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INTENT OF SPECIFICATION This sub-chapter is intended to cover
materials procurement, manufacture/fabrication, testing and supply of various types of fabricated and boughtout pipes,fittings,expansion joints, gates, screens and other miscellanious items connected with the circulating water system of 2 x 210 MW units. C.W.PIPING Scope of Work design, accessories, insurance, at pipes, painting, testing system. like / and required The contractor's scope of work shall supply of steel include
unloading at site, of
comprehensive piping of
required circulating water
outside surface coating and wrapping
inside painting for pipes above 1600mm dia., handling of fabricated pipes at site, erection, and The commissioning of circulating water piping scope of work also includes Civil works
excavation, and back filling, construction of anchor thrust blocks chamber of man holes / air valves
other miscellaneous civil works that would be for installation of piping. Scope of Services
drawings final inlet heat
No.MEC/S/P123/A04/S4/01 and 02 complete with all joint welding at Battery limits viz., piping from and outlet of condensers, cooling water pipe for
exchangers (inlet and outlet), connection of C.W at cooling tower inlet, make up water pipes
blowdown pipes. ends the All bends , reducers, tees distance pieces, dished etc. of all sizes and shape required for complete
system. instruments stubs All piping and fittings for vents, drains, tapping points with stubs and root valves and
for the thermowell connections etc. necessary gaskets All counter flanges, blank flanges, caps etc. for the piping. All necessary bolts, nuts, and
required for installation of the system.
tees valves the nos. (Double be be gate
flanges, manhole and manhole covers, flanged blank on flanges, above automatic piping are air-vent included in
contractor's scope of supply.A minimum number of 6 automatic air vent) air release cum vacuum break valves for each unit (total 12 nos.) shall
on CW piping.The air release valves shall isolation
200 mm dia with separate 200mm dia
valves. the for Manhole Butterfly shall be provided on either side of
valves for maintenance purpose
300mm dia.). also The pipework covered under this section shall
plugs. G. unions. ERW to conforming 3589-1973 but ness as below : O.6 x x x x 6.S.14 . pieces. throttling stubs for primary sensing instruments etc. 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. service air and instrument piping etc. sockets.9 355. T3. nipples.D X Thickness in mm 219. etc) valves.14 7. crosses. covers pipes. for drinking water. fittings reducers. generally tees.1 273.35 7. flanges. pipe work for service water air also included in the scope of the contractor. Pipes ISthickspecified Nominal Dia DN DN DN DN 200 250 300 350 mm mm mm mm : : : : M.I.and other with various work air is - include internal pipework for the pumphouse piping between pump house and main plant and units the as indicated in the drawings enclosed specification and described in pipe paragraphs of the specification.0 323.S ERW Black conforming 1239-1984 (Medium Duty) to Plain ends.14 7..01 specified The The term 'pipework' referred (such herein as bends.
1984 (Part-I) Heavy G.02 T3.25 seamless IS:1239 . specified a) 1984 b) 1984 For Instrument Air : For Service Air : iv) 400 450 500 600 mm mm mm mm : : : : Manufactured - Spirally Welded at Rourkela Plant) of quality. IS:1239 .1984 (Part-I) Heavy / IS:3589.02. O.02 IS:1239 .S.14 7.1984 (Part-I) Heavy duty/IS:1978 St.25 seamless (Hot dip galvanised) c) d) T3.S.90 9.01 Drinking water Service water : : IS:1239 . 1600 mm and above Fabricated Steel Pipe lines All fabricated pipelines specified below shall be conforming welding thickness fabricated to from tested quality M.50 Fabricated from plates as in para T3.4 457.1984 (Part-I) Heavy duty/IS:1978 St.0 610 x x x x 7.D X Thickness in mm 406. Pipes( Steel commercial Nominal Dia DN DN DN DN M.14 7.iii) 400 mm to 600 mm size M. plates Grade -A by submerged arc IS-2O62-1992 process as per IS-10234 or equivalent having indicated against the pipe dia: .I.S.0 508.
03 a any T3.Straps shall be provided at field joints. Pipe sections in straight lengths delivered at site joints done at shall be of suitable length to minimise shall as far as possible.02. ii) iii) Out of straightness : T3.The plate All fabricated using pipes shall be a plate bending manufactured machine.) pipe circumferential weld shall be done in such way that the longitudinal welds become staggered in two consecutive sections. 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 & -1.04 erection field be site The 1 mm per metre length (Max. .5 mm thickness.02 cold plates so plate.------------------------------------------------------Nominal dia Outside dia Plate of pipe mm of pipe mm ------------------------------------------------------16OO mm 24OO mm 1632 2432 16 16 thickness mm ------------------------------------------------------- T3.02.02. the fabrication End preparation yard to facilitate welding.
other of materials. etc required the Gate valves.drawings T3. flanges. Details of hydrostatic and ND tests to be done shall also be specified. T3. Gaskets.03 II from drawings for approval by Purchaser/ Consultants.01 Fabrication of pipelines and welding of pipe joints The contractor welding shall arrange at his cost transformers.04. Drain valves. all plant. service water and drinking water shall be carried out by the contractor. instruments and oxygen consumables including any acytelene cylinders.02. nuts and washers be supplied in quantities and sizes as during detailed engineering with price included in lumpsum quoted. 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.05 The of contractor shall submit detailed working pipelines and fittings including fabrication These complete fabrication proposed T3. fluxes etc. Root valves. drawings bill shall indicate design parameters. All root joint welding from headers for service instrument air. air. and gas welding for T3. etc. welding electrodes for electric arc and filler rods.04 tools. Bolts. for gas welding .. welding and all details. Blind pipe shall flanges.
Pipes. Once welding procedure is qualified. effective control in carrying out welded joints.welding per carrying out the welding at site. thickness range etc.02 The contractor shall indicate the procedure he is to follow for fabrication/erection/hydraulic testing M. Submerged orc as per IS 10234-1982 shall be carried out as relevant International code.04 contractor. reaffirmed in 1991 and shall be carried out to quality procedures.04. make Strength-equality with parent metal Absence of defects iii) Corrosion resistance of the weld shall not be than that of the parent metal in environment. IS:7310 Welders employed shall be qualified as per . strict to it shall be made during actual welding. i) ii) less agressive T3. Method of Quality Control in Welded Joints Following besides steps shall be taken quality in by the to controlling general.04. with tests Number like a adherence b) a) Welding procedures shall be prepared in line IS:7307(Part-I)-1974.S.03 requirements Requirement of welded joints The contractor shall ensure the following while welding the plates/ pipejoints etc. all The contractor shall arrange at his own cost for tests outlined in this section. of procedures will depend on variables positions of welding. going of T3. T3.04.
uniform and from fins. ANSI size and dimensions of the vee-grooves B-16. reaffirmed in 1987 after c) type. necessary tests. welded approved T3. to 1991. approved subject qualifying initial check tests as per IS:814The contractor shall strictly follow welding procedures during actual welding. proper weld profile shall be checked visually. teers. ii) i) Weld edge preparation before welding. approved Besides.25 unless otherwise as specified drawings/documents.04.. fit up. position of welding. free may loose The welding surfaces shall be smooth. cleaning of between the passes. amongst others.passing (Part-I)-1974. Preparation of joints The contractor shall prepare the edge correctly to shape. notches or any other defect which adversely afect welding and shall be free from . however. the following stages of inspection shall also carried out : proper slag etc. be d) Welding Such consumables consumables shall be of are.05 the per in Non-destructive joints tests of weld of shall be carried out as per procedures/ drawings.
moisture or any foreign about material. The rate of shall be more or less equal progress and welder uniform. grease. paint. The working employ sufficient number of welders the same time in diagonal quadrants of the shell back-step each method of welding. . before the horizontal circular course shall be aligned and adjusted for correct axes. welding. rust. but in a long joint as in fabrication. 10 mm The clean surface shall the welding faces extend to beyond contamination of the weld metal with foreign and to avoid unsound weld deposit.other to avoid material T3. slag. Assembly. started. 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. 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. seam However. the shell to The general direction of welding shall be towards free end of the joint. back-step technique shall be used reduce distortion.04.06 and about contractor at using of quality scale.
the tack shall be welds into the first layer of weld or else chipped out. areas to than it on both sides of the weld for a width 20 mm shall be cleared of slag not and impurities. Before examining the welded joints. 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. glass Examination shall be done by a which has a magnification power of ten (10) measuring instrument which has an accuracy of + 0.each prein same axis each penstock bigger Alternatively.04. 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. principle such a sequence and planning. course in the contractor shall complete then and the placed the all respects on ground and course In shall be lifted assembled position. 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 .1 or by weld gauges.07 Pipe and attachment and shall be aligned properly welding. either accurate tack permanent methods prior to are used. Welded joints shall be examined both sides. by If fused T3.
The distance between the tip of base . 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. However minimum 10% DPT or MP shall be carried out in the fabricated pipes. (b) Liquid Dye-penetrant Test dye-penetrant tests shall be carried out 1991 Liquid in for accordance with IS:3658-1981. Compressed air shall blown 5 from the opposite side at pressure of 4 kg/cm. reaffirmed in surface/sub-surface defects. as directed the Purchaser. sq.iii) Influx iv) v) Burns Under cuts 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. (c) The Test by Blowing surface of the weld shall be of covered of with water soap and be to and solution consisting one (1) litre hundred (100) grammes of soap.
00 mm + 5 deg.1.of Portable if the weld shall not be more than 50 mm. Any formation soap buble will indicate shall welding defects.00 mm iii) Stepping of one plate over other c) Lap Joint i) Overlap 2. compressor be arranged by necessary. the contractor.00 mm Manual arc Tolerance ------------------------Automatic ii) Stepping of one plate over the other Manual arc 1. for this purpose.00 mm 5.00 mm 5.00 mm 2.00 mm . + 1. + 2.1.00 mm + 1.00 mm 2. 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 + 2.00 mm .00 mm b) Single Vee-groove Joints i) ii) Bevol angle Gap between two + 5 deg.00 mm .
T3. The expansion be designed such that no periodic adjustment required.05 T3.03 used the shall to Body Expansion bellow shall be of heavy duty manufactured from high grade abrasion resistant or synthetic rubber.00 mm 2.ii) d) Gap between the surface 2. adequate design shall be supplied for securely the expansion joint with connecting pipe flanges.05. as specified in data sheets.02 construction natural with of holding T3. be All fabric plies components impregnated with rubber or synthetic permit flexibility between them.00 mm T3.00 mm 1. as stipulated in the specification shall sheets enclosed.05. Carcass Fabrics of high strength synthetic fibres shall be in suitable number of plies to hold the shape of bellow at the working condition.00 mm Tee-filler joints i) Gap between the edge of the web and the surface of the flange 2. angular or rotational movement of the bellow / or the equipment vibration.05. . Split retaining rings integral flanges at both ends.01 the and data joint is Rubber Expansion Joints Design and Construction Design of the expansion joint shall take care of axial.
assembly Protective exterior. nuts Control rod assembly will & lock nuts.05.05.05 rod contraction of washers.embedded the T3. the T3. spherical consist connecting plates (gusset plate) for fixing the with mating flanges.05.06 End Flanges . bolt. and of Control rod assembly shall allow transverse rotational movements under limiting axial conditions the expansion joints. 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. T3. 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.04 shall carcass Copper coated steel wire or solid endless rings in the carcass shall be used for reinforcement of expansion bellow.
08 Required numbers of carbon steel nuts. check Before the hydro test and after the hydro test is the bellow shall be dimensionally inspected to deformation.05. bolts. suitably During the test.07 The expansion joint shall have integral The bolt hole reinforced full face rubber flanges. and rubber gaskets shall be furnished. b) Vacuum Test .fabric on the face.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. washers 7. carried over. Counter Flanges Counter flanges shall be as per AWWA C-207. the control assembly shall be adjusted to obtain the test conditions of the bellow. if any. the be during T3. suitably match The companion flanges shall identification marked for easy erection by others. the flange shall have no eccentricity in relation to corresponding bolt hole of the flange on the other The end rubber flange shall be drilled to suit companion pipe flanges. Hydrostatic Pressure Test and Vacuum Test a) internal half the All Pressure Test expansion bellows shall be subjected to hydrostatic (1.
The external shall and internal surfaces of the with expansion a joint be of Neoprene of 3 mm thickness shore hardness of 65 + 5 deg. or angular or rotational movements of the bellow and/ the equipment vibration. USA joints manufacturers' Association.05. The Rubber Expanson Joints shall conform to following standards/codes: i) Expansion standards ii) Fluid sealing Association. The body of expansion joint shall be made from abrasion resistant rubber. are as described above for pressure test. . USA Design of Expansion joint shall take care of the axial. extra T3.09 the 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.All expansion joint shall be subjected to a vacuum test in thirty positions at 700 mm of Hg vacuum. The expansion joints shall have integral flanges at both ends complete with split retaining rings. The test shall be conducted three different positions for a minimum period of (30) minutes duration in each position. These c) additional assurance.
AWWA-C 207. T3.for Steel wire/synthetic fabric shall be used reinforcement of the expansion bellows. Nominal diameter 5 Nos. Tie rods shall be provided in the expansion joints.5 750mm of Hg vacuum 700mm of Hg vacuum Manufacturers std.10 Design Requirement i) ii) Qty.) . 1-50 lb slip on type xii) Freelength (mm) class xiii)Counter flange xiv) Axial elongation(mm)xv) Axial contraction (mm) - 15 15 15 0. Single arch type. 6 Kg/cm2 Circulating water (for analysis see Annexure-D & E). 1600 mm.05./Min.) - vii) Maximum flow (M3/hr) viii)Location ix) x) xi) Test pressure (kg/cm2g) Vacuum design Vacuum test - 16500 Indoor 7.5 xvi) Lateral deflection (mm) xvii)Angular deflection (deg. 44/30 iii) Type iv) v) Design pressure Liquid to be handled- vi) Working temperature (oC) (Max.
00.W.00 1. Continuous Spool type .) xix) Pump speed (rpm) T3.01.System 1600mm .5 Nos.05.04.00 GENERAL Service Nominal size (NB)/Qty. Duty Type : : : : C.00 1.00 1.02.ASTM A Grade A - 16 mm DATA SHEET FOR RUBBER EXPANSION JOINT 1.03.5 497 Synthetic Rubber Synthetic fibre Manufacturers standard Hypalon or approved equivalent Manufacturer's standard Manufacturer's standard Galvanised Steel Flanges/Counter flanges Gasket Nuts.11 Materials of Construction Bellow Carcass Stiffening ring External cover Internal cover Control assembly Retaining ring - 0. bolts and washers 307 Pipe thickness - Carbon Steel IS:2062 3 mm thick reinforced rubber Carbon Steel .00 1.xviii) Torsional movement (deg.
1.02.05.00 1.5o 0.00 2.05.00 2.00 2.00 No.00 Overall dimensions (mm) Gross weight of the complete assembly (kg) Model No.01. of arch / corrugation Flange pressure rating and drilling standard No.07.02.00.06.00 3. of limit / control rods Bursting pressure of bellow (kg/cm2g) MATERIAL OF CONSTRUCTION : : : : Single BS 4504 PN-10 6Nos.01.00 3.00t 2.00 3.03.00 2. 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. 6 750 60 Design vacuum in mm of mercury: Design Temperature (oC) : 3.03.00 2.00. Kg/cm2g : DESIGN AND CONSTRUCTION Design standard Design pressure (kg/cm2g) : : < 0.00 2.00 3.07. Maximum pressure drop through the expansion joint at design flow rate.00 3.00 3.00 2.08.00 3.00 As per spec./Per Joint Twice the design pressure .04.08.00 2. PERFORMANCE CAPABILITY : : : 750 1750 kgs (appx) During Detail engg.00.07.05.04.06.5 1925 (Appx) 180 During detail Engg.01 3.00 4.00 1.06.
06.00 4. : 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 : Yes : Yes : No .10.0.00 4.04.00 4. Annular IS1367 Gr.A.4.00 Bellow Carcass Bellow exterior Bellow interior : : : : Synthetic Rubber Synthetic fibre Neoprene Rubber Neoprene Rubber IS 2062 Gr.00 6.02.A Fasteners Gaskets : : IS:2062 Gr.03. stretcher plate IS-2062 Gr.02.01.07.02.8/6.00 7.00 6.4.00 7.02.03.00.01. A Sq. nuts spherical washers etc.00 4.03.00 5.6/4. Metal reinforcement : Control rod assembly: Retaining ring segments: IS:2062 Gr.05.00 4.09.00 5.A Galvanised Flanges/counter flanges: IS:2062 Gr.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 6.00 4.08.01.00 4.00 Ring 4. : Yes Counter flanges with nuts.00 5.00. bolts etc.00 5.63.00.00 4.00 7.01.00 7.00 ACCESSORIES INCLUDED Control rod assembly with gusset plate.0 Not recommended as Internal Rubber flange shall act as self gasket 5.04.
00.05.7.E.00.00.E. joint performance The for data. JOINTS 1.00 4.00 Design working pressure of bellow (kg/cm2 g) : 6 Kg/cm2 12 kg/Cm2 15/15 15 0.00 A write-up on the manufacturing inspection and testing facilities available at the manufacturer's works Any other information : : 7.E. 2.A. : 2 sets GUARANTEED DATA FOR R. nuts and gaskets Reinforced Rubber Gasket for above R. 1.00.5 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 : .JOINTS.04. 4.00 2.00 LIST OF MANDATORY SPARES FOR R.00 3. : 1 set : 1 set : N. Joints Control rod assembly complete with nuts etc.00 6.00.00. Note: particular Rubber Expansion Joint Complete assembly of 1600 mm dia. Joint. One set corresponds to the quantity of part used in one R.E.00.00 5. 3.00 7. Slip-on type matching flange with bolts.5 0.
....................... ............... .. NAME ...................... DATE ......................................... DESIGNATION ........ NAME AND ADDRESS OF COMPANY ...SIGNATURE ..............................
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