Specification

Percentage loading shall be as follows

CPU loading (maximum) → 60 %

Memory utilisation (maximum) → 60 %

I /O loading ( maximum) → 60 %

Communication processor loading → 60 %

8.3 Call up time

The Call up time for the Type of display shall be 1 ~ 4 seconds for the Overview

,Group Display, Loop Display Dynamic Graphics, Real Time Trend, Historic Trend, Alarm

Summary ,Alarm History & Configuration.

FACOR ALLOYS LIMITED45MW CAPTIVE POWER PLANT, AT GARIVIDI, ANDHRA PRADESH


ANNEXURE – 9 – SCOPE MATRIX

Note: EPC Contr. : Scope of EPC Contractor as per this specification

FAL : Scope of M/s. Facor Alloys Limited or by other agency

A. CFBC BOILER



ENGINEERING

SL.

NODESCRIPTION

BASIC

DESIGN

INCL

P&ID

ETC.

DETAILED AND

CONSTRUCTION

DRGS

MANUFACTURE

AND SUPPLY

FABRICATION

ERECTION,

TESTING AND

COMMISSIONING

1.

STEAM DRUMFully welded steam drum withinternals, man holes andnecessary nozzle connectionsfor mounting valves, Safety

valves & fittings

EPC

Contr.EPC Contr. EPC Contr. EPC Contr.

WATER WALL

Water cooled membrane

enclosure with headers and

necessary connections like

EPC


2.


EPC TENDER SPECIFICATION Annexure-9 Scope Matrix (contd.)

ENGINEERING

SL.

NODESCRIPTION

BASIC

DESIGN

INCL

DETAILED AND

CONSTRUCTION

MANUFACTURE

AND SUPPLY

FABRICATION

ERECTION,

TESTING AND

COMMISSIONING



INCLP&ID

ETC.

CONSTRUCTIONDRGS

COMMISSIONING

b. Super heater coilsupports

EPC


SUPERHEATER LINKS

a. Drum to convection SHinlet header

EPC


b. Convection SH outletheader to De-SH inlet

EPC


c. De-SH outlet to radiantSH inlet header

EPCContr.

EPC Contr. EPC Contr. EPC Contr.

d. Radiant SH outlet toMSSV with accessoriessafety valve flow meter

EPC


5.



ENGINEERING

SL.

NODESCRIPTION

BASIC

DESIGN

INCL

DETAILED AND

CONSTRUCTION

MANUFACTURE

AND SUPPLY

FABRICATION

ERECTION,

TESTING AND

COMMISSIONING



INCLP&ID

ETC.

CONSTRUCTIONDRGS

COMMISSIONING

e. Economiser / evaporator Ash hopper with isolationgate

EPC


SOOT BLOWERS

a. Retractable sootblower/Rotary sootblowers

EPC


b. Drive motors EPC


c. Local gauge panel /Control panel

EPC


7.

d. PRV/PRDS EPC

Contr EPC Contr. EPC Contr. EPC Contr.



ENGINEERING

SL.

NODESCRIPTION

BASIC

DESIGN

INCL&

DETAILED AND

CONSTRUCTIONGS

MANUFACTURE

AND SUPPLY

FABRICATION

ERECTION,

TESTING AND

COMMISSIONING



INCLP&ID

ETC.

CONSTRUCTIONDRGS

COMMISSIONING

10. RISERS EPC


INTEGRAL PIPINGWATER PIPING

a. From outlet of deaeratorto Economizer inlet.through HP, LP heatersincluding deliveryheader, with fittings,accessories, motorizedcontrol valves & bypass

valves etc.,

EPC


b. From economiser outletto steam drum inlet

EPC


EPC

11.





ENGINEERING

SL.

NODESCRIPTION

BASIC

DESIGN

INCLP&ID

DETAILED AND

CONSTRUCTIONDRGS

MANUFACTURE

AND SUPPLY

FABRICATION

ERECTION,

TESTING AND

COMMISSIONING



INCLP&ID

ETC.

CONSTRUCTIONDRGS

COMMISSIONING

c. Common drain header EPC


d. Common drain header toblowdown tank EPCContr.


e. Piping from blowdowntank outlet to nearesttrench

EPC


f. Flash steam recovery

piping from continuousblowdown tank todeaerator and exhaust

EPCContr.


g. Supports for Blowdown,drain & vent piping

EPC




ENGINEERING

SL.

NODESCRIPTION

BASIC

DESIGN

INCLP&ID

DETAILED AND

CONSTRUCTIONDRGS

MANUFACTURE

AND SUPPLY

FABRICATION

ERECTION,

TESTING AND

COMMISSIONING



P&ID

ETC.

DRGS

18. AIR BOX

Air box with air nozzle & fuelnozzle and ash drain pipe

with knife gates

EPC


AIR DUCTING

a. Air flow measuringdevice as required.

EPC


b. PA fan suction ducting EPCContr.


c. From PA fan dischargeto air heater /Header/ Airbox.

EPC


19.



ENGINEERING

SL.

NODESCRIPTION

BASIC

DESIGN

INCLP&ID

DETAILED AND

CONSTRUCTIONDRGS

MANUFACTURE

AND SUPPLY

FABRICATION

ERECTION,

TESTING AND

COMMISSIONING



P&ID

ETC.

DRGS

Power operated regulateddelivery damper/ poweroperated damper for suctionduct for SA fan

EPC


22. Fuel feeding system frombunker to boiler burningchamber including sliding gates,fuel feeders with VFD, dragchain conveyors / screwfeeders, chutes and drivingmotors.

EPC


23. Seal pot blowers/ motors withauxiliaries complete EPCContr.


24. Ash cooler blowers/ motors withauxiliaries complete

EPC




ENGINEERING

SL.

NODESCRIPTION

BASIC

DESIGN

INCLP&ID

DETAILED AND

CONSTRUCTIONDRGS

MANUFACTURE

AND SUPPLY

FABRICATION

ERECTION,

TESTING AND

COMMISSIONING



P&ID

ETC.

DRGS

c. From ESP outlet tochimney inlet includingthe ID Fan ductingcomplete with necessary

power operateddampers.

EPC


d. Damper & expansion joints in Flue gasducting

EPC


e. Inlet & outlet expansion

joints of ESP

EPC


ID Fan & motor with allaccessories/auxiliaries, 2 x 60%capacity with Voith turbohydraulic couplings

EPC


28.



ENGINEERING

SL.

NODESCRIPTION

BASIC

DESIGN

INCLP&ID

DETAILED AND

CONSTRUCTIONDRGS

MANUFACTURE

AND SUPPLY

FABRICATION

ERECTION,

TESTING AND

COMMISSIONING



P&ID

ETC.

DRGS

d. SS lining of 2mm thkfrom conical portion

EPC


e. Bed material bunker withsupporting structure fromground level

EPCContr.


f. Lime stone bunker withsupporting structure fromoperating floor

EPC


SUPPORTING STRUCTURE

a. Supporting structurefrom ground level

EPC


b. Operating platform EPC

C t


30.



ENGINEERING

SL.

NODESCRIPTION

BASIC

DESIGN

INCLP&ID

DETAILED AND

CONSTRUCTIONDRGS

MANUFACTURE

AND SUPPLY

FABRICATION

ERECTION,

TESTING AND

COMMISSIONING



P&ID

ETC.

DRGS

i. Complete steelsupports for ducting

EPC


j. Refractory supports &

casing

EPC


k. Hanger rod EPC


l. Supporting steelstructures for boiler roof& side cladding

EPC


m. Approach platform fromboiler to turbine hall

EPC


n. GI sheets for roof andside cladding for boiler

EPC EPC Contr EPC Contr EPC Contr



ENGINEERING

SL.

NODESCRIPTION

BASIC

DESIGN

INCL

P&ID

DETAILED AND

CONSTRUCTION

DRGS

MANUFACTURE

AND SUPPLY

FABRICATION

ERECTION,

TESTING AND

COMMISSIONING



ETC.

b. Hot gas generatorcomplete

EPC


c. Combustion control andmanagement system asrequired.

EPCContr.


VALVES & MOUNTINGS

a. Motorised valves whereever required

EPC


34.

b. Boiler feed watercontrol station.i) 1x100% FCS with

pneumatic control.ii) 1x100% mot. Control

station

EPC




ENGINEERING

SL.

NODESCRIPTION

BASIC

DESIGN

INCL

P&ID

DETAILED AND

CONSTRUCTION

DRGS

MANUFACTURE

AND SUPPLY

FABRICATION

ERECTION,

TESTING AND

COMMISSIONING



ETC.

c. All isolation, drain & rootvalves

EPC


MAIN STEAM LINE ( Upto Inletof turbine)

a. Isolation & root valvesfor drain

EPC


b. Spring loadedmechanical safety valve

EPC


c. Non return valve EPC


d. Silencer on SH safety EPCEPC Contr EPC Contr EPC Contr

38.



ENGINEERING

SL.

NODESCRIPTION

BASIC

DESIGN

INCL

P&ID

DETAILED AND

CONSTRUCTION

DRGS

MANUFACTURE

AND SUPPLY

FABRICATION

ERECTION,

TESTING AND

COMMISSIONING



ETC.

c. Air box drain valve EPC


d. Air box bleed off valve EPCContr. EPC Contr. EPC Contr. EPC Contr.

e. Air & gas line non IBRvalves

EPC


INSTRUMENTATION & CONTROL

INSTRUMENTATION

LOCAL FIELD INSTRUMENTS / TRANSMITTER

40.



ENGINEERING

SL.

NODESCRIPTION

BASIC

DESIGN

INCL

P&ID

DETAILED AND

CONSTRUCTION

DRGS

MANUFACTURE

AND SUPPLY

FABRICATION

ERECTION,

TESTING AND

COMMISSIONING



ETC.

Feed water temp-erature beforeeconomiser

Feed water temperature after

economiser

Steam temp. before and afterdesuperheater

Contr.

Pressure gauges to measureSteam pressure at steam drum& superheater outlet

Bed pressure

41.

Feed line pressure before feedcontrol valve

EPC


Draught gauges to measure42



ENGINEERING

SL.

NODESCRIPTION

BASIC

DESIGN

INCL

P&ID

DETAILED AND

CONSTRUCTION

DRGS

MANUFACTURE

AND SUPPLY

FABRICATION

ERECTION,

TESTING AND

COMMISSIONING



ETC.

ID fan inlet EPC


PA fan inlet EPC

Contr.


SA fan inlet EPC


44. Power operated open & closetype damper at

PA header

SA header

ID fan outlet

PA fan outlet

EPC




ENGINEERING

SL.

NODESCRIPTION

BASIC

DESIGN

INCL

P&ID

DETAILED AND

CONSTRUCTION

DRGS

MANUFACTURE

AND SUPPLY

FABRICATION

ERECTION,

TESTING AND

COMMISSIONING



ETC.

45. FIELD INSTRU-MENTSREQUIRED FORCONTROL SYSTEM

Three element drum levelcontrol consists of

Three nos. drum leveltransmitters (1 no. for widerange and 2 nos for Left & Rt.)

Two no. steam flow transmitter.(one for measurement & other

for control)

Two no. feed flowtransmitter(one formeasurement & other forcontrol)

EPCContr.




ENGINEERING

SL.

NODESCRIPTION

BASIC

DESIGN

INCL

P&ID

ETC

DETAILED AND

CONSTRUCTION

DRGS

MANUFACTURE

AND SUPPLY

FABRICATION

ERECTION,

TESTING AND

COMMISSIONING



ETC.

47. Auto combustion controlconsists of

Two no. steam pressure

transmitter

One no. air flow transmitter

Any other instrument asrequired for proper & safetycontrol of the system.

EPCContr.


48. Superheater steam temperature

control consists of

Two no. thermocouple

Two no. temp. transmitterEPC




ENGINEERING

SL.

NODESCRIPTION

BASIC

DESIGN

INCL

P&ID

ETC

DETAILED AND

CONSTRUCTION

DRGS

MANUFACTURE

AND SUPPLY

FABRICATION

ERECTION,

TESTING AND

COMMISSIONING



ETC.

52. Impulse piping, instrumentcables and signal cables fromfield instruments to DCS

Compensating cables upto DCSpanel for all Thermocouple.

EPC


53. SWAS EPC


54. Vibration monitoring systems forfans

EPC


55. Stack monitoring system EPC


56 Cables beyond junction boxes EPC



ENGINEERING

SL.

NODESCRIPTION

BASIC

DESIGN

INCL

P&ID

ETC

DETAILED AND

CONSTRUCTION

DRGS

MANUFACTURE

AND SUPPLY

FABRICATION

ERECTION,

TESTING AND

COMMISSIONING



ETC.

62. SAMPLE COOLERS

Blowdown / Boiler water /saturated steam / SH steam /

feed water etc

EPC


ELECTRICALS

a. All motors forID/FD/SA/blowers, feedpump motors and otherrelated motors required.

EPC


b. Motor for HP&LP dosingsystem, Cyclone, Coalfeeders, lime andcyclone screw, Ashhandling system,compressor motors

EPC


63.



ENGINEERING

SL.

NODESCRIPTION

BASIC

DESIGN

INCL

P&ID

ETC

DETAILED AND

CONSTRUCTION

DRGS

MANUFACTURE

AND SUPPLY

FABRICATION

ERECTION,

TESTING AND

COMMISSIONING



ETC.

g. Load list with in batterylimits

EPC


h. VVFDs / Hydrauliccouplings with in batterylimits

EPCContr.


i. Local push buttonstations for the motorssupplied by EPCCONTR.

EPC


j. Interconnecting LTpower & controlcables including cabletrays from LT MCC todrives supplied by EPCCO

EPC




ENGINEERING

SL.

NODESCRIPTION

BASIC

DESIGN

INCL

P&ID

ETC

DETAILED AND

CONSTRUCTION

DRGS

MANUFACTURE

AND SUPPLY

FABRICATION

ERECTION,

TESTING AND

COMMISSIONING



ETC.

p. Power control center,transformer, switch gear,starters required for HTmotors

EPC


64. Dearator of capacity 230tons/hour with storage tank ofcapacity 60 tons complete withall accessories, inter connectingpipes including pegging steamline, level controller, pressurecontroller, safety valve, vent

valve and Emergency drain v/vwith piping & accessoriesterminating at flash tank to storehot DM water for reuse.

EPC


BOILER FEED WATER65.



ENGINEERING

SL.

NODESCRIPTION

BASIC

DESIGN

INCL

P&ID

ETC

DETAILED AND

CONSTRUCTION

DRGS

MANUFACTURE

AND SUPPLY

FABRICATION

ERECTION,

TESTING AND

COMMISSIONING



ETC.

d. BFP inlet pipingcomplete with valves andaccessories fromDeaerator outlet and all

recirculating lines frompump outlet toDeaerator.

EPC


66. Complete electrostaticprecipitator of suitable size andnumber of fields to ensure adust concentration of less than50mg/Ncum at outlet with allfields in operation and less than75 mg/Ncum with one fielddown.

EPC


CHEMICAL DOSING SYSTEM67.



ENGINEERING

SL.

NODESCRIPTION

BASIC

DESIGN

INCL

P&ID

ETC.

DETAILED AND

CONSTRUCTION

DRGS

MANUFACTURE

AND SUPPLY

FABRICATION

ERECTION,

TESTING AND

COMMISSIONING



ETC.

c. Bed ash cooler with allauxiliaries/accessaries

EPC


69. Ash hopper at the bottom ofradiant chamber, second pass,economiser bottom, ESP etc.forDust collection with valve, with aminimum clearance of 2500mmbetween bottom of the outletflange and ground with isolationgate, expansion bellow andother accessories as required.

EPC


70. BED ASH DISPOSAL SYSTEMbeyond outlet of ash hoppers atvarious locations.

EPC


71 FLY ASH HANDLING SYSEM C



B. STEAM TURBO GENERATOR & ITS AUXILIARIES

ENGINEERING

SL.

NO. DESCRIPTION

BASIC

DESIGNINCL

P&ID

DETAILED ANDCONSTRUCTION

DRGS

MANUFACTURE

AND SUPPLY

FABRICATION

ERECTION,

TESTING ANDCOMMISSIONING



P&ID

ETC.

DRGS

1

Steam Turbine complete with

top and bottom casings /

barrel casing, rotor, bearings,hydraulically operated stop and

emergency valve, integral steam

strainer, hydraulically operated

throttle/governing valves, etc

EPC


2

HP heaters with all auxiliaries &

accessories including thecondensate water line with

necessary control & by pass

valves, drain lines, valves etc.

EPCContr.


LP h t ith ll ili i &



ENGINEERING

SL.

NO.DESCRIPTION

BASIC

DESIGN

INCL

P&ID

ETC.

DETAILED AND

CONSTRUCTION

DRGS

MANUFACTURE

AND SUPPLY

FABRICATION

ERECTION,

TESTING AND

COMMISSIONING



5

Steam supply lines with

necessary PRDS, valves,

metering instruments, supports

etc for supply of steam from the

boiler main steam header to the

ejectors as well as the gland

sealing system including

preparation of

drawings/documents and

obtaining IBR approval.

EPC


6

Combined lube oil cum

governing oil system complete

with MOP, AOP,EOP etc,

strainers, filters, interconnecting

oil lines with all requiredEPC

Contr EPC Contr. EPC Contr. EPC Contr.



ENGINEERING

SL.

NO.DESCRIPTION

BASIC

DESIGN

INCL

P&ID

ETC.

DETAILED AND

CONSTRUCTION

DRGS

MANUFACTURE

AND SUPPLY

FABRICATION

ERECTION,

TESTING AND

COMMISSIONING



11 Turbine governing systemEPC


12 Gland sealing system with GVCetc.

EPC

Contr. EPC Contr. EPC Contr. EPC Contr.

13Local gauge panel EPC


14

Accessories such as barring

gear, QCNRV, FFRV, isolation

valves etc. in bleed lines.

EPC

Contr. EPC Contr.

EPC Contr.

EPC Contr.

15Common base plate for turbine

and gear box

EPC




ENGINEERING

SL.

NO.DESCRIPTION

BASIC

DESIGN

INCL

P&ID

ETC.

DETAILED AND

CONSTRUCTION

DRGS

MANUFACTURE

AND SUPPLY

FABRICATION

ERECTION,

TESTING AND

COMMISSIONING



condensation heater, water

leakage detector, lube oil flow

regulator etc.

21

Generator metering , protectionand control system including

LAPT, MCSP, NGR and inter

connecting cables etc

EPC


22Motors for TG auxiliaries and

EOP along with starters.

EPC


23

Turbine control and

instrumentation including dial

type pressure and temperature

gauges, pressure switches, level

EPC




ENGINEERING

SL.

NO.DESCRIPTION

BASIC

DESIGN

INCL

P&ID

ETC.

DETAILED AND

CONSTRUCTION

DRGS

MANUFACTURE

AND SUPPLY

FABRICATION

ERECTION,

TESTING AND

COMMISSIONING



pipes/tubes etc.

28

Instrument air requirement

2x100 % air compressor with 7

to 8 kg/cm2 (g) dischargepressure will be provided in

load/ unload operation mode.

2nos of air driers and required

nos of air receiver.

EPC


29 a. Ventilation system (A/C)

complete in TG buildingto maintain control room

temperature 22 + 2

degree C.

b. Ventilation fans with



C. AIR COOLED CONDENSER & ITS AUXILIARIES

ENGINEERING

SL.

NO.

DESCRIPTIONBASIC

DESIGNINCL

P&ID


DRGS

MANUFACTURE

AND SUPPLY

FABRICATION

ERECTION,




P&ID

ETC.

DRGS

1. Turbine exhaust duct from

turbine exhaust flange to ACC

inlet duct with expansionbellow, transition piece etc.

EPC


2. Air cooled Condenser (ACC)

complete with structures

EPC


3.

ACC fans & Gear boxes with

proper mounting arrangementand vibration sensor & oil level

sensor.

EPC


Fan motors with VFD & otherEPC



ENGINEERING

SL.

NO.DESCRIPTION

BASIC

DESIGN

INCL

P&ID

ETC.

DETAILED AND

CONSTRUCTION

DRGS

MANUFACTURE

AND SUPPLY

FABRICATION

ERECTION,

TESTING AND

COMMISSIONING



8. Fan rings EPC


9.Rupture disc EPC


10.Drain lines for connecting other

drain lines like turbine casing

drains, GVC drains etc

EPC


11.

11.1

Condenser auxiliaries

Condensate tank with stand

pipe for instruments

EPCContr.


11 2 Flash pipe for receiving steam EPCEPC Contr EPC Contr EPC Contr



ENGINEERING

SL.

NO.DESCRIPTION

BASIC

DESIGN

INCL

P&ID

ETC.

DETAILED AND

CONSTRUCTION

DRGS

MANUFACTURE

AND SUPPLY

FABRICATION

ERECTION,

TESTING AND

COMMISSIONING



condensers, GVC, LP Heater

and up to inlet of Deaerator.

Contr.

12.3

Split range control valves for

Condensate re-circulation

along with controls

EPCContr. EPC Contr. EPC Contr. EPC Contr.

12.4

Pipe supports, strainers, steam

traps, drains, vents and

isolation Valves as required.

EPC


12.5Drain lines with isolation valves

for ejector condenser drains

etc.

EPC


12 6Dry air/vapour line to ejector EPC



ENGINEERING

SL.

NO.DESCRIPTION

BASIC

DESIGN

INCL

P&ID

ETC.

DETAILED AND

CONSTRUCTION

DRGS

MANUFACTURE

AND SUPPLY

FABRICATION

ERECTION,

TESTING AND

COMMISSIONING



13.4

Inter and after condensers

individually for each service

ejector

EPC


14.

Fin cleaning system:

Fin cleaning system with water

pumps, motor required pipe

lines or high pressure hoses,

valves, water tank etc.

EPC


15. C&I for ACC comprising but

not limited to:

Split range hot well level control

valves complete with LevelEPC




ENGINEERING

SL.

NO.DESCRIPTION

BASIC

DESIGN

INCL

P&IDETC.

DETAILED AND

CONSTRUCTION

DRGS

MANUFACTURE

AND SUPPLY

FABRICATION

ERECTION,

TESTING AND

COMMISSIONING



15.5Temperature gauge for

condensate outlet, condensate

tank, ejector outlet

EPC


15.6

Pressure switches for

Condenser pressure high trip &

alarm, CEP & CDP auto start

interlock on very high level and

auto stop on very low level,

alarm for high and low on

exhaust drain and condenser

tank.

EPC


15.7

Level switches for Low level,

Low-Low level, high level,

High high level & CEP auto

EPC




ENGINEERING

SL.

NO.DESCRIPTION

BASIC

DESIGN

INCL

P&IDETC.

DETAILED AND

CONSTRUCTION

DRGS

MANUFACTURE

AND SUPPLY

FABRICATION

ERECTION,

TESTING AND

COMMISSIONING



15.11Instruments cables up to

junction boxes for connecting to

purchaser’s DCS system

EPC


15.12RTDs, Thermo wells for all the

temperature measuring points

for purchaser’s DCS system.

EPC


15.13Provision for level transmitters

for DCS controls and

instrumentation

EPC


15.14Vibration switches for high and

Very high for each fan for

connecting to DCS logic.

EPC




D. FUEL HANDLING SYSTEM (90 TPH min)

ENGINEERING

SL.NO.

DESCRIPTION

BASICDESIGN

INCL

P&IDETC.


DRGS

MANUFACTUREAND SUPPLY

FABRICATIONERECTION,

TESTING AND

COMMISSIONING



1 Electromechanical Vibratingfeeder of required capacity atoutlet of Coal ground hopper.

EPCcontr.

EPC contr. EPC contr. EPC contr.

2 Required motor with gear box,couplings, coupling guards withpush button for BC1.

EPCcontr.


3

Belt of N/N of required size ofstrength with all drive pulley,end pulleys, snap pulleys, VST

complete, impact rollers,conveyor rollers, skirt rubbersetc.

EPC

contr.


Magnetic separators, metal



ENGINEERING

SL.NO.

DESCRIPTION

BASICDESIGN

INCLP&IDETC.


DRGS




7

Flip flow vibrating screen ofrated capacity to separate250mm coal before primary

EPCcontr




250mm coal before primarycrusher.

contr.

8

Primary crusher – 1 requiredcapacity with drive motor forcrushing coal from 250 mm size

to 75mm size with motorpulleys, belt safety guards etc.

EPC

contr.


9

Bypass chute for primarycrusher, vibrating screencomplete with duct, pneumatic /rack & pinion gates etc.

EPCcontr.


10

Belt conveyor (BC-02) of ratedcapacity from primary crusherhouse to secondary crusher,with closed gallery of CGIcladding and roofing,walkways gratings trestle

EPCcontr.




ENGINEERING

SL.NO.

DESCRIPTION

BASICDESIGN

INCLP&IDETC.


DRGS




13

Secondary crushers of ratedcapacity to crush the oversizematerial (75 mm size) to ( ) 10

EPCEPC contr EPC contr EPC contr



13 material (75 mm size) to (-) 10mm with motors, pulleys, beltdrive safety guard etc.

contr. EPC contr. EPC contr. EPC contr.

14

Flip flow type vibrating screens

of rated capacity to separateout (-) 10 mm, complete withsupporting frame, chutes anddust cover before secondarycrusher.

EPCcontr.


15Required motor with gear box,couplings, coupling guards withpush button for BC1.

EPCcontr.


16

Belt of N/N of required size ofstrength with all drive pulley,end pulleys, snap pulleys, VSTcomplete, impact rollers,

EPCcontr.




ENGINEERING

SL.NO.

DESCRIPTION

BASICDESIGN

INCLP&IDETC.


DRGS




20

Monorails with hoists at primarycrusher house, secondarycrusher house, screen house EPC

EPC contr EPC contr EPC contr



20and transfer tower. The liftingcapacities to be decided by thebidder.

contr. EPC contr. EPC contr. EPC contr.

21

Belt conveyors (BC-04) of rated

capacity, from secondarycrusher to boiler bunkers, withclosed gallery of CGI claddingand roofing, both sideswalkway, gratings, trestlesupports, etc.

EPCcontr.


22

Belt conveyor of rated capacity

for feeding crushed material forprimary crusher to BC1 withtransfer tower complete. Itincludes closed gallery of CGIcladding of roofing both sidewalkways, gratings, trestle

EPCcontr.




ENGINEERING

SL.NO.

DESCRIPTION

BASICDESIGN

INCLP&IDETC.


DRGS




27 Compressed air pipingdistribution for coal handlingsystem.

EPCcontr.




y

28

All foundation bolts required forinstallation of all equipment andstructure under CHS vendor’sscope.

EPCcontr.


29

Dust extraction system (DE-01)with Bag filter, exhaust fan androtary air lock at primarycrusher house.

EPCcontr.


30

Dust extraction system (DE-02)with Bag filter, exhaust fan androtary air lock at secondarycrusher / screen house.

EPCcontr.


31

Bag filters (IBF-01 & IBF-02)with Bag filter, exhaust fan androtary air lock at bunkers for

EPCcontr.




E. ASH HANDLING SYSTEM

ENGINEERING

SL.

NO.

DESCRIPTION

BASIC

DESIGN

INCL

P&ID

ETC.

DETAILED AND

CONSTRUCTION

DRGS

MANUFACTURE

AND SUPPLY

FABRICATION

ERECTION,

TESTING AND

COMMISSIONING



A. CFBC BOILER FURNACE

1. Bottom ash hopperEPC


2. Sliding gate.EPC


3. Surge hopperEPC


4. Isolation plate valveEPC

Contr.


5. Level probe and accessoriesEPC


6 Expansion jointsEPC

EPC Contr EPC Contr EPC Contr



ENGINEERING

SL.

NO.

DESCRIPTION

BASIC

DESIGN

INCL

P&ID

ETC.

DETAILED AND

CONSTRUCTION

DRGS

MANUFACTURE

AND SUPPLY

FABRICATION

ERECTION,

TESTING AND

COMMISSIONING

13Supporting structure for EPC




13.vessels/ash pipe line Contr.


CFBC BOILER CYCLONES



15. Sliding gate.EPC


16. Surge hopperEPC




18. Level probe and accessoriesEPC

ContrEPC Contr. EPC Contr. EPC Contr.



ENGINEERING

SL.

NO.

DESCRIPTION

BASIC

DESIGN

INCL

P&ID

ETC.

DETAILED AND

CONSTRUCTION

DRGS

MANUFACTURE

AND SUPPLY

FABRICATION

ERECTION,

TESTING AND

COMMISSIONING

25Instrument air/water line up to EPC




25.terminal point Contr.


26.Supporting structure for

vessels/ash pipe line

EPC


CFBC BOILER ECO / APH



28. Sliding gateEPC


29. Surge hopper EPCContr.








ENGINEERING

SL.

NO.

DESCRIPTION

BASIC

DESIGN

INCL

P&ID

ETC.

DETAILED AND

CONSTRUCTION

DRGS

MANUFACTURE

AND SUPPLY

FABRICATION

ERECTION,

TESTING AND

COMMISSIONING

49. Ash conveying line (pipe,

fl k t )

EPC

C tEPC Contr. EPC Contr. EPC Contr.



flanges, gaskets) Contr.

50.Service/ash conveying air line

up to terminal point

EPC


51.Instrument air/water line up to

terminal point

EPC


52.Supporting structure for vessels

& pipe line

EPC


CFBC BOILER – BED ASH STROAGE SILO

53. SiloEPC


54.Silo accessories (bag filters, fan

etc)

EPC




ENGINEERING

SL.

NO.

DESCRIPTION

BASIC

DESIGN

INCL

P&ID

ETC.

DETAILED AND

CONSTRUCTION

DRGS

MANUFACTURE

AND SUPPLY

FABRICATION

ERECTION,

TESTING AND

COMMISSIONING

61. Rotary feederEPC

C tEPC Contr. EPC Contr. EPC Contr.



yContr.

62. Ash conditioner assembly

complete

EPC


63. Plate valve (ash conveyingvessel)

EPCContr.


64. Dome valveEPC


65. Ash conveying vessel (master

& slave) complete

EPC


66. Ash conveying line bendsEPC


67 Ash conveying line (pipe, EPC




ENGINEERING

SL.

NO.

DESCRIPTION

BASIC

DESIGN

INCL

P&ID

ETC.

DETAILED AND

CONSTRUCTION

DRGS

MANUFACTURE

AND SUPPLY

FABRICATION

ERECTION,

TESTING AND

COMMISSIONING

73. Bottom chuteEPC




Contr.

74. Terminal end box at silo topEPC


75. Sliding gate (manual) EPCContr.


76. Rotary feederEPC


77. Ash conditioner assembly

complete

EPC

Contr.


78. Fluidizing padsEPC




ENGINEERING

SL.

NO.

DESCRIPTION

BASIC

DESIGN

INCL

P&ID

ETC.

DETAILED AND

CONSTRUCTION

DRGS

MANUFACTURE

AND SUPPLY

FABRICATION

ERECTION,

TESTING AND

COMMISSIONING

85

Necessary compressed air

piping instrument and manualEPC




85. piping, instrument and manual

valves with in battery limit.Contr.


86.

Service air requirement 2x100

% air compressor with 7 to 8

kg/cm2 (g) discharge pressure

will be provided in load/ unload

operation mode and required

nos of air receiver.

EPC


B. ELECTRICAL

87. Motors of suitable capacityEPC


88.EPC Control cable up to

junction box

EPC


EPC



ENGINEERING

SL.

NO.

DESCRIPTION

BASIC

DESIGN

INCL

P&ID

ETC.

DETAILED AND

CONSTRUCTION

DRGS

MANUFACTURE

AND SUPPLY

FABRICATION

ERECTION,

TESTING AND

COMMISSIONING

95. Junction boxesEPC




Contr.

96. Cables up to junction boxesEPC


97. DCS

EPC


98. Cables from PLC panel to DCSEPC


99.Copper tubing for air line to the

field instruments.

EPC


100.

Cable from local Junction box

to PLC panel.

EPC




F. DM PLANT

ENGINEERING

SL.

NO.DESCRIPTION

BASIC

DESIGN

INCL

P&ID

ETC.

DETAILED AND

CONSTRUCTION

DRGS



TESTING AND

COMMISSIONING

One No water storage tank of EPC



1One No. water storage tank of

4 hrs holding capacity.

EPC


2

Two Nos. (1W +1S) pump sets

for feeding treated water to

MGF.

EPC

Contr.


3

Two Nos. (1 x 100%) Vertical

Multi Grade Filters (MGF)

complete with frontal piping,

valves, media and Internals,

instrument etc.

EPC


4

1 X 100% Activated Carbon

Filters (ACF) for removal of

odour, colour, oil and chlorine,

if any.

EPC






ENGINEERING

SL.

NO.DESCRIPTION

BASIC

DESIGN

INCL

P&ID

ETC.

DETAILED AND

CONSTRUCTION

DRGS




(MOC: FRP) of capacity 100

m3 each.

Contr.



21

Three Nos. (2W+1S) DM water

transfer pumps of capacity 7

m3/hr with a head 90MWC

(min.) for Boiler make up andLP / HP dosing system.

EPC


22

1Nos. boiler initial fill pumps

each of capacity 50 m3/hr with

a head of 90 MWC.

EPC


Balance of Plant (BOP)

Neutralizing pit with 1 nos.

sump pump sets. Bidder shall

connect the necessary

Neutralizing lines from Acid &EPC



ENGINEERING

SL.

NO.DESCRIPTION

BASIC

DESIGN

INCL

P&ID

ETC.

DETAILED AND

CONSTRUCTION

DRGS




28

1 no. (1W+1S) of caustic

unloading pumps shall beEPC




considered.Contr.

29

1 no. caustic day tanks (MOC

shall be MSRL) for SBA & MB

units.

EPC


30Chlorination system for cooling

tower water shall be provided.

EPC


OTHERS

31

All frontal/interconnecting pipe

work/Valves/Fittings/Resintraps.

EPC


32

O/P platforms, ladders, hand

rails and pipe supportingEPC




ENGINEERING

SL.

NO.DESCRIPTION

BASIC

DESIGN

INCL

P&ID

ETC.

DETAILED AND

CONSTRUCTION

DRGS




control cables with steel

supports.

Contr.



39

Inter connecting cables both

power and control, cable glands

and lugs with in the battery

limit.

EPC


40Lightning protection and

earthing work.

EPC


INSTRUMENT

41

All instruments viz. pressure

gauge, flow indicators, flow

transmitters, flow totalizes,

conductivity analyzers, silica

analyzers, indicators,

transmitters, level gauges, pH

EPC




G. AUXILIARY COOLING TOWER

ENGINEERING

SL.

NODESCRIPTION

BASIC

DESIGNINCL

P&ID

ETC


DRGS

MANUFACTURE

AND SUPPLY

FABRICATION,

ERECTION,




ETC.

1

Cooling Tower complete with

Tower fills, fill supports, water

distributors, drift eliminators,fans, gearbox etc.,

EPC

Contr.


2

Complete hot water piping with

isolation valves and

accessories.

EPC

Contr.


3Foundation bolts, embedded

parts, inserts pipes etc.

EPC


4Pipe work of the cooling tower. EPC

Contr.




Annexure-9 Scope Matrix (contd.)

H. WATER PUMPS AND PIPINGS

ENGINEERING

SL.

NO

DESCRIPTION

BASIC

DESIGN

INCL

P&ID

ETC.

DETAILED AND

CONSTRUCTION

DRGS

MANUFACTURE

AND SUPPLY

FABRICATION

ERECTION,

TESTING AND

COMMISSIONING



1

Auxiliary cooling water system

pump, Raw water pumps,

Deaerator Makeup pumps,

Effluent discharge pumps, DM

plant make up pumps, Drinking

water pump, Boiler blow down

pumps, Reuse water pumps,

Initial filling pump and its motor.

EPC


2

Motor complete, coupling,

coupling guard etc, for all

pumps. (Make ABB, Bharath

Bijlee and Siemns).

EPCContr.


Combined base frame for pump




I. EOT CRANE

ENGINEERING

SL.

NO.DESCRIPTION BASIC

DESIGNINCL

P&ID

ETC.


DRGS

MANUFACTURE

AND SUPPLY

FABRICATION

ERECTION,

TESTING AND

COMMISSIONING



ETC.

1 One No. minimum 60 Tonnes

lifting capacity, Double girder

Electric Overhead TravellingCrane with plain shank hook for

main hoist and one no. auxiliary

hoist (5 Tonnes), complete with

all accessories as detailed in

the crane data sheet and Data

specification sheets, for Steam

Turbine Generator building.

EPC

contr.EPC contr. EPC contr. EPC contr.

2 Maintenance platforms and

access ladders as required,

also monorail facility at the end EPC




ENGINEERING

SL.

NO.DESCRIPTION BASIC

DESIGN

INCL

P&ID

ETC.

DETAILED AND

CONSTRUCTION

DRGS

MANUFACTURE

AND SUPPLY

FABRICATION

ERECTION,

TESTING AND

COMMISSIONING

7 All hoist and travel motors



7 All hoist and travel motors

including creep motors for

crane as applicable.

EPC


8 All power and control cabling /

wiring bridge cross conductors,

current collectors etc. as

required for safe and

satisfactory operation of the

crane.

EPC


9 All safety switches. EPC


10 All protective, control and

lighting panels push buttonsEPC

EPC contr EPC contr EPC contr




J. FIRE FIGHTING SYSTEM

ENGINEERING

SL.NO DESCRIPTION

BASIC

DESIGN

INCL

LAYOU

T ETC

DETAILED

AND

CONSTRUCTION DRGS

MANUFACTURE

AND SUPPLY

FABRICATION

ERECTION,

TESTING AND

COMMISSIONING

Fire hydrant system for complete



1

plant with necessary pumps i.e

1W + 1S AC pumps, 1W+1S

Jacking oil pump & 1 no diesel oil

pump with required capacity270m3/hr and hookup to DCS

EPC


2

Hydrant line from the pump house

to all interior area covering all

buildings and equipments, coal

yard with required valves,

hydrants points, hoses etc.

EPC


3

MVWS system for conveyors and

bunker with all the auxiliaries &

accessories and hookup to DCS

EPC





K. VENTILATION & A/C SYSTEM

ENGINEERING

SL.NO. DESCRIPTION

BASIC

DESIGN

INCL

LAYOU

T ETC

DETAILED

AND

CONSTRUCTION DRGS

MANUFACTURE

AND SUPPLY

FABRICATION

ERECTION,

TESTING AND

COMMISSIONING

1Supply air system for electrical EPC




1rooms Contr.


2 A/C system from control roomEPC


3TG operating floor and TG

building general ventilation

EPC


4

A/C system local control /

electrical room in FHS, AHS etc

as required.

EPC





L. ELECTRICAL SYSTEM

ENGINEERING

SL.

NODESCRIPTION BASIC

DESIGN

DETAIL

ED AND

CONST

RUCTIO

N DRGS

MANUFAC

TURE

AND

SUPPLY

FABRICATION

, ERECTION,

TESTING AND

COMMISSIONI

NG

1. Generator and its Auxiliaries:

AC l t i t ti f 45 MW bl f

EPC

Contr

EPC

Contr

EPC Contr. EPC Contr.



AC electric generator rating of 45 MW capable of

operating with a power factor of 0.8 lag, generation

voltage 11 KV and frequency 50 Hz shall be

supplied. The generator shall be capable of stableoperation even with a variation in voltage of +/- 5%

and frequency variation of +/- 5%.

Contr. Contr.

2. The excitation system shall be brushless type. The

brushless exciter shall consist of a permanent

magnet generator, AC exciter. Shell and tube heat

exchangers shall be mounted on the machine for

air-cooling.

EPC

Contr.

EPC

Contr.


3. Lightning Arrestor and Surge Protection (LAPT)

cubicle for the Generator.

EPC

Contr.

EPC

Contr





ENGINEERING

SL.

NODESCRIPTION BASIC

DESIGN

DETAIL

ED AND

CONST

RUCTIO

N DRGS

MANUFAC

TURE

AND

SUPPLY

FABRICATION

, ERECTION,

TESTING AND

COMMISSIONI

NG

11. Switchyard:

132/11 KV Switchyard & accessories and

switchyard end connect to existing 132KV bus

EPC

Contr.

EPC

Contr.




switchyard end connect to existing 132KV bus

through 132KV HT cables.

12. Single bus system with suitable post insulators,

Bus Potential transformer with isolators, breaker formain bus with CTs on each side, Potential

transformers, Lightning arrestors and feeder

protection on transformers and transmission lines.

EPC

Contr.

EPC

Contr.


13. Generator Transformers:

1 no. of generator transformers of capacity 53

MVA, ONAN/ONAF of voltage rating 11KV / 132

KV, 50HZ suitable for export of power with ON load

tap changer.

EPC

Contr.

EPC

Contr.


14. LT Auxiliary transformers: EPC EPC EPC Contr. EPC Contr.




ENGINEERING

SL.

NODESCRIPTION BASIC

DESIGN

DETAIL

ED AND

CONST

RUCTIO

N DRGS

MANUFAC

TURE

AND

SUPPLY

FABRICATION

, ERECTION,

TESTING AND

COMMISSIONI

NG

breakers, earthing switches, bus bars, draw-out

type voltage transformers, CTs, cable connections

etc. sheet steel having minimum thickness of 2 mm

Contr. Contr.



and the construction shall conform to IP 52 degree

of protection for the enclosure. Panel height should

not exceed 2200mm.

20. MCC Panels:

TG MCC, Boiler, ESP, DM plant, ACC, WTS, AHS,

FHS, MPDB, MLDB, Capacitor Panel with APFC,

VFD panel.

EPC

Contr.

EPC

Contr.


21. LT motors will be squirrel cage induction type

machines and will operate on 415V, 3 phase, and

50Hz power supply. Motors of rating 200KW and

below will have rated voltage of 415V and above

200KW shall be rated for 3.3KV voltage.

EPC

Contr.

EPC

Contr.


22. Complete interconnecting power and control cables EPC EPC EPC Contr EPC Contr




ENGINEERING

SL.

NODESCRIPTION BASIC

DESIGN

DETAIL

ED AND

CONST

RUCTIO

N DRGS

MANUFAC

TURE

AND

SUPPLY

FABRICATION

, ERECTION,

TESTING AND

COMMISSIONI

NG

26. Battery & battery charger:

110V DC suitable capacity of battery will be

provided for catering the power requirement of TG,

EPC

Contr.

EPC

Contr.




p g p q

Breaker closing and tripping coils, relays and

protection panels etc. Suitable battery charger with

float/ trickle/ boost charging will be provided.

Suitable DCDB shall be included for control supply

and other DG emergency load.

27. UPS:

2 no’s of Single phase uninterrupted power system

of 110VAC of suitable capacity will be provided for

supplying control power supplies. The source for

this UPS will be from Emergency PCC. Suitable

AC distribution board shall be included in the scope

for control supply.

EPC

Contr.

EPC

Contr.







M. CONTROL & INSTRUMENTATION

ENGINEERING

SL.

NODESCRIPTION BASIC

DESIGN

DETAILE

D AND

CONSTR

UCTION

DRGS

MANUFA

CTURE

AND

SUPPLY

FABRICATION

, ERECTION,

TESTING AND

COMMISSIONI

NG

1 Complete design, system detailed engineering,

documentation, manufacture, supply, softwareEPC

Contr

EPC

Contr

EPC

Contr EPC Contr.



, , pp y,

development, Installation, Inspection.

Contr. Contr. Contr.

2 All automation Systems and their subsystem

covered in this specification shall be designed,manufactured and tested in compliance with the

latest relevant codes and standards of practices

published by the Bureau of Indian Standards and

Foreign Standards.

EPC

Contr.

EPC

Contr.

EPC

Contr.EPC Contr.

3 DCS shall be inclusive with its subsystems,

associated software & hardware connected with

each other

EPC

Contr.

EPC

Contr.

EPC

Contr.

EPC Contr.

4 Redundancy shall be provided at all levels in DCS.

except the I / O’s modules

EPC

Contr.

EPC

Contr.

EPC

Contr.EPC Contr.




ENGINEERING

SL.

NODESCRIPTION BASIC

DESIGN

DETAILE

D AND

CONSTR

UCTION

DRGS

MANUFA

CTURE

AND

SUPPLY

FABRICATION

, ERECTION,

TESTING AND

COMMISSIONI

NG

capable of driving a load of 700 Ω. Contr. Contr. Contr.

10 Separate marshalling cabinets with terminal blocks

shall be provided at DCS panels to terminate cableEPC

Contr

EPC

Contr

EPC

Contr EPC Contr.



shall be provided at DCS panels to terminate cable

from the field as well as from MCC


11 Scan time includes the time for scanning the input,

A/D conversion, signal processing and control and

outputting shall be 2 to 500ms.

EPC

Contr.

EPC

Contr.

EPC

Contr. EPC Contr.

12 System shall be provided with self diagnostic

features.

EPC

Contr.

EPC

Contr.

EPC

Contr.EPC Contr.

13 Engineering and Operator workstations of the DCS

shall be identical and interchangeable. These shall

be of Business Grade PC units from reputed MNC

Brand and shall be complete with processor,

memory, power supply, bulk memory units, high

resolution colour monitor, key-board, mouse,

EPC

Contr.

EPC

Contr.

EPC

Contr.EPC Contr.




ENGINEERING

SL.

NODESCRIPTION BASIC

DESIGN

DETAILE

D AND

CONSTR

UCTION

DRGS

MANUFA

CTURE

AND

SUPPLY

FABRICATION

, ERECTION,

TESTING AND

COMMISSIONI

NG

shall be pre-treated and powder coated.

18 The supply voltage for all the sub-system and the

workstations of DCS shall be of 110VAC 50Hz

EPC

Contr.

EPC

Contr.

EPC

Contr.EPC Contr.



19 Redundant 110 Vac UPS with required VA ratingEPC

Contr.

EPC

Contr.

EPC

Contr.EPC Contr.

20 Special microprocessor based instruments such aselectronic governor, tri-vector meters, precision

meters which shall be provided as part of the

package equipment supply, shall have RS 485

MODBUS serial interface connectivity to the DCS.

EPC

Contr.

EPC

Contr.

EPC

Contr.EPC Contr.

21 Design, supply, procurement & delivery to site of

instrumentation & control cable

EPC

Contr.

EPC

Contr.

EPC

Contr.EPC Contr.

22 Cable laying & Termination from Field instruments

to the DCS along with Testing / checking of all

Control Loops.

EPC

Contr.

EPC

Contr.

EPC

Contr.EPC Contr.




ENGINEERING

SL.

NODESCRIPTION BASIC

DESIGN

DETAILE

D AND

CONSTR

UCTION

DRGS

MANUFA

CTURE

AND

SUPPLY

FABRICATION

, ERECTION,

TESTING AND

COMMISSIONI

NG

Testing (FAT),packing, shipment, delivery to the

site,


29 Supervision of erection, system setup,

i i i f / (SAT) EPC EPC EPC



commissioning, performance/acceptance test (SAT)

training of purchaser persons O & M manuals, &

final handing over of the Plant Automation System

EPC

Contr.

EPC

Contr.

EPC

Contr.EPC Contr.

30 Organizing training programmes at manufacturer’s

works as well as at site during commissioning for

the purchaser’s personnel in operation and

maintenance of DCS.

EPC

Contr.

EPC

Contr.

EPC

Contr.EPC Contr.




N. CIVIL AND STRUCTURAL WORKS

ENGINEERINGSL.

NODESCRIPTION BASIC

DESIGN

ETC.

DETAILED AND

CONSTRUCTION

DRGS

MANUFACTUR

E AND SUPPLY

FABRICATION

ERECTION,

TESTING AND

COMMISSIONING



1. CFBC Boiler

1.1

RCC for column supporting

and operating floor slabs.

Staircase wherever required.

EPC


1.2Rain gutters and drain piping

for boiler hopper, roof and

side cladding

EPC


2. Boiler Auxiliaries

2.1. Fans




ENGINEERINGSL.

NODESCRIPTION BASIC

DESIGN

ETC.

DETAILED AND

CONSTRUCTION

DRGS

MANUFACTUR

E AND SUPPLY

FABRICATION

ERECTION,

TESTING AND

COMMISSIONI

NG

2.2. Electro precipitator static



2.2.1Electro static precipitator

column foundation and

staircase column foundation.

EPC


2.3. Chimney (100 mts)

2.3.1

RCC Chimney complete

including foundation, inside

refractory work with lending

wherever required staircases,

hand- railing, aviation lampassembly etc.

EPC


2.4. Blowdown Tank

EPC




ENGINEERINGSL.

NODESCRIPTION BASIC

DESIGN

ETC.

DETAILED AND

CONSTRUCTION

DRGS

MANUFACTUR

E AND SUPPLY

FABRICATION

ERECTION,

TESTING AND

COMMISSIONI

NG

3.2TG Deck foundation. The

deck foundation, deck slabEPC




,

with required cut-outs.

Contr.

3.3 TG auxiliary foundations

a. Oil system

i. Emergency Oil Pump.

ii. Auxiliary Oil Pump.

iii. Jacking Oil Pump

iv. Main oil tank and

pump

Iii. Centrifuge oil purifier

system

iv. Over head oil tank/

over flow oil tank.

Oil l

EPC

Contr.





ENGINEERINGSL.

NODESCRIPTION BASIC

DESIGN

ETC.

DETAILED AND

CONSTRUCTION

DRGS

MANUFACTUR

E AND SUPPLY

FABRICATION

ERECTION,

TESTING AND

COMMISSIONI

NG

3.9 HP/LP dosing system

f d ti

EPC




foundation Contr.

3.10 Staircase and walkwayswherever required

EPCContr.

EPC Contr. EPC Contr.EPC Contr.

3.11

Approach platform between

TG building and air cooled

condenser building &

approach platform TG buildingto boiler.

EPC


EPC




ENGINEERINGSL.

NODESCRIPTION BASIC

DESIGN

ETC.

DETAILED AND

CONSTRUCTION

DRGS

MANUFACTUR

E AND SUPPLY

FABRICATION

ERECTION,

TESTING AND

COMMISSIONI

NG

4.0 Air Cooled Condenser



4.1

Complete air cooled

condenser RCC and structural

works including tie beams, fansupports, fan stacks,

stiffeners, platforms and

corridor etc.,.

EPCContr.


4.2 Condensate extraction pump

foundation

EPC


4.3 Condensate drain Boot pump

foundation

EPC


EPC




ENGINEERINGSL.

NODESCRIPTION BASIC

DESIGN

ETC.

DETAILED AND

CONSTRUCTION

DRGS

MANUFACTUR

E AND SUPPLY

FABRICATION

ERECTION,

TESTING AND

COMMISSIONI

NG

5.0 Balance of Plant



5.1 Fuel Handling System

5.1.1 Ground Hopper in RCC

construction with square

grizzly on top, manual rack

and pinion gate at bottom,

with wear resistant liner on

inclined surfaces.

EPC

Contr.


5.1.2 Ground hopper, conveyor

structure column foundation,

crusher house, crusher

foundation etc.,

EPC

Contr.


5 1 3 P i h h i il EPC EPC C t EPC C t EPC C t




ENGINEERINGSL.

NODESCRIPTION BASIC

DESIGN

ETC.

DETAILED AND

CONSTRUCTION

DRGS

MANUFACTUR

E AND SUPPLY

FABRICATION

ERECTION,

TESTING AND

COMMISSIONI

NG

5.1.5 Fuel transfer house and civil

foundation etc.

EPC

Contr.




5.1.6 Steel structure with side

sheeting and staircaseswherever required

EPC

Contr.


5.1.7 Portable dewatering pumps

RCC Tunnel.

EPC

Contr.


5.2 Ash Handling System

5.2.1

Ash handling system

foundation, Ash conveying

pipe racks steel structure and

i t

EPC





ENGINEERINGSL.

NODESCRIPTION BASIC

DESIGN

ETC.

DETAILED AND

CONSTRUCTION

DRGS

MANUFACTUR

E AND SUPPLY

FABRICATION

ERECTION,

TESTING AND

COMMISSIONI

NG

5.4 Auxiliary Cooling Tower

and Pump



5.4.1 Civil work complete, including

basin of required capacity

EPC


5.4.2 Auxiliary cooling tower

foundations including basin

EPC


5.4.3 Auxiliary cooling water pump

foundation

EPC


5.5 Water system piping and

pumps

5 5 1EPC





ENGINEERINGSL.

NODESCRIPTION BASIC

DESIGN

ETC.

DETAILED AND

CONSTRUCTION

DRGS

MANUFACTUR

E AND SUPPLY

FABRICATION

ERECTION,

TESTING AND

COMMISSIONI

NG

7.0 General



7.1 Soil investigationEPC


7.2 Site levelingEPC


7.3 ExcavationEPC


7.4 Approach roads to all main

equipments of coal yard.

EPCContr.


7 5 Weighbridge foundation / EPCEPC C t EPC C t EPC C t




ENGINEERINGSL.

NODESCRIPTION BASIC

DESIGN

ETC.

DETAILED AND

CONSTRUCTION

DRGS

MANUFACTUR

E AND SUPPLY

FABRICATION

ERECTION,

TESTING AND

COMMISSIONI

NG

within the CPP area and

around plant buildings

i l di fl d d i

Contr.



including flood water drainage

system.

7.11 All RCC & steel column

structures.

EPC


7.12 Grouting for all equipmentsEPC

Contr.


7.13 Flood water drainage, cabletrench valve pits.

EPC

Contr.





O. COMMON FOR ALL PACKAGES

S.NO DESCRIPTION Scope Remarks

1 Commissioning spares EPC Contr.

2 Set of special tools and tackles for the

all equipments

3 The initial requirement of all

consumables and first fill of materials

such as oil, lubricants etc. required tillEPC Contr.



such as oil, lubricants etc. required till

final commissioning

4 Unloading at site EPC Contr.

5 Performance test EPC Contr.

6 Two years O&M spares List of

recommended spares to be furnished

for all equipments.

EPC Contr.

7 PAINTING – Two coats of primer and

Two coats of finish painting of all

equipment, structures, piping, ductingEPC Contr.



P. SITE FACILITIES AND SERVICES


1 Providing Erection tools, tackles,

hoists, derricks, slings, scaffolding,

rigging tools, welding sets,

instruments, appliances, consumables

required for unloading, transporting,

storing, erection, inspection, testing and

commissioning to accomplish the work.

EPC Contr.



2 Unloading at site EPC Contr.

3 Steam blowing Pre-commissioning

check, trial run of equipment calibration

of instrument & control etc.

EPC Contr.

4 Pre-commissioning check, trial run of all

equipment calibration of instrument &

control etc.

EPC Contr

5 Providing instrument for above testing EPC Contr.

6 Performance test at shop and at site EPC Contr




cost at one point

13 All IBR approvals / formalities till steam

test and safety valve floating.EPC Contr.

14 Telephone facilities EPC Contr.

15 Emergency / first aid medical facilities

to SUP staff and erection crew posted

at site

EPC Contr.



16 Security, Inventory and accounting of

SUP equipment and property till final

take over by FACOR

EPC Contr.

17 Lighting facilities at erection site

EPC Contr.

FACOR will be only responsible for the

overall lighting such as road lighting,

lighting in the erection site etc. in the

plant area. Lighting within EPCCONTR. facilities i.e EPC CONTR.

storage area, office etc will be

responsibility of EPC CONTR.


45 MW CAPTIVE POWER PLANT AT GARIVIDI, ANDHRA PRADESHEPC TENDER SPECIFICATION

ANNEXURE – 10

QUESTIONNAIRE

A. BOILER & AUXILIARIES

S.NO DESCRIPTION UNITSTECHNICAL

PARAMETERS

1 Type of Boiler

1.1 Number of boiler No



1.2 Type of circulation

1.3 Type of feeding system

1.4 Type of support

1.5 Design code

1.6 Steam generated, Tons / hr

1.7 Steam purity

1.8 Steam pressure in the steam drum, Kg/cm2

1.9Steam pressure at the main steam

stop valve,kg/cm2



Annexure-10 Questionnaire (contd.)


PARAMETERS

2.4 Ash analysis/qty considered for

design

2.5 Flue gas temperature, deg. C

2.5.1 - At APH outlet deg. C

2.5.2 - At ID fan outlet deg. C



2.6 Turn down ratio boiler

2.7 Superheater steam temp. Controlrange – first stage

% BMCR

2.8Super heater steam temp. Control

range - second stage%

2.9 Combustor outlet temperature

2.10 Cyclone efficiency %

2.11 Primary air qty/ % of total air %

2.12 Secondary air qty/ % of total air %





PARAMETERS

4.1.5 Outlet secondary superheater deg. C

4.1.6 Inlet primary superheater deg. C

4.1.7 Outlet primary superheater deg. C

4.1.8 Inlet economizer deg. C

4.1.9 Outlet economizer deg. C



g

4.1.10 Inlet air heater deg. C

4.1.11 Outlet air heater deg. C

4.1.12 Inlet of ESP deg. C

4.1.13 Outlet of ESP deg. C

4.1.14 At stack entrance deg. C

4.2 Air

4.2.1 Inlet air preheater deg. C

4.2.2 Outlet air preheater deg. C





PARAMETERS

final superheater outlet header)

5.2 Water side

5.2.1From feed pump discharge to steam

drum inletKg/cm2

6.0 Velocity



6.1 Gas side

6.1.1 Fluidizing velocity m/s

6.1.2 Super heater zone m/s

6.1.3 Economizer zone m/s

6.1.4 Air heater zone m/s

6.2 Air side

6.2.1 Air heater region m/s

7.0 Ducting

7 1 Cold air m/s





PARAMETERS

8.5 Thickness mm

8.6 Corrosion allowance mm

8.7 Type of dished end

8.9 Drum internals

9.0 Water fall / furnace



9.1 Type of construction

9.2 Furnace depth m

9.3 Furnace width m

9.4 Furnace volume m3

9.5 Furnace height m

9.6 Tube size (OD) mm

9.7 Tube thickness mm

9.8 Tube material





PARAMETERS

11.1 Type

11.2 Nos

11.3 Type of construction

11.4 Tube OD mm




11.6 Tube material

11.7 Fin width mm

11.8 Fin thickness mm

12.0 Super heaters

12.1 Type of flow

12.2 Type of arrangement

12.3 Material

12.4 Tube diameter mm





PARAMETERS

14.1 Type

14.2 No.

14.3 Fluid inside tubes

14.4 Fluid outside tubes

14.5 Arrangement



14.6 Tube OD mm


14.8 Tube material

14.9 No of blocks

14.10 Casing material

14.11 Casing thickness mm

14.12 Expansion joint

15.0 Fuel storage system





PARAMETERS

17.6 Motor rating KW

17.7 Type of control

18.0 Lime stone storage system

18.1 No off bunker

18.2 Type of bunker



18.3 Bunker plate material

18.4 Capacity of bunker m3

18.5 Limestone consumption TPH

18.6 Sulphur capture efficiency %

18.7 Ca: S molar ratio

18.8 Storage time for limestone Hrs

19.0 Limestone feeding system

19.1 Type of feeder





PARAMETERS

21.5 Motor rating kw

21.6 Type of control

22.0 Start up oil firing system

22.1 Type

22.2 Bunkers/ steam generator nos



22.3 Capacity of each bunker % MCR

22.4 Type of oil pump

22.5 Oil pressure at burner inlet Kg/cm2 (g)

22.6 Atomizing air pressure Kg/cm2 (g)

22.7 Type of oil used for start -up

22.8 GCV of oil considered Kcal / kg

22.9 Turn down ratio

22.10 Igniters type





PARAMETERS

24.2 Head @ BMCR mmwc

24.3 Speed of the blower rpm

24.4 Type of coupling

25.0 Safety valves

25.1 Location



25.2 Type

25.3 Relieving capacity Kg/hr

25.4 Set pressure Kg/cm2

25.6 Over pressure / blow down pressure

26.0 Feed water pumps

26.1 Type

26.2 No:

26.3Feed water temp. at the inlet of feed

pumpDeg c





PARAMETERS

27.5 No. of fields

27.6 No . of hoppers

28.0 HP dosing system

28.1 Type of system

28.2 Tank capacity Ltrs



28.3 Tank material

28.4 Chemical dosing system

28.5 Type of stirrer

28.6 Type of pump

28.7 No. of pump

28.8

Piping material from dosing tank to

steam drum

29.0 LP dosing system

29 1 T f t





PARAMETERS

30.1.6 Safety valves set pressure Kg/cm2(g)

30.1.7 Corrosion allowance mm

30.2.0 Intermittent blow down tank

30.2.1 Tank material

30.2.2 Drain



30.2.3 Vent

30.2.4 Corrosion allowance mm

31.0 Insulation

31.1 Type of insulation material

31.2 Density of insulation material Kg/m3

31.3

Type of cladding sheet for main

boiler

31.4Thickness of cladding sheet for

main boiler





PARAMETERS

34.1 Type

34.2 Material

34.3 Thickness of plate mm

35.0 Painting

35.1 No. of primer coats



35.2 Type of primer paint

35.3 No. of final coat

35.4 Type of final paint

36 Feed water system

36.1 Deaerator cum storage tank

36.1.1 Deaerator

36.1.2 Type

36 1 3 Design standard





PARAMETERS

36.3.3 Spray nozzles / trays

36.3.4 Internals

36.3.5Piping between deaerator and boiler

feed pump

37 Chimney

37 1 General



37.1 General

37.2 Quantity

37.3 Mode of operation

37.4 Height m

37.5 Supporting arrangements

37.6 Flue gas temperature at exit Deg c

37.7 Material of construction

37.8 Lightning arrestor

37 9 Aviation lamps




B. TURBINE & AUXILIARIES

S.NO DESCRIPTION TECHNICAL PARAMETERS

1.0 TURBINE

1.1 Make

1.2 Type and description

1.3 Inlet steam conditions

1.4 Pressure, Ksca



1.5 Temperature, °C

1.6 Number of Extractions

1.7

Bleed conditions for Deaerator

Flow (TPH),

Pressure (Ksca)

Temperature (°C)

1.8

HP heater steam

-Flow

-Temperature





1.19 Governor

1.20 Make

1.21

Type

1.22 Range of speed control

1.23

Critical speed of rotor

1.24

Type of bearing



1.25 Thrust

1.26 Journal

1.27

Type of bearing lubrication system and

description

1.28

Material specifications for

1.29 Casing

1.30 Rotor

1.31 Shaft





lubricating oil pressure

1.46 Noise level at 1 m, dba

1.47

Details of special measures for noiseattenuation

1.48

Type and details of vibration isolator

1.49 Base plate details

1 49 Overall dimensions of turbine assembly



1.49 Overall dimensions of turbine assembly

1.50

Details of insulation of turbine

1.51 Weight, kg

1.52 Pipe work

1.53

Details of pipe work covering material

specifications, dimensional, fabrication

and testing standards shall be furnished

service wise for different conditions of

temperature and pressure

Schedule for pipes valves fittings and





manufacturing and testing

2.4 Maximum continuous rating, kW

2.5 Maximum continuous rating, kVA

2.6

Rated terminal voltage and permissible

voltage variation

2.7 Rated power factor

2 8 Rated stator current



2.8 Rated stator current

2.9

Rated frequency and permissiblefrequency variation

2.10 Rated speed

2.11 Number of phases

2.12 Phase connection

2.13

Flux density at rated operating point

2.14

Excitation current at rated power output

and rated power factor


EPC TENDER SPECIFICATION Annexure-10 Questionnaire (contd.)


2.27

Stator resistance at 75oC, ohms

2.28

Rotor resistance at 75oC, ohms

2.29

Maximum value of sudden short circuitcurrent including DC component

2.30

Sustained three phase short circuit

current (peak/rms values)

2 31Sustained line to line short circuit



2.31

(peak/rms values)

2.32

Permissible momentary over-loads as

percent of full load and duration

2.33

Permissible asynchronous operation time

under loss of excitation

2.34

Permissible operating time under single

phase to ground fault

2.35

Maximum inductive and capacitive output

at the rated voltage and speed at zero PF




2.46

Critical speed, rpm

2.47

Generator housing diameter, mm

2.48

Winding cooling details

2.49 Stator

2.50

Rotor

2.51

Winding insulation details



2.52 Stator

2.53 Rotor

2.54 Moment of inertia of rotor GD2

2.55 Material specification for slip rings

2.56 Grade of brushes for slip rings

2.57 Details of insulation for slip rings

2.58 Number of embedded RTDs and type

2.59 Weight, kg




section out of service

2.73 Excitation System

2.74

AC Exciter

2.75 Make

2.76 Standard followed

2.77 Rated output

2 78 Rated voltage



2.78 Rated voltage

2.79 Rated current

2.80

Exciter ceiling voltage

2.81

Maximum continuous exciter current

2.82 Nominal exciter response ratio

2.83

Rated speed

2.84

Class of insulation

2.85 Rotating Rectifiers




2.98 Gear Box

2.99

Manufacturer

2.100

Type of gear box

2.101 Service

2.102

Gear type

2.103

Teeth

2 104 R t d kW



2.104 Rated, kW

2.105 Input speed, rpm

2.106 Max. Continuous, rpm

2.107 Max. Torque

2.108 Service factor as per AGMA 421

2.109 Gear efficiency, %

3.0 Turbine Oil System

3.1 Lubricating and Control Oil System




3.3.3 Type and description

3.3.4 Number

3.3.5 Capacity, litre/min.

3.3.6 Total differential pressure, kg/sq. cm.

3.3.7 Speed, rpm

3.3.8 Power required at shaft, kW

3 3 9 B i



3.3.9 Bearings

3.3.10 Others (specify)

3.4 Emergency oil pump

3.4.1 Make

3.4.2 Type and description

3.4.3 Number

3.4.4 Capacity, litre/min.

3.4.5 Total differential pressure, kg/sq. cm




3.6.5 Filtration efficiency, % particle size

3.7 Oil tank

3.7.1 Type

3.7.2 Number

3.7.3 Capacity, litre

3.7.4 Material specifications

3 8 Oil vapour removal system



3.8 Oil vapour removal system

3.8.1 Type

3.8.2 Capacity, N cu m / hr.

4.0 Gland Vent Condenser (GVC)

4.1 Make, Type and description

4.2 Number

4.3 Steam condensing rate, tons/hour

4.4 Design code




5.0 Flash Tank

5.1 Make

5.2 Type and description

5.3 Number

5.4 Design Steam flow, tons/hour

6.0 Piping & Utilities

6 1 Pipe work



6.1 Pipe work

6.1.1

Details of pipe work covering material

specifications, dimensional, fabrication

and testing standards shall be furnished

service wise for different conditions of

temperature and pressure

6.1.2

Schedule for pipes, valves, fittings and

supports shall be furnished service wise

for different conditions of temperature and

pressure




7.0 Instrumentation And Control

7.1 Furnish P & ID with list of instruments

8.0 Governing System

8.1 Make

8.2Write-up on governing system with

catalogs and literature

8 3Schematic diagram for governing system



8.3envisaged

8.4 Turbine Supervisory system

8.5Make and model no of the Vibration

monitoring system offered

8.6Make model no of the Temperature

scanner system offered

8.7

Whether list of measurements provided

for TG unit and auxiliary condenser is

included




9.13Maximum temperature of surface where

insulation not provided

9.14Maximum surface temperature of Al

cladding for insulated surfaces

9.15Wind speed considered for design of

insulation Indoor and outdoor

9.16 Al cladding thickness

10 0 Parameters Guaranteed



10.0 Parameters Guaranteed

10.1Turbine steam flow at rated output when

bleed taken for heating steam

10.2

Turbine exhaust pressure with air cooled

condenser and ambient temperature of 45

deg C

10.3 Vibration level in different location of theturbine train.

Total auxiliary power required for



C. ACC & AUXILIARIES:

S.NO. DESCRIPTION UNITTECHNICAL

PARAMETERS

A. DESIGN DATA

1 Turbine Exhaust Steam flow rate Tons/Hr.

2 Guaranteed Back Pressure Kg/cm2 (A)

3 Steam Enthalpy / Dryness fraction kcal/ kg

4 Temperature at TG Exhaust °C



5 Condensate temperature °C

6 Heat rejected Kcal/hr

7Overall heat transfer coeff ( Bare /

Fin )kcal/hr m2°C

8 MTD °C

9 Design ambient Temperature (dry) °C

10 Outlet temp of air °C

11 Altitude m




PARAMETERS

5 Plot area without walkways m x m

6 Plot area with walkways m x m

7 Number of bundles per module

8 Air inlet height mts

9 Platform height mts

10 Total height up to top of duct mts



C-2. HEAT TRANSFER SURFACE

1 Finned Area sq.m

2 Bare Tube area sq.m

C-3. POWER CONSUMPTION

1 At fan motor @ Motor shaft (Each) BkW

2 At CEP Motor shaft BkW

3 At Drain Pump Motor shaft BkW




PARAMETERS

10 Tube pitch mm

11 Tube sheet MOC

12 Tube-to-tube sheet connection

C-6. FANS

1 Make / Model

2 No. of fans Nos



3 Diameter / Speed mm / rpm

4 Air flow Quantity for each fan cum/sec

5 Total air flow quantity (for all fans)kg / hr

6 Bundle face velocity m/sec

7 Static pressure mmWC

8 Fan shaft power FkW




PARAMETERS

C-9. CONDENSATE PIPING

1 Diameter NB

2 Material of construction

C-10. AIR EVACUATION PIPING

1 Diameter NB




C-11. RUPTURE DISC

1 Size/Qty mm/Nos

2 Rupture pressure Kg/cm2(g)

C-12. CONDENSATE TANK

1 Capacity (Total) Cu.m

2 Retention time min





PARAMETERS

3 Capacity / Head Cu.m/hr/MWC

4 Motor rating KW

5 Pump Make

C-15. DRAIN PUMP

1 Type centrifugal

2 Quantity No



y

3 Capacity / Head Cu.m/hr/MWC

4 Motor rating KW

5 Motor Make



D. FUEL HANDLING SYSTEM

Sl. No DESCRIPTION TECHNICAL PARAMETERS

1.0 Rated Capacity of System, TPH

2.0 No. of Operating hours per day

3.0 Power Consumption for Operating at maximum

rated capacity

4.0 BELT CONVEYORS

4.1 Rated and design capacity, TPH



g y

4.2 Belt width, mm

4.3 Belt speed, mps

4.4 Material of belt

4.5 Toughing angle, degree

4.6 Drive unit - Details

4.7 Gear Box – Details




4.10 Brake

4.10.1 Type and quantity

4.10.2 Make and size

4.10.3 Hold back – type and make

4.10.4

Furnish details of pulleys & idlers with shell dia.

& thickness and shaft dia. at bearing and

bearing designation, no. & its quantity



4.10.5 Details of safety switch & spacing

5.0 PRIMARY COAL CRUSHER

5.1 Type

5.2 Make

5.3 Design capacity, TPH

5.4 Feed size, mm




7.2 Type

7.3 Material handled

7.4 Design capacity, TPH

7.5 Feed size, mm

7.6 Product size, mm

7.7 Screen size (l x w), mm



7.8 Screen deck opening, mm

7.9 Top deck

7.10 Bottom deck

7.11 Frequency of vibration, cycle/sec

7.12 Declination of Screen, deg

7.13 Type of mounting

7 14 Drive details




9.0 METAL DECTOR MD-03

10.0TRAMP IRON SEPARATOR (PERMANENT

MAGNET) / INLINE MAGNETIC SEPARATOR

10.1 Type

10.2 Make

10.3 Location

11.0 BELT SCALE



11.0 BELT SCALE

11.1 Type

11.2 Make

11.3 Location

11.4 Number of load cells per belt scale

12.0 GATES

12.1 Type




15.2 Qty

15.3 Make

15.4 Location

15.5 Pump capacity, cu. m /hr

16.0

DUST EXTRACTION SYSTEM –

Give full details/ contents of the system.

Enclose scheme and typical GA drawing of



similar system

17.0

DUST SUPPRESSION SYSTEM –

Give full details/ contents of the system and

quantity. Enclose scheme diagram


18.1Details of instrumentation and control

system provided



E. ASH HANDLING SYSTEM:

S.NO DESCRIPTIONTECHNICAL

PARAMETER

1.1Rated capacity of each System

- For CFBC BOILER- fly ash – System-I

- For CFBC BOILER bed ash – System-II

1.2Rated power consumption of Compressor when CFBC

boiler operating at full load.



CAPACITIES/NO ;s

1.3 Bed ash transfer vessel below furnace ash hoppers

1.4 Fly ash Transfer vessel below hoppers of CFBC BOILER

- Cyclone hopper

- Eco./APH hopper

- ESP-1 hopper

- ESP-2 hopper

- ESP-3 hopper




PARAMETER

1.16 Details of ceramic lined pipe work

DENSE PHASE VESSEL

1.17 Type and Make


1.19 Valve access door arrangement

1.20 Pressure for sealing



1.21 Conveying pressure

1.22 Inlet and outlet nozzle size

ACCESSORIES

1.23 Adopters type and make

1.24 Equaliser valve make and type

1.25 Ash handling valves make and type

1.26 Arrangement for increasing the abrasive resistance




PARAMETER

1.39 Vent blowers capacity and other details

1.40 Capacity and Details of Aeration blowers

1.41 Vacuum pressure and relief door details

FLY ASH STORAGE SILO

1.42 Type and size of bottom opening for unloading

1.43 Vent Filters size and capacity



1.44 Vent blowers capacity and other details

1.45 Capacity and Details of Aeration blowers

1.46 Vacuum pressure and relief door details

DUST UNLOADER FOR BED ASH SILO TRUCK

1.47 Type and Make

1.48 Pocket feeder motor power KW/RPM

1.49 Capacity




PARAMETER

ELECTRICAL DRIVES

1.66 List of drives

1.67 Rating of the motor

1.68 Make of motors

1.69 Operating frequency / Duty cycle

AIR COMPRESSORS



1.70 Type

1.71 Make

1.72 Quantity

1.73 Capacity, Nm3/hr

1.74 Delivery pressure, Kg/cm2


1.76 Drive motor rating, kw



F. DM WATER PLANT

S.NO. DESCRIPTION TECHNICAL PARAMETERS

DM Plant capacity

1.0 MGF

1.1 No. of units

1.2 Type

1.3 Flow rate (normal and maximum), cu m / hr



1.4 Design surface flow rate, cum/hr sqm

1.5Total water requirement for back wash & rinse

(cu m), flow rate (cu m/hr), duration (min.).

1.6 Design pressure, kg/sq cm (g)

1.7 Test pressure. Kg/sq. cm (g)

1.8 MOC

2 0 ACTIVATED CARBON FILTER (ACF)




4.0 CONSTRUCTION FEATURES

4.1 Material

4.2 Diameter x HOS, mm

4.3 Thickness, mm

4.3.1 - Shell

4.3.2 - top dish



4.3.3 - bottom dish

4.4 Inlet distribution system

4.4.1 - type

4.4.2 - material

4.5 Under bed collector system

4.5.1 - Type

4 5 2 - Material




6.4 Design pressure, kg/sq. m (g)

6.5 Test pressure, kg/sq.cm (g)

6.6Total water treated per unit between two

consecutive regenerations, cu m

6.6.1 - Gross, cu m

6.6.2 - Duration of regeneration, min

Total waste water generated per each



6.7 generation (m3)

7.0 RESIN DETAILS

7.1 Name of resin

7.2 Manufacturer

7.3 Resin type

7.4Exchange capacity, kg CaCo3 /cu m of resin

(enclose resin curves)




8.7 -Total volume of rinse water, cum


9.1 -Shell diameter, mm

9.2 -Height of shell, mm

9.3 -Thickness, mm

9.3.1 - Shell

9 3 2 T di h



9.3.2 - Top dish

9.3.3 - Bottom dish

9.3.4 - Lining

9.4 Inlet distribution system

9.4.1 - Type

9.4.2 - Materials

9 5 Under bed collector system




10.10 Fill type

10.11 Fill material

10.12 Shell material

10.13 Rubber lining thickness, mm

10.14 Pumps

10.15 Blowers

10 16 T k



10.16 Tank

11.0 PUMPS

11.1 Type of pump

11.2 Capacity in cu m/hr

11.3 Total developed head, in mmWC

11.4 No. of working

11 5 No of standby





12.8.1 - Casing

12.8.2 - Impeller

12.8.3 - Shaft

13.0 REGENERATION SYSTEM

13.1 Preparation / Dilution Tank

13 2 N b f t k



13.2 Number of tanks

13.3 Capacity, cu m

13.4 Dia x Height


13.6 Agitator type & material

13.7 Agitator kW rating

13 8 Level indicator




14.9.1 - Number

14.9.2 - Type

14.9.3 - Make

15.0 MIXED BED UNIT

15.1 No. of units

15.2 Design flow, cu m/hr

15 3 Design surface flow rate cum / hr m2



15.3 Design surface flow rate, cum / hr m2

15.4 Design pressure, kg/sq. m (g)

15.5 Test pressure, kg/sq.cm (g)

15.6Total water treated per unit between two

consecutive regenerations, cu m

15.6.1 - Gross, cu m

15.6.2 - Duration of regeneration, min


EPC TENDER

SPECIFICATION Annexure-10 Questionnaire (contd.)


17.0 REGENERATION

17.1 -Regenerant used

17.2 -Mode of regeneration, CO/CCR

17.3 -Regeneration level, kg/cu m of resin

17.4 -Regenerant concentration, %

17.5 -Total flow rate, cum/hr

17 6 Quantity of regenerant required (100%) per



17.6 -Quantity of regenerant required (100%) perregeneration per unit, kg

17.7 -Total volume of rinse water, cum


18.1 -Shell diameter, mm

18.2 -Height of shell, mm

18.3 -Thickness, mm


EPC

TENDER

SPECIFICATION Annexure-10 Questionnaire (contd.)


19.0CHEMICAL DOSING SYSTEM (CDS) FOR PH

CONTROL

19.1 Pump

19.1.1 -Type

19.1.2 -Capacity

19.1.3 -Quantity

19.2 Chemical used for dosing :



19.2.1 -Name of chemical

19.2.2 -Quantity of chemical, liters

19.2.3 -Dosing rate liters /hr

19.3 Chemical solution tank

19.3.1 -Capacity

19.3.2 -Diameter




G. AUXILIARY COOLING TOWER PUMPS:

S.NO. DESCRIPTION TECHNICAL

PARAMETERS

1.0. COOLING TOWER

1.1 Type of cooling tower :

1.2 No. of cells :

1.3 Capacity of each cell,m3/hr :

1.4 Total capacity of the cooling tower, m3/hr :



1.5 Cooling range and hot & cold water temperature. :

1.6 Drift loss :

1.7 Wet bulb temperature :

1.8Make up water requirement with a cycle of concentration

of 4.

:

1.9 Design hot water temperature, deg C :





PARAMETERS

4 Distribution system

4.1 Type :

5 Reduction gear box

5.1 Make and type :

5.2 Service factor at design kW :

5 3 Reduction ratio :



5.3 Reduction ratio :

6 Valves, gate and retaining grate details (indicate quantity against each item)

6.1 Cell inlet water control valve, mm dia :

6.2 Cell isolation valve, mm dia :

6.3 Desludging valve, mm dia :





PARAMETERS

iii) Pressure rating and Class :

9.0 INSTRUMENTS AND GUAGES

10.0 ELECTRICALS

10.1 Motor

10.1.1 Make :

10 1 2 Type :



10.1.2 Type :

10.1.3 KW rating :

10.1.4 Type of enclosure, IP No. (including terminal box) :

10.1.5 Class of insulation :

10.2 AUXILARY COOLING WATER PUMPS

10.2.1 Make :




H. INSTRUMENTATION & AUTOMATION SYSTEM

S.NO. DESCRIPTION

TECHNICAL

PARAMETERS

1.0 GENERAL

1.01 Name and address of the Tenderer

1.02 Place of Manufacturing

1.03 Location of Service Centre

1.04 List of Installation Reference

1.05 No. of Trained Engineers

1 06 S ti f t t f tifi t



1.06 Satisfactory system performance certificate

1.07 MTBF figure of the offered system

1.08 Bar chart for the delivery schedule

1.09 Offered System Name / Series

1.10 Operator Station name & model

1.10 Control Station name & model

1 11 M i O i T i °C




S.NO. DESCRIPTION

TECHNICAL

PARAMETERS

2.03 Clock Speed

2.04 Word Length

2.05 Main Memory

2.06 RAM provided / expandable

2.07 Cache Memory (MB)

2.08 Flash Memory provided (MB)

2.09 Capacity of Hard disk (GB)



2.10 Capacity & Speed CD – R/W (MB)

2.11 Size / Type of Screen

2.12 Resolution of Screen

2.13 No. Colours supported

2.14 Type of Key Board

2.15 Details of Mouse




S.NO. DESCRIPTION

TECHNICAL

PARAMETERS

4.06 No. of Tags per trend group

4.07 Is X – Y plotting possible

5.0 HISTORICAL TREND

5.01No. of Graphics pages that can be stored in each

Operator Station

5.02 No. of Tags that can be assigned

5.03 Maximum no. of dynamic points/screen

5 04 Sampling Interval (in sec)



5.04 Sampling Interval (in sec)

5.05 Zooming facility on time & data axis

5.06 No. of Tags per trend group

5.07 Is X – Y plotting possible

6.0 WINDOW FEATURE (multiple Screen)

6.01 Max. no. of dynamic graphics screens (multiple Screen)

6 02 Is Positioning & sizing of displays freely configurable




S.NO. DESCRIPTION

TECHNICAL

PARAMETERS

9.0 SYSTEM ALARM

9.01 No. of alarms that can be stored in alarm summary

9.02 No. of alarms per page

9.03 Is the audio tone distinct from process alarm

9.04Possibility to store alarms in hard disk beyond the alarm

summary

10.0 COMMUNICATION at Supervisory network

10.01 Communication Standard



10.01 Communication Standard

10.02 Communication protocol

10.03 100 % redundancy provided for communication hardware

10.04 Data Highway

10.05 Highway topology

10.06 Access Method

10 07 Rate of Data Transmission




S.NO. DESCRIPTION

TECHNICAL

PARAMETERS

11.10Time taken to change over to the standby communication

link bus

12.0 OPEN SYSTEM CONNECTUVITY with LAN/ExpertSystem

12.01 Open system connectivity at what level

12.02 Data Server required

12.03 Data exchange method (DDE / OPC)

12.04 Graphic support availability



12.05 Active “X” support

12.06 Rate of Data Transmission

12.07 Topology

12.08 Media Type

12.09 Length supported

13.0 FIELD CONTROL SYSTEM




S.NO. DESCRIPTION

TECHNICAL

PARAMETERS

14.02 No. of slots per rack or cluster or file

14.03 Is Power Supply redundant

14.04I/O Rack or Cluster or File communication with CPU true

redundant (module & media)

14.05Wiring done directly on the module TB or on remote

terminal plan

14.06Possibility of on-line replacement of I/O modules &

Communication Processor



14.07Is it necessary to disconnect any cable to replace

I/O modules

14.08Is the system able to detect open/short circuit of sensor

open/short circuit of sensor & output device

14.09 Is bulk Power Supply regulated & redundant

15.0 DIGITAL INPUT MODULE (DI)

15.01 Type (24 V dc)




S.NO. DESCRIPTION

TECHNICAL

PARAMETERS

16.02 Module model No

16.03 No. of channels per module

16.04Provision of Isolation at Field to Module & Channel to

Channel

16.05 Off to ON delay (in msec)

16.06 On to Off delay (in msec)

16.07 Status LED for all channels

16.08 Current rating(surge/steady state ) per channel in Amps



g( g y )

16.08 Short circuit / overload protection of Outputs

16.09 DO Interface cards required

16.10Provision of changing the output channel to wet or dry

provided

17.0 ANALOG INPUT MODULE (AI)

17.01 Type (4 ~ 20mA)




S.NO. DESCRIPTION

TECHNICAL

PARAMETERS

18.05 Type of Input Isolation boards with noise filter considered

18.06 Analog Accuracy

18.07 In D/A Conversion no. of D/A Converters offered

18.08 D/A Converter resolution (no. of bits)

18.08 Maximum load resistance in Ω.

18.09 Output Interface-isolation board type

19.0 RTD INPUT MODULE (PT - 100Ω)

19 01 Type (3 wire or 4 wire)



19.01 Type (3 wire or 4 wire)

19.02 Module model No

19.03 No. of channels per module

19.04Provision of galvanic Isolation at Field to Module &

Channel to Channel

19.05 Scan Time per channel

19 06 A/D Converter Accuracy (no of bits)




S.NO. DESCRIPTION

TECHNICAL

PARAMETERS

20.10 Memory for Real Time Trending (MB)

20.11 Memory for database (MB)

21.0 ENGINEERING PACKAGE

21.01No. of Control Station that can be loaded with HMI/FCS

engineering package

21.02 Is it necessary to HMI edits to all other stations

21.03Possibility to do concurrent engineering of HMI/FCS from

non-resident operator station



21.04 Is engineering package offered separately for OS & FCS

21.05Is it possible to edit one package without closing the other

package

21.06 On-line editing available

21.07 Possibility of editing the FCS engineering package froman active graphic display when the plant is in operation

21 08 I th d t b l b l




S.NO. DESCRIPTION

TECHNICAL

PARAMETERS

23.0 SYSTEM RESPONSE TIME

23.01Control Processing switch over time to redundant pair of

Controller

23.02 Display call-up time with dynamic data

23.03 Display update time

23.04Elapsed time between the operator command & the

actual change in output value

23.05 Elapsed time between fault occurrence & the time tripwithin one field control system



within one field control system

23.06 Scan time for closed loops

23.07 Scan Time for open loops (Analog & RTD)

23.08 Scan Time for sequence control (DI/DO)

24.0 SPECIAL REQUIREMENTS

24.01 Possibility of Import / Export data to excel spreadsheet




S.NO. DESCRIPTION

TECHNICAL

PARAMETERS

25.10 No. of spare DI Modules offered

25.11 No. of DI-SOE Modules offered

25.12 No. of spare DI-SOE Modules offered

25.13 No. of DO Modules offered

25.14 No. of spare DO Modules offered

25.16 No. of FCS offered

25.17 No. of Processor Panel offered

25.18 No. of IO cum Marshalling Panel offered



5 8 o o O cu a s a g a e o e ed

25.17 No. of Engineering Station

25.18 No. of Operator Station

25.19 No. of Control Desk




I. VENTILATION SYSTEM


1.0 THROW FLOW FANS

1.1 Make

1.2 Type

1.3 Model and size

1.4 Number of fans.

1.5 Operating fluid

1.6 Specific gravity of fluid considered

1 7 Capacity m3/hr



1.7 Capacity, m3/hr

1.8 Total Differential Head, mmWC at normal flow

1.9

Pressure

Suction

Discharge

1.10 Operating temperature, °C





1.25 Accessories as per standard

1.26 Degree of protection as per IS

1.27 Type of cable box

1.28 Weight

1.29

Material Specification

Impeller

Base frame

Air Filter Type



1.30

Type

Internals

Material details

Air Pressure at inlet

Air Pressure at outlet

1.31 Method of Lubrication

1 32 W i ht f F





2.13 Efficiency of the Fan

2.14 Fan input KW at rated flow

2.15 Impeller diameter

2.16 Impeller width & Thick

2.17 Impeller mounting

2.18 Casing type

2.19 Casing mounting

2.20 Direction of rotation

2 21 M k d t



2.21 Make and type

2.22 Rated capacity

2.23 Voltage, frequency and variations

2.24 Accessories as per standard2.25 Degree of protection as per IS




J. 132KV SWITCHYARD


PARAMETERS

1. Name of manufacturer

2. Standards followed in design, manufacture, testingand erection of 132KV Switch yard & its accessories

with integral instruments

3. SF6 CIRCUIT BREAKER

3.1 Make

3.2 Type

3.3 Rated Voltage



g

3.4 Rated frequency

3.5 Rated current

3.6 Short circuit breaking current

3.7 Making current

3.8 Operating duty





PARAMETERS

3.14 Minimum clearances in air

Between phases

Between live parts and earth

3.15 Type of operating mechanism

Method of tripping

Normal / Emergency

Normal voltage of trip coil

Pick-up range

Power for tripping mechanism

3.16 Method of closing



3.16 g

Normal voltage of closing coils

Power for closing mechanism

3.17 Rated line charging breaking current

3.18 Rated cable charging breaking current.

3.19 Rated (single) capacitor bank breaking current

3 20 Maximum over voltage to earth of the circuit





PARAMETERS

4.5 Frequency

4.6 No. of phases

4.7 Rated conditions current

4.8 Short time current

Rating and duration

4.9 Rated peak short circuit current

4.10 Capacity to interrupt magnetizing current at p f

4.11 Capacity to interrupt line charging current at p f

4 12 D i i t f i l t



4.12 Design requirements for isolator

4.13 Ambient temperature

4.14 Insulation level

4.15 Phase spacing

4.16 Type of break

4 17 Type of mounting





PARAMETERS

5.11 Miscellaneous

5.12 Auxi liary supply

5.13 Interlocks with circuit breakers

5.14 Whether type tests carried out on similar isolators

5.15 Whether all routine / acceptance tests as per latest

standards will be carried out on each isolator

6. 132 KV CURRENT TRANSFORMER

6.1 Type

6 2 Nominal / Highest system voltage



6.2 Nominal / Highest system voltage

6.3 Frequency

6.4 No. of cores

6.5 Rated primary current for each core

6.6 Rated secondary current

6 7 Ratio taps for each core





PARAMETERS

8.7 Class of Insulation

8.8 Maximum temp. rise of winding above ambient of

50°C

8.9 Cantilever strength of CT at the terminal

8.10 1.2 /50 μ sec impulse positive & negative.

8.11 One min. power frequency withstands voltage.

8.12 Creepage distance

8.13 Partial discharge level

9 LIGHTNING ARRESTER



9 LIGHTNING ARRESTER

9.1 Quantity

9.2 Installation

9.3 System Voltage –Nominal / Highest

9.4 Type of earthing

9.5 Type of arrester





PARAMETERS

10.3 Voltage class

10.4 Total Creepage distance

10.5 Cantilever strength

10.6 Withstand voltages

a) 1 min. power frequency – Dry / wet

b) 1 min. Impulse withstand voltage – Dry / wet

10.7 Puncture voltage

11 Disc Insulator

11.1 Voltage class



g

11.2 Type

11.3 Creepage distance

11.4 Electromechanical strength

11.5 Withstand /flashover voltages

a) 1 min. power frequency – Dry / wet




K. TRANSFORMERS

SL.

NODESCRIPTION

Power

Transformer

HT aux.

Transformer

Auxiliary

Transformer

1 Name of manufacturer

1.1 Standards followed in design,

manufacture and testing

2 Continuous Rating, KVA

3 Performance guarantee Parameters

3.1 Rating in KV- HV/LV

3.2 Losses in HV / LV

4 Transformer No-load Voltage

5 Transformer Rated current



5 Transformer Rated current

6 Rated frequency

7 Number of phases

8 Vector group reference

9 Impedance voltage between HVand LV at rated current for the

principal tapping




SL.

NODESCRIPTION

Power

Transformer

HT aux.

Transformer

Auxiliary

Transformer

18.2 No of coolers per bank

18.3 Logics proposed

18.4 Capacity of each cooler

18.5 Motor rating

19 Type of tap changer

19.1 No. of plus taps

19.2 No. of minus taps

19.3 Voltage per step

19.4 Time for one tap change19.5 On load or off load?



20 Guaranteed loss particulars

20.1 Iron losses in kW at rated voltage

and frequency

20.2 Copper losses in kW at rated full-

load current and frequency at 75’C20.3 Calculation for capitalisation of

losses




SL.

NODESCRIPTION

Power

Transformer

HT aux.

Transformer

Auxiliary

Transformer

27 Details of bushings

27.1 Name of manufacturer

27.2 Type

27.3 Dry flash over voltage, kV

27.4 One-minute dry withstand test

voltage, kV

27.5 Rated short-time fault current and

its duration

28 Dimensions

28.1 Overall dimensions of transformer

complete with radiator banks (L x W



complete with radiator banks (L x W

x B) m

28.2 Transportation dimension

28.3 De-tanking height

29 Weights

29.1 Total Weight including oil

29.2 Transportation




L. 11KV INDOOR VCB


PARAMETERS


2.0 Standards followed in design, manufacture and testing

for switch board and the vacuum interrupter

3.0 VACUUM CIRCUIT BREAKER PANEL

3.1 No. Phases

3.2 Continuous current rating of the main busbars

3.3 System Voltage & frequency

3.4 System earthing considered

3 5 Rated current of feeders/ bus bar



3.5 Rated current of feeders/ bus bar

3.6 Rated power frequency withstand voltage

3.7 Rated lighting impulse withstand voltage

3.8 Rated short-circuit breaking current

3.9 Rated short time current withstand

3.10 Rated short circuit making current (peak)





PARAMETERS

3.27 Overall size (L x B x H), mm

3.28 Weight of Panel

3.29Catalogue of switchgear panel enclosed? Yes / no

4.0 CURRENT TRANSFORMER

4.1 Make / Type

4.2 No of core

4.3 Accuracy class / burden

4.4 Outdoor / Indoor?

4.5 Enclosed illustrative catalogue / brochure? Yes / no



5.0 POTENTIAL TRANSFORMER

(BUS PT, TRANSFORMER LINE PT, GENERATOR PT)

5.1 Make / Type

5.2 Ratio

5.3 Accuracy class / burden

5.4 Draw out / non- draw out




M. 3.3KV VCB


PARAMETERS


2 Standards followed in design, manufacture, testing and

erection of SF6 Circuit breaker & its accessories with

integral instruments

3 Vaccum circuit breaker

4 Make

5 Type

6 Rated Voltage

7 Rated frequency



8 Rated current

9 Short circuit breaking current

10 Making current

11 Operating duty12 Auto Reclosing





PARAMETERS

Pick-up range

Power for tripping mechanism

20 Method of closing

Normal voltage of closing coils

Power for closing mechanism

21 Rated line charging breaking current

22 Rated cable charging breaking current.

23 Overall dimension of complete 3-phase circuit breaker with

structure

24 Weight of complete 3-phase circuit breaker

25 Control panels



25 Control panels

26 Control panel Dimensions ( width x height x depth in mm)

27 Degree of protection of enclosure in terms of IP no.

28 Material and size of earth bus in the panel

29 Control wiring - size and specification

30 Control cable make




N. HT CABLES


PARAMETERS

1.0 Name of Manufacturer

2.0 Whether offered cable design is type tested. If yes

enclose the type test certificate.

3.0 Standards followed in design, manufacture and

testing for switch board and the vacuum interrupter

4.0 Type of Cables

7. Voltage rating

8. Current rating Nominal

9. Voltage grade

10 Derating factors to be considered



10. Derating factors to be considered

Laid on ground / air

Temperature correction Ground / air

Thermal resistivity of soil

Grouping factor

Depth of laying

Thermal resistivity




O. LT CABLES

S.NO DESCRIPTION

11KV CABLE

TECHNICAL

PARAMETERS

1 Name of Manufacturer

2 Whether offered cable design is type tested. If yes

enclose the type test certificate.

3 Standards followed in design, manufacture and

testing for switch board and the vacuum interrupter

4 Type of Cables

5 Voltage rating

6 Current rating Nominal

7 Voltage grade



7 g g

8 Derating factors to be considered

Laid on ground / air

Temperature correction Ground / air

Thermal resistivity of soil

Grouping factor

Depth of laying




P. LT CABLES

S.NO DESCRIPTION LT Control

TECHNICAL

PARAMETERS


2 Standards followed in design, manufactureand testing

3 Type of cable (Armoured / un armoured)

4 Voltage Grade

5 Materials of conductor

6 Cross- section of conductor



7 No of cores

8 Overall diameter of cable

9 PVC insulated? Yes / No

10 PVC sheathed? Yes / No




S.NO DESCRIPTION LT Control

TECHNICAL

PARAMETERS

with time duration, for each type and size ofcables, with final temperature not exceeding

200deg.c20 Maximum conductor temperature permissible

a) Continuous operation deg. C

b) During short circuit condition deg. C

c) Short circuit current for one second, deg. C

21 Whether metallic screening armour providedwould carry specified earth fault current. A



y pwith final temperature not exceeding 200deg.c

22 Copies Of All Type Test Certificates, includingthat of earth fault current carrying capacityenclosed? Yes / No

23 Cable Fully Confirm To IS Specification? Yes/ No

24 W i ht t f l t d bl i k




Q. CABLE RACK / TRAYS

S.NO DESCRIPTION TECHNICALPARAMETERS

1 Make

2 Material

3 Galvanised or not

4 Thickness of sheet for perforated trays, mm

5 Sizes of trays offered, mm

6Weight per metre of different sizes of ladder and

perforated type trays, kg

7 Enclose illustrative literature/catalogues



7




R. LT PANELS


1.0 About Company

1.1 Tenderer Name & Address

1.2 Quotation number and date

1.3 Previous experience list of similar job with year of

supply, name of purchaser etc

1.4 Deviation proposed by the bidder

2.0 Documents details

2.1 Drawing no of Single line diagram showing

current rating, CT& PT details



2.2 Technical documents enclosed with bid

2.3 Commercial documents enclosed with bid

2.4 Any certification for factory, design etc.

2.5 List of drawings that will be furnished aftercontract finalisation





3.12 -Degree of protection for enclosure

3.13 -Control voltage rating

3.14 -Control voltage supply arrangement

3.15 -Details of incomers

3.16 415V Air break circuit breaker

3.17 Make & Type

3.18 Electrical or manual operation

3.19 Protection device provided –Micro processor /solid state- details of release

3 20 Standards followed



3.20 Standards followed

3.21 Manufacturers type designation

3.22 Dimensions and weight of each complete unit in

kg

3.23 Rated voltage and current

3 24 Maximum voltage in V at which the breaker





3.37 -Make of push buttons & control switches

3.38 -Make of indicating lamps

3.39 -Make of indicating meters

3.40 -Single line diagram enclosed

3.41 -Overall size (Lx B x H), mm

3.42 -Weight of MCC

3.43 -Enclose technical literature/brochure for MCC

enclosed?

4.0 Power & Lighting distribution board (PDB&LDB)

4 1 Make & Type



4.1 Make & Type

4.2 Rated voltage

4.3 Continuous current rating for main Bus bars- A

4.4 Bus bar sizes and materials

4.5 Rating of incomer, A




S. PCC PANEL

S. NoDESCRIPTION

TECHNICAL

PARAMETERS

1.0 About Company

1.1 Tenderer Name & Address

1.2 Quotation number and date

1.3Previous experience list of similar job with year of

supply, name of purchaser etc

1.4 Deviation proposed by the bidder

2.0 Power control centre (PCC)

2.1 Standards followed

2.2 Rated voltage



2.3 Rated insulation voltage

2.4Continuous current rating of Bus bars specified

ambient temperature while installed in switchboard

2.5 Material of Bus bars / grade used

2.6 Nominal cross section of Bus bars Sq. mm




S. NoDESCRIPTION

TECHNICAL

PARAMETERS

3.7 Rated voltage and current

3.8 Maximum voltage in V at which the breaker

operator under normal condition

3.9 Maximum voltage in V at which the breaker can

interrupt its rated MVA

3.10 Spring charge motor details and voltage required

3.11 Draw-out/ Non-draw out

3.12 Make type and catalogue no. of HRC fuses

3.13 Make and type of CT

3.14 CT- Ratio, VA, class



3.15 Make/ specification of potential transformer

3.16 Make/ specification of push buttons, switches

3.17 Make / specification of indicating lamps

3.18 Make/ specification of indicating meters

3 19 Make/ specification of energy meters




S. NoDESCRIPTION

TECHNICAL

PARAMETERS

4.12 Insulation class

4.13 Rated insulation voltage

4.14 One minute power frequency voltage

4.15 Max. Hot spot temp.raise over ambient temp. Of

50ºC

4.16 Bus enclosure and support structure

4.17 Clearance in air

4.18 Phase to phase

4.19 Phase to earth






T. BATTERY & BATTERY CHARGER

SL.NO DESCRIPTIONBATTERY CUM

CHARGER


2.0 List of reference for supply of similar panels with

contact addresses

3.0 Standards followed in design, manufacture and

testing for the panel

4.0 Whether offer is as per specification.

5.0 Delivery schedule

5.1 Drawings and document submission

5.2 Despatch of material

6.0 Deviations (Enclose list of deviations)



7.0 PANELS- GENERAL

7.1 Standards followed for panel construction

7.2 Limiting Dimension

7.3 Degree of protection

7 4 System Voltage & frequency






U. UPS

Sl. No DESCRIPTIONTECHNICAL

PARAMETERS

1.0 UPS System details

1.1 Capacity of UPS

1.2 Type

1.3 Parallel Redundant Unit

1.4 Continuous rating

1.5 Location

1.6 Degree of protection

1.7 Tentative dimension



1.7

1.8 Paint shade

1.9 Input supply

1.10 Input frequency





PARAMETERS

3.0 CHARGER ( RECTIFIER )

3.1 Type

3.2 DC Output

3.3 Float Charging Mode

3.4 Boost charging Mode

3.5 Rating

3.6 Efficiency

4.0 BATTERY

4 1 Type



4.1 Type

4.2 Type of electrolyte

4.3 Type of Cell container

4.4 No of cells / battery





PARAMETERS

6.2 Single harmonic

7.0 OVERLOAD CAPABILITY

7.1 125% of full load

7.2 150% of full load

7.3 Power factor range

7.4 Branch fuse clearing capability

8.0 STATIC TRANSFER SWITCHES

8.1 Type






V. EPABX SYSTEM

S.NO DESCRIPTION EPABX DETAILS


2 Whether offer is as per specification.

3 Delivery schedule

4 Drawings and document submission

5 Despatch of material

6 Deviations ( Enclose list of deviations)

7 System Voltage & frequency

8 System earthing considered

9 Features

C bli i d ifi ti



10 Cabling - size and specification

11 Cable make

12 Whether RS 232/485 ports are connected

for PC connectivity

13 UPS details




W. MCB DISTRIBUTION BOARD

Sl.No Description TECHNICALPARAMETERS

I MCB distribution boards/MLDB

1Make of board

2 Standards followed for MCB

3 Rated voltage and frequency

4 Make and type of MCB

5 Rated current A

6 Breaking capacity A

8 Tripping time ms



8 Tripping time ms

9 Sheet steel thickness of the board

10 Degree of protection for enclosure

II 415V TPN isolator in sheet steel enclosure




Sl.No Description TECHNICALPARAMETERS

4 Max.size of Aluminium cable that can be

terminated


9 Sheet steel thickness, mm

10 Other accessories, if any

IV 240V SPN Switch Socket Outlet

1 Make and Type

2 Rated voltage V, at 50Hz

3 Max.size of Aluminium cable that can be

terminated



terminated


5 Sheet steel thickness, mm

V MCB isolating switch




X. PLANT LIGHTING

Sl.No DescriptionTECHNICAL

PARAMETERS

1 Voltage

2 Luminaries

3 Make4 Ballast & capacitor used

Floodlight-HPSV -70W

Well glass fitting -70W

Industrial type HPSV -250W


Out door type Fluorescent lamp-36w

Mirror optic type Fluorescent lamp-

2X36w

Twin tube light with lamp-2x36w




Single tube light with lamp-36w

Street light fitting-HPSV-150W

5 Nominal power factor


Well glass fitting 70W




8 Catalogue no





Out door type Fluorescent lamp-36wMirror optic type Fluorescent lamp-

2X36w


Single tube light with lamp-36w


9 Degree of protection IP

10 Material of construction details





Well glass fitting 70W



Out door type Fluorescent lamp-36w

Mirror optic type Fluorescent lamp-

2X36w




Y. BALANCE LIGHTING

Sl.No Description TECHNICAL

PARAMETERS

1 Voltage

2 Luminaries

3 Make

4 Ballast & capacitor used




Out door type Fluorescent lamp-40W

Twin tube light with lamp-2x40WSingle tube light with lamp-40W

5 Nominal power factor

Fl dli h HPSV 2 0W






Out door type Fluorescent lamp-40WTwin tube light with lamp-2x40W






Twin tube light with lamp-2x40W

Single tube light with lamp-40W

11 Colour finish

Floodlight-HPSV -250WStreet light fitting-HPSV-150W



Twin tube light with lamp-2x40W

Single tube light with lamp-40W

Z. CAPACITOR

S.NO DESCRIPTION DETAILS



1 Make

2 Type

3Capacitor design calculation furnished–

(YES/NO)

FACOR POWER LIMITED45 MW CAPTIVE POWER PLANT AT GARIVIDI, ANDHRA PRADESH


ANNEXURE-11

VENDOR LIST

S.NO DESCRIPTION VENDORS NAME

A MECHANICAL EQUIPMENT

1. TURBINE SIEMENS/APT/HTC/BHEL

2. BOILER THERMAX/CVL/IJT/BHEL

3. AIR COOLED CONDENSER GEA/PAHARPUR

4.

AUXILIARY COOLING TOWER PAHARPUR/PALTECH/SHRIRAM

COTRELL/SOUTHERN COOLING

TOWER

5.DM PLANT THERMAX/ DOSION / TRIVENI / ION

EXCHANGE/

6.FUEL HANDLING SYSTEM BEVCON/ HYQUIP/ TECPRO/ PROMAC/

ELECON / TRF



7. ASH HANDLING SYSTEM BEVCON/ MACAWBEEKAYAR/

MECGALE/ OSM

8.FIRE FIGHTING SYSTEM STERLING WILSON/ NEW FIRECON/

FIRECON/ GPR

9. HVAC BLUESTAR / VOLTAS



ANNEXURE – 11 VENDOR LIST (CONTD.)

22. VIBROMETER BENTLE NEVEDA

23. FLUID COUPLINGVOITH/ELECON/FLUIDOMAT/PEMBRIL

(GREAVES)

24. TYPE COUPLING LOVEJOY/FENNER/ ESBI

25. GEAR COUPLING

NAW/FENNER/ELECON/FMG/HI-CLIFF

/LOVEJOY/ WMI CRANES / FLENDER

26. PIN-BUSH COUPLING NAW/FENNER/LOVEJOY/ELECON

27. RESILIENT COUPLING LOVEJOY (BIBBY)/GBM/FENNER

28. DISC BRAKE KATEEL/SVENDBORG

29. THRUSTER BRAKE SVENDBORG/STROM KRAFT/KAKKU

30.BALL BEARING /ROLLER

BEARINGSKF/KOYO/NTN/INA/NBC/FAG/ZKL

31 BELT VULCANIZING UNIT SV DATTER



31. BELT VULCANIZING UNIT SV DATTER

32. RUBBER LINER TEGA/KAVERI/FORECH

33.

SUSPENDED

ELECTROMAGNET

ERIEZ/ELEKTROMAG/POWER BUILD/

ELECTROZAVOD/KAKKU




44.GREASE LUBRICATION

SYSTEM

LINCOLN HELIOS INDIA

LTD/DELIMON/AFMC MAIN

45.PNEUMATIC CYLINDERS VELJAN/NUCON/FESTO/SCHRADER

/NORGREN/SMC (JAPAN)/PARKER

46. PNEUMATIC AIR BOOSTER SMC (JAPAN)

47.

PNEUMATIC CONVEYING

SYSTEM

RIECO/MBE/MACAWBER-

BEEKAY/MAHINDRA

ASHTECH/ENERGO/VCC

48.

PRESSURE VESSELS BHARAT HEAVY PLATES &

VESSELS/ISGEC/ASSOCIATED PLATES

& VESSELS/DECTEL/LLOYDS STEEL/L

& T/BOC

49.

AIR COMPRESSOR ATLAS COPCO / IR / ELGI / KIRLOSKER

PNEUMATICS



50. AIR DRYER DELAIR/INDCON/ATLAS COPCO/PACE

51.

DUST SUPPRESSION

SYSTEM(SPRINKLER/DRY-

FOG TYPE)

TPS/F.HARLEY/ KAVERI / PROJECTS &

CONTROL




11. PROCESS VALVES

i. IBR AUDCO / BHEL / M&M /KSB / BDK /

FOURESS

ii. NON IBR BDK/ BHEL/ AUDCO /KSB /FISCHER

XOMAX / FOURESS / VALTECH /

BERMACO/ CRESENT /NECO

12. SPRING HANGER SARATHI / MYRICKS

CINSTRUMENTATION &

CONTROLS

1.GOVERNOR WOODWARD505E

2.

TEMPERATURE GAUGES H. GURU / GENERAL INSTRUMENTS

/BELLS / OLYMPUS

3.PRESSURE GAUGES H. GURU / GENERAL INSTRUMENTS

/A.N. INSTRUMENTS /BELLS/ OLYMPUS



4. LEVEL GAUGES LEVCON

5.

PRESSURE TRANSMITTER ROSEMOUNT /YBL /TATA HONEYWELL

/

C.G. HARTMAN & BROWN




SYSTEM (DCS) SIEMENS

16.

PLC ROCKWELL AUTOMATION / SIEMENS

/ABB

/SCHNEIDER/ GE-FANUC

17. HMI-PC IBM / HP / DELL

18.

HMI SOFTWARE (3RD PARTY) WONDERWARE (INTOUCH) /

INTELLUTION(FIX) / US DATA

(FACTORY LINK)

19.

CONTROLLER YOKAGAWA/HONEYWELL/SIEMENS/AB

B/EUROTHER M/ INVENSYS(FOXBORO)

20

RECORDER YOKOGAWA/LAXONS(CHINO)/EUROTH



20. ERM/ABB/ HONEYWELL

21.

BARGRAPH & DIGITAL

INDICATOR

MASIBUS/ EUROTHERM/ YOKOGAWA/

HONEYWELL

TOTALISER YOKOGAWA / ABB / MASIBUS/




INSTRUMENTATION ENGINEERS /

KROHNE MARSHALL/ INSTRUMENTS /

PLACKA/ ROTA

30.

VORTEX FLOWMETER ENDRESS

HAUSER/YOKOGAWA/KRHONE/

EMERSON/ABB

31.

CONTROL VALVE AND ON-OFF

VALVE

IL/FISHER-XOMOX/SAMSON/ DRESSER

MASONEILAN/ FOURESS/FORBES

MARSHALL(ARCA)/ R.K.CONTROLS /

MIL / ABB (INTROL)

32.

ELECTRIC ACTUATOR AUMA / IL / LIMITORQUE / ROTORK /

ABB

33.

SOLENOID VALVE AVCON/ROTEX/ASCO/VICKERS/SCHRA

DER



33. DER

34. AIR FILTER REGULATOR PLACA/SHAVO NORGREN

35. ENCODER P&F/ROCKWELL/HUBNER

G S S S SO / C /




MONITOR FROBESMARSHALL (SHINKAWA)/

SHERMAN

42. POLLUTION CONTROL &

STACK MONITORINR SYSTEM

DRAGER/ HONEYWELL/ ENVIROTECH/

EMERSON/ FROBES MARSHALL/

DURAG/ OPSIS

43. FLAME DETECTOR HONEYWELL/ FIRE-EYE/ FROM

SCHODER/ DURAG

D AUXILIARIES

1. PAINTS BERGER / SHALIMAR / NEROLAC

2. CRANES UNITEK / WMI

3. WEIGHIGHING m/c J&N / IPA / PHILIPS

4. COMPRESSORS ELGI / INGARSOL RAND / KIRLOSKAR /

5CRUSHER TRF OR EQVT. TO BE APPROVED BY



5.CONSULTANT

6.

M.S.TANKS / SS TANKS FABRICATED IN A REPUTED

MANUFACTURING UNIT SUBJECT TO

APPROVAL OF CONSULTANT




4. LIGHTNING ARRESTORS ELPRO / AREVA (WSI) / CGL / ABB

5. CTSBHEL / ABB / TELK / CGL / AREVA

(WSI)

6. PTSBHEL / ABB / TELK / CGL / AREVA

(WSI)

7. INSULATORSJAYASHRI INSULATOR / WSI /

MODERN INSULATOR / BHEL

8. HT BUS DUCTC&S/ ECC/ STAR DRIVE/ ENPRO/

GENERAL ENGINEERING

9. VACUUM CONTACTORS AREVA / BHEL / SIEMENS / ABB

10. HRC FUSES AREVA / DP / S&S/ COOPER BUSSMAN

11. NEUTRAL GROUNDING

RESISTOR

NARKHADE / PEFCO / RESITECH /

NATIONAL



12. TRANSFORMERSCGL / AREVA / VOLTAMP / EMCO/ TELK

ABB / SIEMENS

13. METERS AE /IMP/ L&T




VENUS CONTROL / PYRAMID

SWITCHGEAR

26. ACB L&T / SIEMENS / ABB / SCHNEIDER /

C&S

27.MCCB L&T / SIEMENS / ABB / SCHNEIDER /

C&S

28.SFU L&T / SIEMENS / ABB / SCHNEIDER /

C&S

29.CONTACTOR L&T / SIEMENS / ABB / SCHNEIDER /

C&S

30. OVER LOAD RELAY L&T / SIEMENS / ABB / SCHNEIDER /C&S

31.VFD L&T / SIEMENS / ABB / SCHNEIDER /

C&S



C&S

32. CT/PT’S KAPPA / VOLTAMP / AE

33. INSTRUMENTS AE / IMP

34 ENERGY METERS / MFM CONSERV / L&T




46. AC DRIVES, VVVF DRIVE ABB / SIEMENS /

HITACHI/AREVA/CGL/KEC/BBL

47. MOTOR PROTECTION RELAYSGE POWER / SCHNEIDER / L&T /

SIEMENS / ABB /C&S

48. AUXILIARY RELAYS

AREVA / EASUN / ABB / L&T /

SCHNEIDER / SIEMENS/BCH /

ROCKWELL / GE

49.NUMERICAL PROTECTION

RELAYS (FOR HT SYSTEM) ABB / SIEMENS / AREVA / GE / L&T

50.

NUMERICAL PROTECTION

RELAYS (FOR LT SYSTEM

ABB/ SIEMENS /AREVA /GE

SCHNEIDER / L&T / ASHIDA

51132KV/ 11KV/ 3.3 KV XLPE

RPG / UNIVERSAL / CCI/NICCO /

TORRENT CABLES /



51.CABLE INDUSTRIAL/INCAB / CRYSTAL/

UNIFLEX

1.1 KV PVC/XLPE/HRPVCRPG / UNIVERSAL /CCI/NICCO/TORRENT/INDUSTRIAL/




60. UPS

KELTRON / GUJRAT HI-REL / SIEMENS /

EMERSON /GE / DB POWER

CONTROLS

61. CONTROL SWITCHSIEMENS / KAYCEE / AREVA / L&T /

VAISHNO / C&S

62. PUSH BUTTONSIEMENS / BCH / L&T / VAISHNO / C&S /

SCHNEIDER / TECHNIC / KAYCEE

63. LIMIT SWITCH

AG SYSTEMS/JAY

BALAJI/TECHNOCRATS/ ELECTROMAG/

JSI/ TECHNIC (SIEMENS / BCH MAY BE

CONSIDERED ONLY FOR LIGHT DUTY)

64.CHANGE OVER

SWITCH/SELECTOR SWITCH

C&S / STANDARD / HHE /KAYCEE /

SIEMENS/ BCH/L&T/ INDOASIAN



65.DISCREPANCY CONTROL

SWITCH ABB / AG SYSTEMS

66. EPABAX SYSTEM AVAYA / TADIRAN /GTL (NORTEL) /SIEMENS











