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BFV Std.specdamper

BFV Std.specdamper

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Published by: Kalai Selvan on Aug 27, 2013
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INTENT OF SPECIFICATION This sub-chapter is intended to cover design, procurement,manufacture/fabrication,shop supply of various types of valves the testing C.W.system

2 nos 210 MW units. Scope of Work: Design, painting, site, comprehensive Testing as with of The contractor's scope of work shall Manufacture, at works, at site, Shop include

engineering, Packing, Unloading, insurance, commissioning

testing, to


Transportation Storage, Erection, of


Preservation, of the

required number


listed below along with a pair of counter flanges necessary nuts, bolts, washers and gaskets for each the valves. Scope of Supply

covered valves




of supply of



under this specifications shall include the as specified in the following paragraphs; and

maintenance T2.01 tested other and specified T2.01.02 T2.01.01







tools and tackles. Equipment Specifications The as valves shall be designed, manufactured and per relevant Indian Standards or as per

International standards acceptable to the Purchaser will below. Motor operated Butterfly i) No.of valves Valves 6 Nos. be suitable for the duty conditions

ii) valve 5155/AWWA electric iv)

Nominal diameter


1600 mm. Flanged as C per - 504 Butterfly BS with

iii) Type of valve

actuator. Location Indoor in pump house.


Motor operated butterfly i) No.of valves Location -

valve 2 Nos. Makeup forebay. water pipe



iii) Nominal diameter valve 5155/AWWA electric up v) T2.01.04 A. for nos. pipeline iii) Nominal diameter Gear i) ii) Location operated butterfly No.of valves Location iv) Type of valve


600 mm. Flanged as C-504 actuator water. Butterfly

Per BS with for make-


Outdoor valves


8 Nos. 4 nos. on tappings

heat exchangers & 4 on makeup water as shown in the drawing. 600 mm

Flanged Per B. water tower)


Type6 of valve



operated valve as


BS- 5155/AWWA. i) ii) No.of valves Location 4 Nos. Cooling Tower Hot

inlet (2 Nos. per iii) Nominal diameter iv) Type of valve 1600 mm Gear operated

Flanged BS T2.01.05 Manually operated butterfly i) ii) No.of valves Nominal diameter -

Butterfly valve as Per - 5155/AWWA. valves 2 Nos. 300 mm.

operated valve for T2.01.06 and

iii) Type of valve


Manually Flanged as Butterfly

Per BS- 5155/AWWA

blow-down water. Miscellaneous valves Gate/sluice valves shall conform to IS:780-1984

IS:2906-1984(R.A.1990)Class PN 1.0 as applicable. I. I. Globe valves shall conform to IS:778-1984, Class

Non-return valves shall conform to IS:5312-1986,Part Butterfly valves shall conform to AWWA C-504/BS 5155.

Flange drilling of all valves shall be as per table 11

necessary . The analysis of liquid to be handled given in Annexures-D All electric actuator a) Complete drive.torque position limit switches and terminal board. power b) Complete with Micro switch for disconnecting supply when the valve is operated manually.bolts. be and T2. the Direction of flow shall be clearly indicated on valve by embossing an arrow on the valve body. and c) All limit and torque switches shall be dust water proof. and and simultasuit T2.07 All the Butterfly valves shall be of 6 Kg/cm2 and conform to B.nuts of is T2.01.10 steel All the valves shall have a permanent stainless . with matching ANSI/AWWA-C-504type and shall flanges .01.01. driven valves electric motor shall be : .of IS:6392-1971.C with maximum temparature of humidity but both not occuring neously.01.S -5155-1984 or The valves shall be double flanged supplied gaskets.08 gear switches Drilling of flanges shall be as per table-11 IS-6392.09 d) The humid 100% climate prevailing at site is tropical 50 Deg. rating 1987. T2.1971. The equipment shall be designed to this condition. with & E.

S.pressure and manufacturing standard code of the valve. Materials of construction: 1. (304) Self lubricated TECHNICAL SPECIFICATION FOR MOTOR ACTUATORS FOR VALVES AC Motors cooled. and Degree of protection for motors.01. fan squirrel cage type. (304) S.I.01.13 All the valves shall be supplied with companion made of Carbon Steel plates conforming to Gr. 3. IS-210 Grade FG260 Nitrite rubber/S. T2.S (304) S. Bearing suitable for running of motors in direction.11 name plate and stainless steel tag fixed on the body indicating the tag number.I. bearings terminal boxes shall be IP-55.S. Terminal box liberally Terminal box of all motors shall be . 2.S. flanges 1992 T2. IS-210 Grade FG260 C.valve rating T2. 6.14 Body Disc Seat Shaft Seat retaining rings/and screws Shaft bearing : : : : : : C.6392-1971 Table-11. 5.diameter. marked face of the wheel/lever shall with the words OPEN and CLOSE and an indicate the direction for opening/closing.01.01.12 All the valves shall be provided The with hand be arrow lever. - Motor shall be totally enclosed. either Shaft extension as per requirement. shut The valves shall be designed for 100% water tight off. wheel/ clearly to T2.2A IS:2062- and drilled to I. 4.

Aluminium enclosed sized to accomodate PVC termination as of per Conductor table.C over with an earthing 325- temperature rise limited ambient of 55 deg. Vibration and noise level shall be as irrespective per IS-12O75. Limit switches .1991 & IS-12O65-1987 respectively. All motors shall be provided with 2 nos. Cooling Motors shall be TEFC design Ventilation system shall be effective of direction of rotation. armoured cables the on Terminal box shall be provided normally on right side when viewed from the driving end or the top. 50HZ + 3% Motors shall have class B to 65 insulation deg. All motors shall be designed conforming to IS1978. Electrical Design Motors shall be suitable for DOL starting Shall be suitable for 415V + 6% . bolts. Quality of operation Rotor shall be dynamically balanced.C.

TESTING & SHOP PAINTING Inspection & Testing The tests to be conducted at shop for various assemblies/assemblies of equipment shall include. contacts. operations.02. capable of withstanding depending - Shall be lever or rotating cam type upon requirement.robust repetitive - All limit switches shall be of construction.01 subbut Shall be provided with suitable cable gland with knockout holes of required size INSPECTION. dust to IP- enclosure conforming enclosure. Any other test. as required to prove the of guaranteed opening & closing functional requirement of various parts of equipment/system. not limited to the following: Material test Testing during manufacture/fabrication Dimensional checking Hydrostatic testing of body and seat. in robust metalic. .02 T2. and 65 Shall be provided with 10 A. suitable for outdoor installation. Earthing studs (2 nos) shall be provided plates T2. Demonstration time. 2 NO + 2 NC Shall weather be housed proof.

items shall tests Material test certificates for bought be obtained from original out shall turer/reputed test test house. T2. shall be made Test certificates available to the Purchaser's different Purchaser.03 or GERMAN All the equipments shall be subject to stage by the contractor's Purchaser's own inspecting visit the However.03 inspection authority. be T2. works all any T2. two coats phenolic with Zn of drying primer modified phosphate as composition IS:2074-1992 shall be applied. Dry Film of each coat should be 40 microns(minimum).of for the out manufacitems. from the Inspector may time to time places who should have free access to premises where of the manufacturing part/parts are under manufacture.02 The final tests shall be conducted in the presence representative.02. For all bought certificates as relevant to the items furnished by the contractor.02. gloss c) Two coats of single pack air drying high . Shop Painting a) Surface St-3 of preparation shall be as per St-2 and/ Swedish standard SIS 055900 or STANDARD DIN 55928 Part 4 single alkyd per Thickness b After pack surface air preparation.

4. Shaft Shaft key Bearings Allen screw 'O' rings Gland packing Seal clamping units and bolts Position indicator Actuators (as applicable) Torque/limit switches Handle 1 Set 1 set 1 set 1 set 1 set 1 set 2 sets 1 set 1 set NA NA 1 set . 9. LIST OF MANDATORY SPARES FOR VALVES the The following mandatory spares shall be included in contract for Butterfly valves of each size. 10. 3.Dry film 25 microns. 1. 4. 10. 2. 5. 3. Valve disc. II) Valve disc. thickness of each coat shall Performance Guarantee and Warranty The valves supplied shall be as guaranteed per satisfactory performance Conditions Of Contract. 1. 12. 5. 6. 6. 11. 12. Shaft Shaft key Bearings Allen screw 'O' rings Gland packing Seal clamping units and bolts Position indicator Actuators (as applicable) Torque/limit switches Handle 1 1 1 1 1 1 2 1 1 1 1 1 Set set set set set set sets set set set set set For DN 1600 gear operated butterfly valves. 9. Final be T2.04 for General phenolic suitably alkyd modified synthetic pigmented shall be enamel as given paint. 11. 8.paint. 8. I) For DN 1600 motor operated butterfly valves. 7. 7. 2.

7. 4. 4. Valve disc. 12. iii) For DN 600 motor / gear operated butterfly 1. 1.valves. Shaft Shaft key Bearings Allen screw 'O' rings Gland packing Seal clamping units and bolts Position indicator Actuators (as applicable) Torque/limit switches Handle 1 Set 1 set 1 set 1 set 1 set 1 set 2 sets 1 set 1 set NA NA 1 set Notes: 1. Shaft Shaft key Bearings Allen screw 'O' rings Gland packing Seal clamping units and bolts Position indicator Actuators (as applicable) Torque/limit switches Handle 2 2 2 2 2 2 4 2 2 2 2 2 Set set set set set set sets set set set set set For DN 300 manually operated butterfly valves. 2. 5. Test Pressure a) b) Body Seat -Kg/Cm2 -Kg/Cm2 : : 9 6 : : Fouress 1600 . 5. 3. 10. 9. 11. 8. 2. DATA SHEET FOR VALVES I) MOTOR OPERATED BUTTERFLY VALVE AT PUMP DISCHARGE 1) 2) 3) Name of manufacturer Nominal diameter of valve in mm. 8. 12. 11. 7. 6. each One set shall be applicable for one valve of size. 9. 10. 3. Iv) Valve disc. 6.

4) 5) 6) 7) 8) 9) Quantity . sq.mm Details of motor actuator. motor speed Output RPM Class of Insulation/ degree of protection Voltage Frequency Duty : : : : : : : : : : : : : Auma SA30E90 3 Phase AC motor. a) b) c) Make Model Type of motor K.5 2800 90 CL B / IP68 415 V 50 Hz S2-15 75 + 5 cage d) e) f) g) h) i) j) 10) Valve opening/ closing time in seconds 11) Materials of construction a) b) c) d) e) f) Body Disc Drive Shaft Stub Shaft Seat Ring Clamping Ring : : : : : : IS 210 Gr. Manufacturing Standard : : 6 BS 5155 As per BS 4504 PN-10 440 190 Drilling Standard for flanges : Length over flanges .mm Thickness of valve disc . FG 260 IS 210 Gr. 2.W. FG 260 AISI 431 AISI 431 Stainless Steel S.Nos.Iron .G.

FG 260 AISI 431 Nitrile rubber S.G.IS2062.g) h) i) j) k) l) m) n) o) p) q) r) 12) II.mm Details of motor actuator. Manufacturing Standard Drilling Standard for flanges : Length over flanges .Gr-2A Iinternal SS304/External HTS/CS HTS/CS Nitrile Rubber 5650 (approx) Weight of Valve Assembly MOTOR OPERATED BUTTERFLY VALVE ON MAKE-UP WATER PIPELINE Name of manufacturer Nominal diameter of valve in mm.Iron Fabricated steel Steel IS 210 Gr.mm Thickness of valve disc . : : Fouress 600 3) Test Pressure a) b) Body Seat -Kg/Cm2 -Kg/Cm2 : : : : 9 6 2 BS 5155 IS 6392-1971 Table-11 / 267 80 4) 5) 6) 7) 8) 9) Quantity .Nos. 1) 2) Bearing End Cover Plate Shaft Pin Seal Gears Hand Wheel Eye Bolt Integral Flanges Matching Flanges Bolts Nuts Gaskets : : : : : : : : : : : : Kg. : Teflon IS 210 Gr. FG 260 Carbonsteel. : : .

FG 260 IS 210 Gr.G. Motor speed Output RPM Class of Insulation/ degree of protection Voltage Frequency Duty : : : : : : : : : : : Auma SA12E63 3 Phase AC motor.G.Iron Fabricated steel . FG 260 AISI 431 AISI 431 e) f) g) h) i) j) k) l) Seat Ring Clamping Ring Bearing End Cover Plate Shaft Pin Seal Gears Hand Wheel : : : : : : : : Stainless Steel S.W. 1.Iron Teflon IS 210 Gr.1 2800 63 CL B / IP68 415 V 50 Hz S2-15 42 + 5 Valve opening/ closing time in seconds Materials of construction a) b) c) d) Body Disc Drive Shaft Stub Shaft : : : : IS 210 Gr.a) b) cage c) d) e) f) g) h) i) j) 10) 11) Make Model Type of motor K.FG 260 AISI 431 Nitrile rubber S. sq.

FG 260 Carbonsteel.m) n) 2A o) Eye Bolt Integral Flanges Matching Flanges Bolts : : : : Steel IS 210 Gr. Test Pressure a) b) 4) 5) 6) Body Seat -Kg/Cm2 -Kg/Cm2 -Nos.IS2062. FG 260 IS 210 Gr.GrIinternal HTS/CS p) SS304/External q) r) 12) Nuts Gaskets : : : HTS/CS Nitrile Rubber 600 (approx) Weight of Valve Assembly Kg. Standard : : : : 9 6 8 BS5155 IS 6392-1971 Table-11/ BS4504 PN10 4 : : Fouress 600 1600 Quantity Manufacturing Drilling Standard for flanges: 7) 8) 9) Length over flanges -mm Details of gears Materials of construction a) b) c) d) e) Body Disc Drive Shaft Stub Shaft Seat Ring : : 267 440 : : : : : IS 210 Gr. III) GEAR OPERATED BUTTERFLY VALVE 1) 2) 3) Name of manufacturer Nominal diameter of valve in mm. FG 260 AISI 431 AISI 431 Stainless Steel .

Iron Teflon IS 210 Gr.f) g) h) i) j) k) l) m) n) 2A o) Clamping Ring Bearing End Cover Plate Shaft Pin Seal Gears Hand Wheel Eye Bolt Integral Flanges Matching Flanges Bolts : : : : : : : : : : : S. FG260 AISI 431 Nitrile rubber SG iron Fabricated steel Steel IS 210 Gr.IS2062.GrIinternal HTS/CS p) SS304/External q) r) 10) (appx) Nuts Gaskets : : : HTS/CS Nitrile Rubber 530 kg 5650 Kg Weight of Valve Assembly IV) 1) 2) 3) MANUALLY OPERATED BUTTERFLY VALVES Name of manufacturer Nominal diameter of valve in mm.G. Test Pressure a) b) Body Seat -Kg/Cm2 -Kg/Cm2 -Nos : : : : 9 6 2 IS 5155 IS 6392-1971 Table-11 114 : : Fouress 300 4) 5) 6) 7) Quantity Manufacturing Standard Drilling Standard for flanges: : Length over flanges .mm . FG 260 Carbonsteel.

FG 260 Carbonsteel.F.Gr- 2A o) SS304/External p) q) 9) 10) Bolts : Iinternal HTS/CS Nuts Gaskets : : : HTS/CS Nitrile Rubber 120 kg(approx) Weight of Valve Any other information GUARNTEED DATA FOR B.IS2062. FG 260 AISI 431 AISI 431 Stainless Steel SG Iron Teflon IS210 Gr.FG 260 AISI 431 Nitrile rubber Fabricated steel Steel IS 210 Gr.8) Materials of construction a) b) c) d) e) f) g) h) i) j) k) l) m) n) Body Disc Drive Shaft Stub Shaft Seat Ring Clamping Ring Bearing End Cover Plate Shaft Pin Seal Hand Wheel Eye Bolt Integral Flanges Matching Flanges : : : : : : : : : : : : : : : IS 210 Gr. FG 260 IS 210 Gr.VALVES .

.....00 2.... ............. Not Applicable 4....00 2.....02................. .00. DESIGNATION .................. from open to close and viceversa (only for electrically operated valves) : : : : : : : : 6 6 Nil 6 For 1600mm dia 75 +15 sec... DATE .for performance The contractor guarantees that meet each the Butterfly valve following cooling water system shall requirement : 1......00 2. For 600mm dia 42 +5 sec...........01.. contractor ......00.........00 Guarantee Characteristic curves: for regulating valves submitted Note : This Guaranteed Performance Data is applicable for each size of the valve.... NAME AND ADDRESS OF COMPANY ..... procurement.............00...00 Design working pressure of Butterfly Valve (Kg/cm2(g)) When valve fully closed Rate of leakage Maximum shut-off pressure. SIGNATURE OF THE NAME ....00 3........................00... (Kg/cm2(g)) Valve operating time in secs. COMPANY SEAL: T3...00 design. INTENT OF SPECIFICATION This sub-chapter is intended to cover materials manufacture/fabrication...

expansion and other miscellanious system gates. C. and back filling.MEC/S/P123/A04/S4/01 and 02 complete with all joint welding at Battery limits viz. erection. construction of anchor thrust blocks chamber of man holes / air valves other miscellaneous civil works that would be for installation of piping. connection of C. unloading at site. like / and required The contractor's scope of work shall supply of steel include engineering. required circulating water outside surface coating and wrapping inside painting for pipes above 1600mm dia.W at cooling tower inlet.fabricated joints. Scope of Services drawings final inlet heat piping and All piping systems as shown in enclosed No. loading. of comprehensive piping of fabrication site. . handling of fabricated pipes at site. at pipes. and The commissioning of circulating water piping scope of work also includes Civil works excavation. connected with the circulating water 2 x 210 MW units. plates..PIPING Scope of Work design. insurance. items of testing and supply of various types of and boughtout screens pipes. cooling water pipe for exchangers (inlet and outlet).W.. piping from and outlet of condensers. painting. make up water pipes blowdown pipes.fittings. testing system. accessories.

manhole and manhole covers. of all sizes and shape required for complete system. for the piping.) shall provided of on CW piping. also and other with The pipework covered under this section shall include internal pipework for the pumphouse piping between pump house and main plant and units as indicated in the drawings enclosed . tapping points with stubs and root valves and for the thermowell connections etc.A minimum number of 6 automatic air vent) air release cum vacuum break valves for each unit (total 12 nos. tees valves the nos. tees distance pieces. reducers. necessary gaskets All counter flanges.The air release valves shall isolation 200 mm dia with separate 200mm dia valves. instruments stubs All piping and fittings for vents. nuts. and required for installation of the system. flanged blank on flanges. the for Manhole Butterfly shall be provided on either side of valves for maintenance purpose (except 300mm dia. above automatic piping are air-vent included in required contractor's scope of supply. (Double be be gate All with flanges. dished etc. All necessary bolts. drains.ends the All bends .). caps etc. blank flanges.

plugs. for drinking water.0 323.14 7. generally tees. Pipes ISthickspecified Nominal Dia DN DN DN DN 200 250 300 350 mm mm mm mm : : : : M.I. unions. ERW to conforming 3589-1973 but ness as below : O.14 .S ERW Black conforming 1239-1984 (Medium Duty) to Plain ends. service air and instrument piping etc.6 x x x x 6.S. pipe work for service water air also included in the scope of the contractor. fittings reducers. nipples. throttling stubs for primary sensing instruments etc.9 355. pieces.35 7. sockets.. T3.01 specified The The term 'pipework' referred (such herein as bends. crosses.1 273. G. pipes shall be manufactured/supplied as below: pipes ISPart-I With ii) 200 mm to 350 mm size i) Upto 150 mm nominal size M. flanges.D X Thickness in mm 219.14 7. covers pipes.various work air is - the specification and described in pipe paragraphs of the specification. etc) valves.

01 Fabricated Steel Pipe lines All fabricated pipelines specified below shall conforming welding thickness fabricated to from tested quality M.02.1984 (Part-I) Heavy G.I.S.S. Nominal Dia DN DN DN DN iv) 400 450 500 600 mm mm mm mm : : : : O.1984 (Part-I) Heavy duty/IS:1978 St.D X Thickness in mm 406.14 7.14 7.02 be T3.25 seamless b) For Instrument Air : IS:1239 .4 457.1984 (Part-I) Heavy duty/IS:1978 St. specified 1984 1984 T3.0 610 x x x x 7. plates Grade -A by submerged arc IS-2O62-1992 process as per IS-10234 or equivalent having indicated against the pipe dia: ------------------------------------------------------Nominal dia Outside dia Plate of pipe mm of pipe mm thickness mm .02 a) For Service Air : IS:1239 .1984 (Part-I) Heavy / IS:3589.M. 1600 mm and above M.S. IS:1239 .90 9.50 Fabricated from plates as in para T3.0 508. Pipes( Steel commercial iii) 400 mm to 600 mm size Manufactured - Spirally Welded at Rourkela Plant) of quality.25 seamless (Hot dip galvanised) c) d) Drinking water Service water : : IS:1239 .

02 cold plates so plate. the fabrication End preparation yard to facilitate welding. The of contractor shall submit detailed working pipelines and fittings including .05 drawings fabrication The 1 mm per metre length (Max. The by bending shall that be gradually bent to true cylindrical no undue stress develops in the shape tolerances on dimensions of pipe fabricated from shall be as follows: i) On outer diameter as calculated from circumference Out of roundness : : + 1/4 of plate + 3 mm & -1.02. Pipe sections in straight lengths delivered at site joints done at shall be of suitable length to minimise shall as far as possible.02.03 a any T3.02.Straps shall be provided at field joints.The plate All fabricated using pipes shall be a plate bending manufactured machine. ii) iii) Out of straightness : T3.------------------------------------------------------16OO mm 24OO mm 1632 2432 16 16 ------------------------------------------------------- T3.02.5 mm thickness.04 erection field be site T3.) pipe circumferential weld shall be done in such way that the longitudinal welds become staggered in two consecutive sections.

Details of hydrostatic and ND tests to be done shall also be specified. welding electrodes for electric arc and filler rods.04. instruments and oxygen consumables including any acytelene cylinders. etc. Submerged orc as per IS 10234-1982 shall be carried out as relevant International code.03 II from drawings for approval by Purchaser/ Consultants. welding and all details. fluxes etc. other of materials. All root joint welding from headers for service instrument air. Drain valves. . flanges. Gaskets. etc required the Gate valves.These complete fabrication proposed T3. for gas welding carrying out the welding at site. drawings bill shall indicate design parameters. all plant. Pipe fittings Fittings shall be supplied as per IS:1239-1992 Part for pipes upto 150 mm dia and shall be fabricated pipes for dia 200 mm and above. Bolts.01 Fabrication of pipelines and welding of pipe joints The contractor welding shall arrange at his cost transformers. nuts and washers be supplied in quantities and sizes as during detailed engineering with price included in lumpsum quoted. service water and drinking water shall be carried out by the contractor. Root valves. air.04 tools. and gas welding for welding per T3. T3.. Blind pipe shall flanges.

i) ii) Strength-equality with parent metal Absence of defects iii) Corrosion resistance of the weld shall not be less agressive T3.04.04. of procedures will depend on variables with tests Number like a adherence b) IS:7310 passing positions of welding. effective control in carrying out welded joints.03 requirements to follow for fabrication/erection/hydraulic testing M. reaffirmed in 1991 and shall be carried out to quality procedures. Once welding procedure is qualified.02 all T3. Method of Quality Control in Welded Joints Following besides steps shall be taken quality in by the to controlling general. The contractor shall arrange at his own cost for tests outlined in this section.Pipes. Welders employed shall be qualified as per (Part-I)-1974. strict to it shall be made during actual welding.The contractor shall indicate the procedure he is going of T3. a) Welding procedures shall be prepared in line IS:7307(Part-I)-1974. Requirement of welded joints The contractor shall ensure the following while welding the plates/ pipejoints etc.S.04. necessary tests. reaffirmed in 1987 after . make than that of the parent metal in environment.04 contractor. thickness range etc.

approved Besides.04. position of welding. moisture or any foreign about material. slag.05 the per in Non-destructive joints tests of weld of shall be carried out as per procedures/ drawings. cleaning of between the passes. ii) i) Weld edge preparation before welding. be d) Welding Such consumables consumables shall be of are. welded approved T3. proper weld profile shall be checked visually. amongst others. free may loose other to avoid The welding surfaces shall be smooth. however.25 unless otherwise as specified drawings/documents.. Preparation of joints The contractor shall prepare the edge correctly to shape. paint. fit up. rust. ANSI size and dimensions of the vee-grooves B-16. teers. uniform and from fins. approved subject qualifying initial check tests as per IS:814The contractor shall strictly follow welding procedures during actual welding. 10 mm The clean surface shall the welding faces extend to beyond . notches or any other defect which adversely afect welding and shall be free from scale. to 1991. the following stages of inspection shall also carried out : proper slag etc. grease.c) type.

back-step technique shall be used reduce distortion.04. before the horizontal circular course shall be aligned and adjusted for correct axes. The working employ sufficient number of welders the same time in diagonal quadrants of the shell back-step each method of welding. but in a long joint as in fabrication. Assembly.material T3. Alignment & Welding The sequence of welding shall be so planned followed that there shall be a balance of welding the shall neutral axis of the fabrication. seam However. the shell to The general direction of welding shall be towards free end of the joint. The rate of shall be more or less equal progress and welder uniform. started. course in the contractor shall complete then and the placed all respects on ground and course shall be lifted assembled . each prein Alternatively.06 and about contractor at using of quality contamination of the weld metal with foreign and to avoid unsound weld deposit. and horizontal the complete their To minimise internal locked up stresses due to the vertical joints for the shell shall be welded completed to a circular course and then the circumferential welding of seam welded. welding.

07 Pipe and attachment and shall be aligned properly welding. by If fused T3. either accurate tack permanent methods prior to are used. Tests on welded joints (a) and all close less other magnifying and mm from following The Visual examination contractor shall conduct visual examination measurement of external dimensions of the weld for joints. the tack shall be welds into the first layer of weld or else chipped out.1 or by weld gauges.04. Before examining the welded joints. glass Examination shall be done by a which has a magnification power of ten (10) measuring instrument which has an accuracy of + 0. areas to than it on both sides of the weld for a width 20 mm shall be cleared of slag not and impurities. the of balancing of weld about the neutral shall be followed and the method of fabrication of course pipes shall be similar to fabrication of of or transmission/industrial pipelines diameter. Welded joints shall be examined both sides. principle In such a sequence and planning. The contractor shall examine the during the visual examination :- the i) Check the correctness of shape and size of welded joints ii) Incomplete penetration of weld metal iii) Influx iv) v) Burns Under cuts .same axis each penstock bigger position.

reaffirmed in surface/sub-surface defects. sq. However minimum 10% DPT or MP shall be carried out in the fabricated pipes. compressor be arranged by . Any formation soap buble will indicate shall welding defects. (c) The Test by Blowing surface of the weld shall be of covered of with water soap and be to and of Portable if solution consisting one (1) litre hundred (100) grammes of soap.vi) Unwelded crates vii) Cracks in welded spots and heat affected zones viii)Porosity in welds and spot welds ix) of contact x) The as about by test Compression electrode welding Displacement of welded element. the contractor. (b) Liquid Dye-penetrant Test dye-penetrant tests shall be carried out 1991 Liquid in for accordance with IS:3658-1981. The distance between the tip of base the weld shall not be more than 50 mm. contractor shall carryout any or all tests in welded while joints as a out result impact carrying specified hereinafter to satisfy the Purchaser the acceptability of the welded joints. as directed the Purchaser. Compressed air shall blown 5 from the opposite side at pressure of 4 kg/cm.

00 mm iii) Stepping of one plate over other c) Lap Joint i) ii) d) Overlap Gap between the surface 2.00 mm .00 mm + 1.00 mm 5.00 mm 2.1.00 mm + 5 deg. + 2.00 mm 2.00 mm Manual arc Tolerance ------------------------Automatic ii) Stepping of one plate over the other Manual arc 1.00 mm .00 mm b) Single Vee-groove Joints i) ii) Bevol angle Gap between two + 5 deg.00 mm 1.1.00 mm 2.00 mm 2.00 mm .00 mm 5. Tolerance be Deviations for assembly of welded joints may permitted to the following extent : Tolerance ------------------------Automatic a) Source butt-joints i) Gap between the ends of plates + 2. + 1.00 mm Tee-filler joints i) Gap between the 2.necessary. for this purpose.

05.05. T3. . adequate design shall be supplied for securely the expansion joint with connecting pipe flanges.05. as stipulated in the specification shall sheets enclosed. Split retaining rings integral flanges at both ends.03 used the shall to Body Expansion bellow shall be of heavy duty manufactured from high grade abrasion resistant or synthetic rubber.edge of the web and the surface of the flange T3. Carcass Fabrics of high strength synthetic fibres shall be in suitable number of plies to hold the shape of bellow at the working condition. The expansion be designed such that no periodic adjustment required. Copper coated steel wire or solid endless rings embedded the in the carcass shall be used for reinforcement of expansion bellow.01 the and data joint is Rubber Expansion Joints Design and Construction Design of the expansion joint shall take care of axial.05 T3.02 construction natural with of holding T3. as specified in data sheets. angular or rotational movement of the bellow / or the equipment vibration. be All fabric plies components impregnated with rubber or synthetic permit flexibility between them.

hypalon coatings may be applied at Control Rod Assembly Each expansion joint shall be supplied with control assembly to prevent excessive elongation or of long the bellow. and of Control rod assembly shall allow transverse rotational movements under limiting axial conditions the expansion joints. the T3. spherical consist connecting plates (gusset plate) for fixing the with mating flanges. assembly Protective exterior.05.04 shall carcass Cover The exterior and interior surfaces of the bellow be coated with suitable material to protect the from outside damage and fluid corrosion. of on the Design of the control rod assembly shall take care the maximum axial thrust across the bellow calculated the basis of maximum fluid internal pressure and internal diameter of the arch.06 fabric on the End Flanges The expansion joint shall have integral The bolt hole reinforced full face rubber flanges.05 rod contraction of washers.05. T3.T3. the flange shall have no eccentricity in relation to . bolt. nuts Control rod assembly will & lock nuts.05.

carried over.08 Required numbers of carbon steel nuts. washers 7.5) times pressure test at a value of one and a the maximum working pressure under following conditions for thirty (30) minutes: i) ii) lateral Free position of the bellow With permitted (design) elongation and deflections iii) With design contraction and lateral deflection Inspection for leakage from the bellow shall be out during pressure test.05.07 corresponding bolt hole of the flange on the other The end rubber flange shall be drilled to suit companion pipe flanges. The test shall be conducted .face. and rubber gaskets shall be furnished. bolts. b) test in Vacuum Test All expansion joint shall be subjected to a vacuum at 700 mm of Hg vacuum. the be during T3. check Before the hydro test and after the hydro test is the bellow shall be dimensionally inspected to deformation. Counter Flanges Counter flanges shall be as per AWWA C-207. suitably match The companion flanges shall identification marked for easy erection by others. Hydrostatic Pressure Test and Vacuum Test a) internal half the All Pressure Test expansion bellows shall be subjected to hydrostatic (1. the control assembly shall be adjusted to obtain the test conditions of the bellow. if any.05. suitably During the test.

at The expansion joints shall have integral flanges both ends complete with split retaining rings. These c) additional assurance.05. Design of Expansion joint shall take care of the angular or rotational movements of the bellow and/ the equipment vibration. expansion a The joint external shall and internal surfaces of the with be of Neoprene of 3 mm thickness shore hardness of 65 + 5 deg. Tie rods shall be provided in the expansion joints. . are as described above for pressure test.09 Additional Tests shall have the right to demand Purchaser tests as may be found necessary for quality All the above tests shall be carried out without cost to Purchaser. or Fluid sealing Association. the The Rubber Expanson Joints shall conform to following standards/codes: USA i) Expansion standards ii) axial. for Steel wire/synthetic fabric shall be used reinforcement of the expansion bellows. abrasion The body of expansion joint shall be made from resistant rubber. USA joints manufacturers' Association. extra T3.thirty positions three different positions for a minimum period of (30) minutes duration in each position.

44/30 iii) Type iv) v) Design pressure Liquid to be handled- vi) Working temperature (oC) (Max. 6 Kg/cm2 Circulating water (for analysis see Annexure-D & E).10 Design Requirement i) ii) Qty./Min. AWWA-C 207.5 0. 1600 mm.) xix) Pump speed (rpm) - .5 750mm of Hg vacuum 700mm of Hg vacuum Manufacturers std.05.) - vii) Maximum flow (M3/hr) viii)Location ix) x) xi) Test pressure (kg/cm2g) Vacuum design Vacuum test - 16500 Indoor 7. Single arch type. Nominal diameter 5 Nos.) xviii) Torsional movement (deg.T3.5 497 xvi) Lateral deflection (mm) xvii)Angular deflection (deg. 1-50 lb slip on type xii) Freelength (mm) xiii)Counter flange class xiv) Axial elongation(mm)xv) Axial contraction (mm) - 15 15 15 0.

T3. Duty Type Overall dimensions (mm) Gross weight of the complete assembly (kg) : : : : : : C.System 1600mm .05.00 Materials of Construction Bellow Carcass Stiffening ring External cover Internal cover Control assembly Retaining ring Synthetic Rubber Synthetic fibre Manufacturers standard Hypalon or approved equivalent Manufacturer's standard Manufacturer's standard Galvanised Steel Flanges/Counter flanges Gasket Nuts.00 1.5 Nos.00 1.00 1.00 GENERAL Service Nominal size (NB)/Qty.00.02.04.W.01.ASTM A Grade A 307 Pipe thickness - 16 mm DATA SHEET FOR RUBBER EXPANSION JOINT 1.00 1. bolts and washers - Carbon Steel IS:2062 3 mm thick reinforced rubber Carbon Steel .00 1. Continuous Spool type 750 1750 kgs (appx) .06.

00 2.01.00 2.00 2.08.00 Model No.00 4. of arch / corrugation Flange pressure rating and drilling standard No.02.1.00t 2.01 3.00.00 3. 6 750 60 Design vacuum in mm of mercury: Design Temperature (oC) : 3. Axial elongation / contraction (mm) : Lateral deflection (mm) Angular movement Torsional movement (degrees) Axial spring rate (N/mm) Torsional spring rate (kg/mm/deg) Frequency of vibration (Hz) : : : : : : 15/15 15 0.02. of limit / control rods Bursting pressure of bellow (kg/cm2g) MATERIAL OF CONSTRUCTION Bellow Carcass Bellow exterior : : : : : : : Single BS 4504 PN-10 6Nos. PERFORMANCE CAPABILITY : During Detail engg.01.5o 0.00 3.02.00 As per spec.06.00 2.00 2.00 2./Per Joint Twice the design pressure Synthetic Rubber Synthetic fibre Neoprene Rubber .05.00 No.00 3. Maximum pressure drop through the expansion joint at design flow rate.00 Kg/cm2g : DESIGN AND CONSTRUCTION Design standard Design pressure (kg/cm2g) : : < 0.03.00 2.00 2.00 3.00 3.00 4.00 3.5 1925 (Appx) 180 During detail Engg.

02.00 Fasteners Gaskets : : IS:2062 Gr.00 .00 ACCESSORIES INCLUDED Control rod assembly with gusset plate.A.00. : Yes LIST OF TECHNICAL DOCUMENTS ENCLOSED WITH THE CONTRACT Dimensional General Arrangement drawing as specified A cross-sectional drawing of the expansion bellow Manufacturers standard catalogues and Literature A write-up on the manufacturing inspection and testing facilities available at the manufacturer's works Any other information : Yes : Yes : No : : 7.00 Bellow interior : Neoprene Rubber IS 2062 Gr.63.00 7.03.00 6.00 7.06.02. bolts etc.A Galvanised Flanges/counter flanges: IS:2062 Gr. A Sq.0 Not recommended as Internal Rubber flange shall act as self gasket 5.05.00 5.00 5.00 4. stretcher plate IS-2062 Gr.00 6. Annular IS1367 Gr.04. Metal reinforcement : Control rod assembly: Retaining ring segments: IS:2062 Gr.00 5.00 4.00 7. : Yes Counter flanges with nuts.00 INSPECTION AND TESTING INCLUDED Materials Test Certificates Certificates for bought out items Dimensional tolerance as per specification Hydrotest as per specification : Yes : Yes : Yes : Yes 6.01.00 7.00 Ring 4.0.8/6. nuts spherical washers etc.00 5.02.09.

E.. 3.00.E.. Slip-on type matching flange with bolts..00. . 4..00 3.. 2..00...00 6. The joint performance for data.00 2. nuts and gaskets Reinforced Rubber Gasket for above R.A..5 0..00 4.00....00. JOINTS 1.00 5.. : 1 set : 1 set : N.. Joints Control rod assembly complete with nuts etc. Joint. : 2 sets particular GUARANTEED DATA FOR R... One set corresponds to the quantity of part used in one R..00 Design working pressure of bellow (kg/cm2 g) : 6 Kg/cm2 12 kg/Cm2 15/15 15 0.JOINTS. 1..5 BS 4504 PN-10 contractor guarantees that each rubber expansion minimum CW system shall meet the following Minimum bursting pressure of bellow (kg/cm2 g) : Axial elongation/contraction (mm) : Lateral deflection (mm) Angular movement (degrees) : : Torsional movement (degrees) : Flange standard : SIGNATURE ...00 7. Note: Rubber Expansion Joint Complete assembly of 1600 mm dia..E.00.E.LIST OF MANDATORY SPARES FOR R..00..

............ DATE ...................... ..NAME ................... DESIGNATION ............................ NAME AND ADDRESS OF COMPANY ................................ ....

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