Ifb Tender DG Sets 19 May 10 TC SP

JINDAL POWER LIMITED
O..P JINDAL SUPER THERMAL POWER PLANT O P JINDAL SUPER THERMAL POWER PLANT 4 X 600 MW UNITS 4 X 600 MW UNITS TAMNAR,, RAIGARH DISTRICT TAMNAR RAIGARH DISTRICT CHHATTISGARH CHHATTISGARH
TECHNICAL SPECIFICATION FOR DIESEL GENERATOR SET

Document No. : K8B15-SPC-M-0023
DEVELOPMENT CONSULTANTS PRIVATE LIMITED

CONSULTING ENGINEERS
BLOCK-DG/4, SALT LAKE CITY, KOLKATA - 700 091, INDIA
May, 2010
JINDAL POWER JINDAL POWER LTD.. LTD
Technical Specification for Diesel Generator Set
O. P. Jindal Super Thermal Power Plant (4 X 600 MW), Tamnar, Chhattisgarh
OVERALL CONTENT
SECTIONS
DESCRIPTION
SECTION-I SECTION-II SECTION-III
CONDITION OF CONTACT TECHNICAL SPECIFICATION PROPOSAL EXHIBIT SHEETS
DOCUMENT NO.: K8B15-DBR-M-0023 , REV -1
Development Consultants Pvt. Ltd.
SECTION-I CONDITIONS OF CONTRACT [TO BE ATTACHED BY JPL]
DOCUMENT NO.: K8B15-SPC-M-0023, REV -1
DEVELOPMENT CONSULTANTS PVT. LTD.
SECTION-II TECHNICAL SPECIFICATION
SECTION II: TECHNICAL SPECIFICATION

SUB-SECTIONS (GENERAL & MECHANICAL) SUB-SECTION M0 SUB-SECTION M1 SUB-SECTION M2 GENERAL TECHNICAL SPECIFICATION GENERAL TECHNICAL REQUIREMENTS TECHNICAL SPECIFICATION FOR DIESEL GENERATOR SET QUALITY ASSURANCE & INSPECTION REQUIREMENTS TECHNICAL SPECIFICATION PREPARATION AND PAINTING ATTCHMENTS ANNEXURE-I DATA SPECIFICATION SHEET FOR SITE METREOLOGICAL CONDITIONS DATA SPECIFICATION SHEET FOR DIESEL GENERATOR SET LIST OF MANDATORY SPARES CLARIFIED WATER ANALYSIS FOR SURFACE
SUB-SECTION M3 SUB-SECTION M4
ANNEXURE-II
ANNEXURE-III ANNEXURE-IV
SUB-SECTION (ELECTRICAL) SUB-SECTION E0 SUB-SECTION E1 SUB-SECTION E2 GENERAL ELECTRICAL SPECIFICATION TECHNICAL SPECIFICATION FOR MOTORS POWER CONTROL CENTER, MOTOR CONTROL CENTER, AMF CONTROL CUM ANNUNCIATION PANEL GENERATOR AND ACCESSORIES BATTERY AND BATTERY CHARGER ERECTION, CABLING & GROUNDING SYSTEM
SUB-SECTION E3 SUB-SECTION E4 SUB-SECTION E5
SECTION III PROPOSAL EXHIBIT SHEETS [SCHEDULES]
SECTION III PROPOSAL EXHIBIT SHEETS [SCHEDULES] CONTENTS SCHEDULES DESCRIPTION
SCHEDULE-I SCHEDULE-II SCHEDULE-III/1 SCHEDULE-III/2 SCHEDULE-III/3 SCHEDULE-IV SCHEDULE-IV/1 SCHEDULE-IV/2 SCHEDULE-IV/3 SCHEDULE-IV/4 SCHEDULE-IV/5 SCHEDULE-V/1 SCHEDULE-V/2 SCHEDULE-V I SCHEDULE-VII SCHEDULE-VIII SCHEDULE-IX
KEY PARTICULARS GUARANTEED DATA TECHNICAL PARTICULARS (MECHANICAL) TECHNICAL PARTICULARS (ELECTRICAL) TECHNICAL PARTICULARS (C & I) LUMP SUM PRICE BREAK-DOWN SHEET PRICE BREAK-DOWN SHEET FOR SUPPLY PRICE BREAK-DOWN SHEET FOR ERECTION & COMMISSIONING BILL OF QUANTITIES AND PRICE SCHEDULE FOR MANDATORY SPARES BILL OF QUANTITIES AND PRICE SCHEDULE FOR RECOMMEND SPARES TOOLS & TACKLE - PRICE PROPOSAL DEVIATION SHEET: PART-A DEVIATION SHEET: PART-B DRAWING SUBMISSION SCHEDULE DECLARATION SHEET QUALIFYING REQUIREMENT WORK SCHEDULE
SECTION-IV SL. NO.
TENDER DRAWINGS DRAWING NUMBER DRAWING TITLE
1. 2
K8B15-DWG-E-0119 K8B15-DWG-E-0433
SINGLE LINE DIAGRAM - DIESEL GENERATOR SYSTEM EQUIPMENT LAYOUT DIESEL GENERATOR BUILDING
SECTION-II SUB SECTION: M0 GENERAL SPECIFICATION
SUB- SECTION: M0 CONTENTS

CLAUSE NUMBER 1.00.00 2.00.00 3.00.00 4.00.00 5.00.00 6.00.00 7.00.00 8.00.00 9.00.00 10.00.00 DESCRIPTION INTENT OF SPECIFICATION GENERAL INFORMATION & SITE CONDITIONS SCOPE OF WORK GUARANTEED PERFORMANCE SPARES SPECIAL TOOLS & TACKLES DEVIATIONS COMPLETION SCHEDULE QUALITY ASSURANCE DRAWINGS/DOCUMENTS TO BE SUBMITTED WITH THE BID PROPOSAL DATA CO-ORDINATION WITH STATUTORY BODIES AND OUTSIDE AGENCIES CO-ORDINATION WITH OTHER CONTRACTORS AND OWNER & OWNERS SYSTEM COMPLETENESS OF SUPPLY & INSTALLATION PAGE NUMBER SS-M0:1 SS-M0:1 SS-M0:2 SS-M0:4 SS-M0:4 SS-M0:5 SS-M0:5 SS-M0:6 SS-M0:6 SS-M0:6
11.00.00 12.00.00
SS-M0:9 SS-M0:9
13.00.00
SS-M0:10
14.00.00
SS-M0:11
SECTION-II SUB-SECTION: M0 GENERAL SPECIFICATION

1.00.00 INTENT OF SPECIFICATION This specification is intended to cover the design, engineering, fabrication, manufacture, pre-assembly, assembly, inspection, testing at manufacturer's works, shop painting, packing, transportation, delivery F.O.R. project site, of Diesel Generator with all accessories to be installed for 4 X 600MW O.P Jindal Super Thermal Power Project, at Tamner, Raigarh district of Chtattisgarh. The scope of work shall also include erection, testing, commissioning and putting into successful commercial operation of the DG sets furnished under this specification. The intent of specification is also to cover unloading at site, receiving, storage, intra site transportation, complete fabrication, erection, installation, taking over of material from Purchaser (if any), pre-commissioning check and commissioning at site, electrical works as specified hereinafter of the entire equipment/machines supplied under this specification to make the system complete in all respects and to achieve efficient, guaranteed operation of the same to entire satisfaction of the Owner. 2.00.00 2.01.00 GENERAL INFORMATION & SITE CONDITIONS Site Condition For site condition please refer to Annexure-I (Data Specification sheet for Site Metreological condition). 2.02.00 All requirements of the latest statutory regulations in force, such as, stipulated regulations of Chtattisgarh State Pollution Control Board; Central Pollution Control Board; Chief controller of Explosive, Department of Environment, Govt. of India, Indian Explosives Act. Indian Factories Act, Indian Boiler Regulation etc. as applicable shall be strictly adhered to. The Bidder shall be responsible for obtaining necessary approval and making whatever additions/modifications considered necessary by the respective Statutory Authorities to bring the installation conformity with the latest Statutory Regulations in force. 2.02.03 All equipment which can conceivably cause hazard to the operator and otherwise authorized personnel within the vicinity of working areas shall be suitably guarded according to the safety regulations. The complete assembled units shall be designed so that all parts subject to wear including shafts and bearings shall be easily accessible for inspection, maintenance and replacement,
SS-M0: 1 DEVELOPMENT CONSULTANTS PVT. LTD.
with minimum loss of time. All equipment supplied shall allow access to facilitate connecting up, and shall operate satisfactorily under such variations of load, pressure and climate conditions as may occur in working. 2.02.04 Bidder shall submit an optional offer for 2000 litre fuel oil storage tank for each DG set with base offer conforming to technical specification. Primary fuel for the engines shall be high speed diesel. However, these engines shall be capable of running with light diesel oil without any difficulty. Bidder to indicate price implication, if any, in his proposal. SCOPE OF WORK The scope of supply under this section shall be as mentioned below. Items not specifically mentioned but deemed necessary by the Bidder for making the system completely reliable and efficient shall also be included. a) Five (5) nos. of Diesel Generator Sets, of 2000KVA feeding power at 415V, 3 phase, 3 wire, 50 HZ, A.C. supply at Power factor 0.8, with neutral grounded, each consisting of the following : i) Diesel engine mounted on vibration dampening pads complete with turbo charging system, integral air intake through dry type air filters and exhaust manifold, metering facility governing system/speed regulation system, crankcase oil dipstick fuel injection system, lubricating oil system, jacket cooling system etc. along with all necessary filters, silencers, ducts, instruments, valves, piping and fittings etc. A.C. Generator along with AVR controlled exciter and Auto Mains failure panel complete with protection system along with remote control panel. Coupling between the engine and the generator together with turning gear.
2.02.05
3.00.00 3.01.00
ii)
iii)
b)
Complete fuel oil system consisting of: i) Total five (5) nos. Fuel Oil Storage tanks of 990 litre capacity each with necessary accessories, one (1) each for each D.G. set. One (1) no. manually operated pump (hand pump) along with connecting hose shall be supplied for all the D.G. sets for filling fuel oil to the fuel oil tanks. All piping, fittings, relief valves, duplex type filters, hoses, supports, control and instrumentation and all other accessories required for the above fuel oil system to make it complete.
ii)
iii)
SS-M0: 2
c)
Complete cooling water system consisting of : Engine cooling water system with engine driven jacket pump, circulating pump, electric heater and head tanks/expansion tanks at top of radiators, radiator, blower type fan, automatic temperature regulator with bypass and any other instrumentations as required.
d)
The system shall consist of five (5) sets of electric starting arrangement complete with D.C. starter motor, cables (supply of cables by the Owner.), D.C. batteries and battery charger. For further details refer electrical sections. Lub oil system, complete with engine driven pumps, one hand pump for initial lubrication coolers, strainers, filters, instrumentation etc. complete with initial charge of lub oil and one additional fill after commissioning. Oil pan immersion heater with thermostat for each engine shall be provided to maintain automatically viscosity of lub oil in normal condition for quick proper starting of engine. If pre-lubrication or lubrication during idle time of engine is required, Bidder is to provide all equipment/system as required for this purpose. Bidder shall provide (1) no. electrically operated and one (1) no. standby DC operated lube oil pump shall also be provided for the purpose.
e)
f)
Five (5) sets of exhaust air ducting (GSS Sheets), one for each DG Set connecting individual radiator to the nearest wall, complete with flexible connection, supports etc. including the radiator water cooling system to be offered by the Bidder. Complete cabling includes laying, termination at both ends, dressing, clamping etc.(supply of cable by Owner), including that from the D.G. Set to AMF panel, DG Set/AMF panel to all D.G. aux. drives/Battery chargers of all power, control & instrumentation cables as required for safe and satisfactory operation of the D.G. sets and plant. Grounding includes complete over-ground earthing of all equipment supplied by the bidder of this package including interconnection with Owners riser to be made available at suitable places. Complete instrumentation, interlock and control, complete wiring of all control, auxiliary power and alarm circuit, necessary annunciation and indication for start up, control, monitoring and safe operation of DG sets. For each of the emergency DG sets, following instruments shall be provided as minimum: i. Temperature Indicators for Lube Oil Temperature,
g)
h)
i)
JINDAL POWER JINDAL POWER LTD.. LTD ii. iii. iv. v. vi. vii.
Pressure gauges for Lube oil, Fuel oil, Cooling Water systems, Pressure switches for Lube oil, Fuel oil, Cooling Water systems, Differential Pressure gauges across strainers and filters, DG set Speed sensors (3 nos. for each of the DG set) and speed Indicator, Level switches in Fuel oil tank for alarm & trip purpose, Level gauges (gauge glass type) in Cooling water tank and Fuel oil tank for level indication purpose.
Any other instrument / hardware, not mentioned explicitly, but essential for successful completion of work and to perform the function intended for the emergency DG system shall be considered in the scope of the Bidder. j) Engine exhaust pipes to be taken outside the shed, up to an elevation of 30m (approx.) above the surrounding ground level and shall be complete with muffler, metal expansion bellow, insulation etc. All pipes, supports, hangers etc.
k) l)
Set of base frames, Foundation bolts, nuts, leveling plates and shims etc.
for all the equipment and accessories. Exhaust pipes up to bird screen. Interfacing with DCS in the form of analogue / digital signal. Potential free contacts will be provided for Start-/ Stop commands, Start permissive, all types of electrical faults, trips and alarms related to the abnormalities of the equipment & system. Analogue / Digital signal for remote monitoring on DDCMIS i) DG voltage measurements 1 no. per DG
m) n)
ii) DG Current measurements (Single phase) - 1 no. per DG iii) DG Frequency measurements 1 no. per DG iv) DG Power (kW) measurements 1 no. per DG o) Preparation of complete electrical layout of DG electrical building showing disposition of electrical equipment, arrangement of cable trays in cable spreader room and also interconnection with respective DG set.
SS-M0: 4
3.02.00
3.02.01
Scope of Services The Contractor shall provide all labour, skilled and unskilled, supervisory and administrative personnel, erection tools and tackle, transport vehicles and mobile cranes, equipment for erection, testing and commissioning and implements necessary for timely and efficient execution of the contract. The installation work is inclusive of supply of erection materials, hardware, consumable and sundry items to complete the installation. The contractor shall also furnish rigid/flexible conduits, conduit accessories, terminal blocks & miscellaneous items as necessary for satisfactory erection, connection of their plant equipment, cables etc. and accessories as per best engineering practices. The installation work under this specification includes erection of items included in the scope of supply under this Package (Including free issued items). Testing and commissioning of electrical equipment erected under this specification. The items of work to be performed by the Contractor for equipment and materials under his scope of work shall include but not limited to: a) Storing all his materials and equipment at the plant site with suitable weather protection. b) Opening and inspecting the materials and equipment and reporting damages. c) d) Taking delivery from store and safe transportation to the site of erection. Repairing minor damages, cleaning before erection and application of anti corrosive paints after cleaning, where needed. e) f) g) Complete assembly, erection and connection. Necessary co ordination between work done by other Contractor. Pre commissioning check up to ensure correctness of erection of his own equipment to be supplied under this Package. h) i) Testing and commissioning in presence of Engineer. Trial operation of the equipment/system, rectifying defects, if any, and making adjustment as necessary. j) Obtaining Engineer's approval and written acceptance of satisfactory operation.
3.02.02
3.02.03
3.02.04
3.02.05
3.02.06
SS-M0: 5
JINDAL POWER JINDAL POWER LTD.. LTD k)
Laying & installation of Fire Retardant Low Smoke (FRLSH) cables including end termination, straight through joints inclusive of all jointing materials e.g. splicing kits, termination kits, standard/special materials and accessories along with ferrules, clamps, cable markers, tags and other sundry items in order to make the cable installation complete in all respects. Supply and installation of conduits and grounding of equipment for the areas as specified elsewhere in the specification and as required. Complete assessment of bill of quantity of Power & Control Cables for the entire DG system and inform Owner for procurement action. Installation and connection of ground conductors for all equipment, conduits etc. under scope of the Contractor from Owner's grounding station grounding mat/grids.
l)
m)
n)
3.02.07 3.02.08 3.02.09 3.02.10
Operation, testing, calibration and setting of relays and meters. Operation, testing, calibration and setting of relays and meters. Handing over the installation for commercial operations. Handing over of one set of "As-Built" marked-up drawings to the Owner for preparation of final "As Built" drawings.
3.03.00
Exclusion
The following items are excluded from the scope of work and will be carried out by others. Supply of DG PCC & Emergency MCC. Laying and termination of control and instrumentation cables required for interface connection between equipment to be supplied under this specification and Owner's equipment. Civil works like buildings, equipment foundation, however, all final dressing of foundations, grouting of equipment and patch work during erection is included in Bidder's scope. Purchaser shall provide civil foundation of equipment like D.G. set F.O. Tank etc. based on detailed dimensioned drawings, specification and loading data to be furnished by the Contractor.
4.00.00
GUARANTEED PERFORMANCE
The performance guarantee of the equipment/system shall be as per subsection-M1 (Technical Specification for Emergency DG Set) of this specification.
SS-M0: 6
The system shall be tested to establish the performance as indicated in the Specification.
5.00.00 5.01.00
SPARES
Recommended Spares Spare parts as necessary and recommended by the Bidder for 3 years of reliable operation of the plant for spares of indigenous origin and for 5 years of reliable operation for spares of non-indigenous origin of the equipment supplied under this specification shall be indicated by the bidder in the proposal. Unit price List shall be as Price Break up for Recommended Spares (Schedule-IX). Bidder shall also assume the responsibility of furnishing all required spare parts that the plant may need for twenty-five (25) years from the date of the contract. Order for the spare may be placed simultaneously or otherwise at the option of the Purchaser.
5.02.00 5.02.01
General Requirement for Spares All spares required for operation/ maintenance by the Purchaser shall be delivered in unused new condition. Spares shall be interchangeable with the parts, for which they are intended for replacement. Bidder shall indicate the service expectancy period for spares under normal operating conditions after which replacement will be necessary. Spares shall be properly packed for long storage under the prevailing site condition. Spares which are required during tests, trial run and commissioning shall be arranged by the Contractor himself and cost of the same shall be included in quoted price. Start-up commissioning spares are those spares which may be required during the start-up and commissioning of the equipment/system. All spares used until the plant is handed over to the Owner shall come under this category. The contractor shall provide for an adequate stock of such start-up commissioning spares, and shall have them at site for tank erection and commissioning and before the equipments are energized. All start-up spares which remain unused after the issue of the Taking-over certificate shall remain the property of the contractor. The list of commissioning spares to be brought by the Contractor to ensure smooth commissioning of the plant shall be subject to the Engineers approval.
5.02.02
5.02.03
5.02.04
5.02.05
5.02.06
SS-M0: 7
JINDAL POWER JINDAL POWER LTD.. LTD 5.02.07
The Contractor shall submit a complete list of all such start-up spares. Costs of the above spares which are consumed before the handing-over of the plant shall be deemed to have been included in the lump sum proposal price of the package, and the contractor shall have nof claim on this account to the Owner.
6.00.00
SPECIAL TOOLS & TACKLES

A set of special tools & tackles which are necessary or convenient for erection, testing, commissioning, maintenance and overhauling of the equipment shall be supplied. Supplier shall furnish separate list and price for the same in his offer.
7.00.00
DEVIATIONS
Bidder shall furnish the offer in line with the specification requirements without any technical deviations. However, in case of any specific deviation taken by the Bidder, same shall be mentioned in a separate deviation sheet as per ScheduleV & VI, attached with reference to respective clause of the specification. Unless otherwise specifically mentioned it will be understood and agreed that offer is based on strict conformance to this specification in all respect.
8.00.00
COMPLETION SCHEDULE
Supply, manufacture, testing, inspection and supervision of installation (if required) of the Equipment/System shall have to be completed as per the schedule indicated in the special conditions of contract. Necessary PERT Network showing schedule of manufacture, testing & commissioning should be submitted with the offer. Bidder, in his proposal, shall indicate the phase-wise design, engineering, manufacturing, testing, delivery, erection and commissioning activities for the complete packages in the form of bar-charts to match with the project schedule. After contract finalization, detail PERT networks shall be furnished by the Contractor for Owners approval and will subsequently form a part of Contract Document. Supply, manufacture, testing, inspection and supervision of installation (if required).
9.00.00
QUALITY ASSURANCE
The Bidder shall have quality assurance plan and programme to manufacture the equipment as per requirement of the specification and applicable standard. The Bidder shall submit QAP for approval of the owner before manufacture of the equipment. The minimum requirements of QAP are indicated in Sub-sectionM3: Quality Assurance Plan.
10.00.00 10.01.00
DRAWINGS/DOCUMENTS TO BE SUBMITTED WITH THE BID Along with the Technical Offer
i) P&I diagram for the system.
SS-M0: 8
JINDAL POWER JINDAL POWER LTD.. LTD ii)
Calculations for DG sizing and the available voltage at highest kW rating motor as per clause no. 3.03.00 of Sub-section: Power distribution scheme. Controls, instrumentation, alarms and protection scheme and write up. Lube oil, fuel oil, jacket cooling water, outer cooling water, and starting air system etc. Write up on Voltage regulator and governor. Single line diagram of generator metering & protection. Dimensional layout and sectional drawings for the complete scope of work (including pipe and cable layout). Schematic and wiring diagram of Battery charger. Dimensional General Arrangement Drawing of various equipment along with cross - Section and bill of material. Layout and mounting arrangement of battery. Any other drawings/document deemed necessary by Purchaser. Generator curves and characteristics.
iii) iv)
v)
vi) vii) viii)
ix) x)
xi) xii) xiii)
a) O.C & S.C Characteristics.

b) "V" curves. c) Reactive capability curves. d) Generator transient and sub-transient reactance. e) Generator losses, fixed and variables. f) Communication non-interference test curves. g) All other necessary curves for the generator, and auxiliaries. xiv) xv) exciter, AVR
Characteristics curves for Pumps and Diesel Engines. Where ever applicable Speed Vs Torque Curve of the pump corresponding to recommended mode of pump starting,
superimposed on speed Vs torque curve of the motor corresponding to 80%, 90% and 100% rated voltage. xvi) xvii) Selection of D.C. battery and charger rating. Calculations for net electrical output at site after deducting power consumption of D.G. auxiliaries. Write-up on specific features of equipment, if any.
xviii)
10.02.00
After award of contract

i) Final version of all data/drawings/schematics/calculations as specified above. Arrangement of generator phase and neutral terminals. Wiring diagram of local control panels, D.C. battery charger etc. Relay setting calculations for generator relays. Any other drawing/document/data deemed necessary by purchaser.
ii) iii) iv) v)
a. Write up on operation, control and monitoring of D.G. plant. b. Cable interconnection diagram and cable schedule. 10.03.00 To be submitted for Approval (A)/Reference (R) and Subsequent Distribution (No. of copies shall be communicated to successful bidder): Transport/shipping dimensions with weights, wheel base detail etc (R) Foundation plan & loading (A) Terminal arrangements of Generator (A) Rating and Diagram Plate (R) Cable Interconnection Diagram and Cable schedule (R) Drawings of major components like starting system, fuel tank, local control panel etc (A) Quality Assurance Plan (A) Detail manufacturing and supply schedule (A) Power distribution scheme (A.)
10.03.01 10.03.02 10.03.03 10.03.04 10.03.05 10.03.06
10.03.07 10.03.08 10.03.09
10.03.10 10.03.11 10.03.12 10.03.13
Controls, instrumentation, alarms and protection scheme and write up (A) Write up on Voltage regulator and governor (R) Single line diagram of generator metering & protection (A) Preparation of dimensional electrical layout of DG electrical building and sectional views showing disposition of electrical equipment, arrangement of cable trays/ cable rack in cable spreader room and also interconnection with respective DG set. (A). Schematic and wiring diagram of Battery charger (A). Dimensional General Arrangement Drawing of various equipment along with cross - Section and bill of material (A). Layout and mounting arrangement of battery (A). Generator curves and characteristics as mentioned in clause no.10.01.00-(xiii) (R). Where ever applicable Speed Vs Torque Curve of the pump corresponding to recommended mode of pump starting, superimposed on speed Vs torque curve of the motor corresponding to 80%, 90% and 100% rated voltage (R). Selection of D.C. battery and charger rating (A). Calculations for net electrical output at site after deducting power consumption of D.G. auxiliaries and for DG sizing and the available voltage at highest kW rating motor as per clause no. 3.03.00 of of Attachment-B1 (A). Write-up on specific features of equipment, if any (R). Arrangement of generator phase and neutral terminals (A). Wiring diagram of local control panels, D.C. battery charger etc.(R). Relay setting calculations for generator relays (R). Any other drawing/document/data deemed necessary by purchaser (R). Write up and logic diagram on operation, control and monitoring of D.G. plant (R). Any other relevant drawing or data necessary for satisfactory installation, operation and maintenance (R).
10.03.14 10.03.15
10.03.16 10.03.17
10.03.18
10.03.19
10.03.20
10.03.21 10.03.22 10.03.23 10.03.24 10.03.25 10.03.26
10.03.27
SS-M0: 11
The drawings mentioned above for Approval Category and Reference Category are indicative only. On submission of the document list by the Contractor during execution of the project, Owner will mark the categories of the document. The Contractor shall be required to submit the document accordingly.
11.00.00
PROPOSAL DATA
The proposal data sheets annexed to this specification shall be filled in without any ambiguity by typing in appropriate place on each page. These pages must be properly signed by authorized representative of the Bidder as verification of the data and submitted along with the bid to form part of the Bidder's formal proposal.
12.00.00
COORDINATION WITH STATUTORY BODIES AND OUTSIDE AGENCIES

The Contractor shall be fully responsible for carrying out all co-ordination & liaison work as may be required with Mechanical / Electrical Inspector, Factory Inspector & other statutory bodies for implementation of the work. The application on behalf of the Employer for submission to the Mechanical/ Electrical Inspector & other statutory bodies along with copies of drawings complete in all respects shall be done by the Contractor & approval/certificates taken well ahead of time so that the actual commissioning of equipment is not delayed for want of inspection and approval by the Inspector & statutory bodies. The Contractor shall arrange the actual inspection work by the Mechanical/ Electrical Inspector. However, official fees paid to Mechanical/Electrical Inspector/ statutory bodies, etc. in this regard shall be borne by the Employer.
13.00.00
COORDINATION WITH OTHER CONTRACTORS AND OWNER & OWNERS SYSTEM

The Contractor shall be fully responsible for carrying out all co-ordination work required with other contractors as well as with Owner & Owners SYSTEM for execution & completion of his work.
14.00.00
14.01.00
COMPLETENESS OF SUPPLY & INSTALLATION

It is not the intent to specify completely herein all details of the equipment & installation. Nevertheless, the equipment & installation shall be complete & operative in all aspects & shall conform to highest standard of engineering, design & workmanship. Any material or accessory which may not have been specifically mentioned but which is necessary or usual for satisfactory & trouble free operation & maintenance of the equipment shall be furnished without any extra charge.
14.02.00
SS-M0: 12
The Contractor shall supply all brand new equipment & accessories as specified herein with such modification and alteration as agreed upon in writing & after mutual discussion.
SS-M0: 13
JIINDAL J NDAL LTD.. LTD
POWER POWER
SUB-SECTION: M1 GENERAL TECHNICAL REQUIREMENTS
POWER POWER
SUB-SECTION: M1 GENERAL TECHNICAL REQUIREMENTS

1.00.00 INTRODUCTION This part covers technical requirements, which will form an integral part of the Contract. The following provisions shall supplement all the detailed technical requirements brought out in the Technical Specifications and the Technical Data Sheets. 2.00.00 BRAND NAME Whenever a material or article is specified or described by the name of a particular brand, manufacturer or vendor, the specific item mentioned shall be understood to be indicative of the function and quality desired, and not restrictive; other manufacturer's products may be considered provided sufficient information is furnished to enable the Owner to determine that the products proposed are equivalent to those named.
3.00.00
BASE OFFER & ALTERNATE PROPOSALS The Bidder's proposal shall be based upon the use of equipment and material complying fully with the requirements specified herein. It is recognized that the Bidder may have standardized on the use of certain components, materials, processes or procedures different than those specified herein. Alternate proposals offering similar equipment based on the manufacturer's standard practice may also be considered, provided the base offer is in line with technical specifications and such proposals meet the specified design standards and performance requirement and are acceptable to the Owner. Sufficient amount of information for justifying such proposals shall be furnished to Owner along with the bid to enable the Owner to determine the acceptability of these proposals.
4.00.00 4.01.00
COMPLETENESS OF FACILITIES Bidders may note that this is a contract inclusive of the scope as indicated elsewhere in the specification. Each of the plant shall be engineered and designed in accordance with the specification requirement. All engineering and associated services are required to ensure that a completely engineered plant is provided. All equipments furnished by the Bidder shall be complete in every respect, with all mountings, fittings, fixtures and standard accessories normally provided with such equipment and/or those needed for erection, completion and safe operation & maintenance of the equipment and for the safety of the operating personnel, as required by applicable codes, though they may not have been specifically detailed in the respective specifications, unless included in the list of exclusions.
4.02.00
POWER POWER
All similar standard components/ parts of similar standard equipment provided, shall be interchangeable with one another. 5.00.00 5.01.00 CODES & STANDARDS In addition to the codes and standards specifically mentioned in the relevant technical specifications for the equipment / plant / system, all equipment parts, systems and works covered under this specification shall comply with all currently applicable statutory regulations and safety codes of the Republic of India as well as of the locality where they will be installed, including the following: a) b) c) d) e) f) g) h) i) j) k) l) Bureau of Indian Standards (BIS) Indian electricity act Indian electricity rules Indian Explosives Act Indian Factories Act and State Factories Act Indian Boiler Regulations (IBR) Regulations of the Central Pollution Control Board, India Regulations of the Ministry of Environment & Forest (MoEF), Government of India Pollution Control Regulations Government of India State Pollution Control Board. Rules for Electrical installation by Tariff Advisory Committee (TAC). Any other statutory codes / standards / regulations, as may be applicable. of Department of Environment,
5.02.00
Unless covered otherwise by Indian codes & standards and in case nothing to the contrary is specifically mentioned elsewhere in the specifications, the latest editions (as applicable as on date of bid opening), of the codes and standards given below shall also apply: a) b) c) d) e) f) g) h) i) Japanese Industrial Standards (JIS) American National Standards Institute (ANSI) American Society of Testing and Materials (ASTM) American Society of Mechanical Engineers (ASME) American Petroleum Institute (API) Standards of the Hydraulic Institute, U.S.A. International Organisation for Standardization (ISO) Tubular Exchanger Manufacturer's Association (TEMA) American Welding Society (AWS)
JIINDAL J NDAL LTD.. LTD j) k) l) m) n) 5.03.00
POWER POWER
National Electrical Manufacturers Association (NEMA) National Fire Protection Association (NFPA) International Electro-Technical Commission (IEC) Expansion Joint Manufacturers Association (EJMA) Heat Exchange Institute (HEI)
Other International/ National standards such as DIN, VDI, BS, etc. shall also be accepted for only material codes and manufacturing standards, subject to the Owner's approval, for which the Bidder shall furnish, alongwith the offer, adequate information to justify that these standards are equivalent or superior to the standards mentioned above. In all such cases the Bidder shall furnish specifically the variations and deviations from the standards mentioned else where in the specification together with the complete word to word translation of the standard that is normally not published in English. As regards highly standardized equipments such as Steam Turbine and Generator, National /International standards such as JIS, DIN, VDI, ISO, SEL, SEW, VDE, IEC & VGB shall also be considered as far as applicable for Design, Manufacturing and Testing of the respective equipment. In addition, these standards shall be referred for the design of machine foundations, wherever specifically mentioned in the specifications. However, for those of the above equipment not covered by these National / International standards, established and proven standards of manufacturers shall also be considered. In the event of any conflict between the codes and standards referred to in the above clauses and the requirement of this specification, the requirement of Technical Specification shall govern. Two (2) English language copies of all-national and international codes and/or standards used in the design of the plant, equipment, civil and structural works shall be provided by the Bidder to the Owner within two calendar months from the date of the Notification of Award. In case of any change in codes, standards & regulations between the date of bid opening and the date when vendors proceed with fabrication, the Owner shall have the option to incorporate the changed requirements or to retain the original standard. It shall be the responsibility of the Bidder to bring to the notice of the Owner such changes and advise Owner of the resulting effect.
5.04.00
5.05.00
5.06.00
5.07.00
6.00.00 6.01.00
EQUIPMENT FUNCTIONAL GUARANTEE The Equipment and Auxiliaries shall be capable of continuous operation in frequency range of 47.5 to 51.5 Hz. The functional guarantees of the equipment under the scope of the Contract is given elsewhere in the technical specification. These guarantees shall supplement the general functional guarantee provisions covered under General Conditions of Contract.
6.02.00
SS-M1: 3
JIINDAL J NDAL LTD.. LTD 6.03.00
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Liquidated damages for shortfall in meeting functional guarantee(s) during the performance and guarantee tests shall be assessed and recovered from the Bidder as specified elsewhere in this specification. DESIGN OF FACILITIES/ MAINTENANCE & AVAILABILITY CONSIDERATIONS Design of Facilities All the design procedures, systems and components proposed shall have already been adequately developed and shall have demonstrated good reliability under similar conditions elsewhere. The Bidder shall be responsible for the selection and design of appropriate equipments to provide the best co-ordinate performance of the entire system. The basic requirements are detailed out in various clauses of the Technical Specifications. The design of various components, assemblies and subassemblies shall be done so that it facilitates easy field assembly and dismantling. All the rotating components shall be so selected that the natural frequency of the complete unit is not critical or close to the operating range of the unit.
7.00.00
7.01.00
7.02.00
Maintenance and Availability Considerations Equipment/facilities offered shall be designed for high availability, low maintenance and ease of maintenance. The Bidder shall specifically state the design features incorporated to achieve high degree of reliability/ availability and ease of maintenance. The Bidder shall also furnish details of availability records in the reference plants stated in his experience list. Bidder shall state in his offer the various maintenance intervals, spare parts and man-hour requirement during such operation. The intervals for each type of maintenance namely inspection of the furnace, inspection of the entire hot gas path and the minor and major overhauls shall be specified in terms of fired hours, clearly defining the spare parts and man-hour requirement for each stage. Lifting devices i.e. hoists and chain pulley jacks, etc. shall be provided by the Bidder for handling of any equipment or any of its part having weight in excess of 500 Kgs during erection and maintenance activities. Lifting devices like lifting tackles, slings, etc. to be connected to hook of the hoist / crane shall be provided by the Bidder for lifting the equipment and accessories covered under the specification.
8.00.00 8.01.00
DOCUMENTS, DATA AND DRAWINGS TO BE FURNISHED BY BIDDER Each of the plant and equipment shall be fully integrated, engineered and designed to perform in accordance with the technical specification. All engineering and technical services required ensuring a completely engineered plant shall be provided in respect of mechanical, electrical, control & instrumentation, civil & structural works as per the scope.
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The Bidder shall furnish engineering data/drgs. in accordance with the schedule of information as specified in Technical Specification and data sheets. 8.02.00 The number of copies/prints/CD-ROMs/manuals to be furnished for various types of documents is given in Annexure-I attached. The documentation that shall be provided by the Bidder is indicated in various sections of specification. The documentation shall include but not be limited to the following: Basic Engineering Documentation i. ii. iii. System description of all the mechanical, electrical, control & instrumentation & civil systems as applicable under scope. Technology scan for each system / sub-system & equipment. Selection of appropriate technology / schemes for various systems/ subsystems including techno-economic studies between various options if asked for. Optimization studies including thermal cycle optimization if asked for. Sizing criteria of all the systems, sub-systems including various piping systems/ equipments/ structures/ equipment foundations along with all calculations justifying and identifying the sizing and the design margins. Schemes and Process & Instrumentation diagrams for the various systems/ sub-system with functional write-ups. Operation Philosophy and the control philosophy of the Plant/ Subsystem/equipment under the scope. General Layout plan of the Plant/System Equipment incorporating all facilities in Bidder's scope as well as interfacing with other facilities. This drawing shall also be furnished in the form of floppy discs to the Owner for engineering of areas not included in Bidder's scope. Basic layouts and cross sections of the plant/buildings (various floor elevations), etc. included in the scope of the Bidder. Documentation in respect of Quality Assurance System as listed out elsewhere in this specification. The successful bidder shall furnish within three (3) weeks from the date of Notification of Award, a list of contents of the Plant Definition Manual (PDMs) including techno-economic studies, which shall then be mutually discussed & finalised with the Owner if specifically asked for. Layouts, general arrangements, elevations and cross-sections drawings for all the equipment and facilities of the plant. Flow diagrams, Process & Instrumentation Diagrams along with write-up and system description. Piping isometric, composite layout and fabrication drawings. Piping engineering diagrams, pipe and fittings schedules, valve
8.03.00
iv. v.
vi. vii. viii.
ix. x. xi.
Detail Engineering Documents i. ii. iii. iv.
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schedules, hanger and support schedules, insulation schedules. v. Technical data sheets for all bought out and manufactured items. Bidder shall use the specifications as a base for placement of orders on their sub-vendors. Detailed design calculations for components, system/sub-system,, piping etc., wherever applicable including sizing calculations for all auxiliaries as per criteria specified elsewhere in specification. Transient, hydraulic and thermal stress analysis of piping and system wherever applicable & input and output data along with stress analysis isometrics showing nodes. Comprehensive list of all terminal points which interface with Owner's facilities giving details of location, terminal pressure, temperature, fluid handled & end connection details, forces, moments etc. Power supply single line diagram, block logics, control schematics, electrical schematics, etc. Protection system diagrams and relay settings. Interconnection diagrams. Cable routing plan. Instrument schedule, measuring point list, I/O list, Interconnection & wiring diagram, functional write-ups, installation drawings for field mounted instruments, logic diagrams, control schematics, wiring and tubing diagrams of panels and enclosures etc. Drawings for open loop and close loop controls (both hardware and software). Motor list and valve schedule including type of actuator etc. Alarm and annunciation list and alarms & trip set points. Sequence and protection interlock schemes. Type test reports and power system stability study report. Control system configuration diagrams and card circuit diagrams and maintenance details. Detailed flow chart for digital control system. Mimic diagram layout. Civil Task drawings (for the Engineering by Owner), Design and Drawings for the Civil & Structural works in the scope of the Bidder. Model study reports wherever applicable.
vi.
vii.
viii.
ix. x. xi. xii. xiii.
xiv. xv. xvi. xvii.
xviii. Detailed software manuals & source software listing. xix. xx. xxi. xxii.
xxiii. Functional & guarantee test procedures and test reports. xxiv. Documentation in respect of Quality Assurance System as listed out elsewhere in this specification. xxv. Documentation in respect of commissioning as listed out elsewhere in this specification.
xxvi. The Bidder while submitting the above documents / drawings for approval / reference as the case may be, shall mark on each copy of submission the reference letter along with the date vide which the submissions are made.
DOCUMENT NO.: K8B15-SPC-M-0023, REV -1 SS-M1: 6 DEVELOPMENT CONSULTANTS PVT. LTD.
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8.03.01
Instruction Manuals The Bidder shall submit to the Owner, draft Instruction Manuals for all the equipments covered under the Contract by the end of one year from the date of his acceptance of the Letter of Award. The Instruction manuals shall contain full details required for erection, commissioning, operation and maintenance of each equipment. The manual shall be specifically compiled for this project. After finalization and approval of the Owner the Instruction Manuals shall be submitted as indicated in Annexure-I. The Contract shall not be considered to be completed for purposes of taking over until the final Instructions manuals have been supplied to the Owner. The Instruction Manuals shall comprise of the following. Erection Manuals The erection manuals shall be submitted atleast three (3) months prior to the commencement of erection activities of particular equipment/system. The erection manual should contain the following as a minimum. a) b) c) d) e) f) g) h) i) j) k) l) m) Erection strategy. Sequence of erection. Erection instructions. Critical checks and permissible deviation/tolerances. List of tool, tackles, heavy equipments like cranes, dozers, etc. Bill of Materials Procedure for erection. General safety procedures to followed during erection/installation. Procedure for initial checking after erection. Procedure for testing and acceptance norms. Procedure / Check list for pre-commissioning activities. Procedure / Check list for commissioning of the system. Safety precautions to be followed in electrical supply distribution during erection
Operation & Maintenance Manuals i. The operating and maintenance instructions together with drawings (other than shop drawings) of the equipment, as completed, shall be in sufficient detail to enable the Owner to operate, maintain, dismantle, reassemble and adjust all parts of the equipment. They shall give a step by step procedure for all operations likely to be carried out during the life of the plant / equipment including, operation, maintenance, dismantling and repair including periodical activities such as chemical cleaning of the generator. Each manual shall also include a complete set of drawings together with performance/rating curves of the equipment and test certificates wherever applicable. The contract shall
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not be considered to be completed for purposes for taking over until these manuals have been supplied to the Owner. ii. If after the commissioning and initial operation of the plant, the manuals require any modification / additions / changes, the same shall be incorporated and the updated final instruction manuals shall be submitted to the Owner for records. A separate section of the manual shall be for each size/ type of equipment and shall contain a detailed description of construction and operation, together with all relevant pamphlets and drawings. The manuals shall include the following : a) b) List of spare parts along with their drawing and catalogues and procedure for ordering spares. Lubrication Schedule including charts showing lubrication checking, testing and replacement procedure to be carried daily, weekly, monthly & at longer intervals to ensure trouble free operation. Where applicable, fault location charts shall be included to facilitate finding the cause of maloperation or break down.
iii.
iv.
c) v.
Detailed specifications for all the consumables including lubricant oils, greases, chemicals etc. system/equipment/assembly/sub-assembly wise required for the complete plant. On completion of erection, a complete list of bearings/equipment giving their location, and identification marks etc. shall also be furnished to the Owner indicating lubrication method for each type/category of bearing.
vi.
8.03.02
Handbook The Bidder shall submit a preliminary hand book preferably in A-4 size sheets which shall contain the design and performance data of various plants, equipments and systems covering the Plant/Equipment under this scope. 1. 2. 3. 4. 5. 6. 7. 8. Design and performance data. Process & Instrumentation diagrams. Single line diagrams. Sequence & Protection Interlock Schemes. Alarm and trip values. Performance Curves. General layout plan and layout of main plant building and auxiliary buildings. Important Do's & Don't's The handbook shall be submitted within twelve (12) months from the date of award of contract. After the incorporation of Owner's comments, the final plant handbook complete in all respects shall be submitted three (3) months before start-up & commissioning activities.
8.03.03
Project Completion Report

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The Bidder shall submit a Project Completion Report at the time of handing over the plant Equipment under this scope. 8.03.04 Drawings a) All documents submitted by the Bidder for Owner's review shall be in electronic form (soft copies) along with the desired number of hard copies as per Annexure-I. The soft copies to be supplied shall be either in CDs, Floppies or through direct transfer via E-mail, etc. depending upon the nature/volume/size of the document. The drawings submitted for approval could be in the Image form. Final copies of the approved drawings shall be submitted on CD-ROM along with the requisite number of hard copies as per Annexure-I. The completed plant documentation with equipment drawings, data sheets, P&ID, BOQ, schematics, logic diagrams, test reports and quality plan, etc. shall be furnished to Owner. All documents/text information shall be in latest version of MS Office. All drawings submitted by the Bidder including those submitted at the time of bid shall be in sufficient detail indicating the type, size, arrangement, weight of each component for packing and shipment, the external connection, fixing arrangement required, the dimensions required for installation and interconnections with other equipments and materials, clearance and spaces required between various portions of equipment and any other information specifically requested in the drawing schedules. Each drawing submitted by the Bidder (including those of subvendors) shall bear a title block at the right hand bottom corner with clear mention of the name of the Owner, Consultant, name of the Project, system designation, the specifications title, the specification number, drawing/document number and revisions. If standard catalogue pages are submitted the applicable items shall be indicated therein. All titles, notings, markings and writings on the drawing shall be in English. All the dimensions should be in metric units. The Bidder shall also furnish a Master Drawing List which shall be a comprehensive list of all drawings/ documents/ calculations envisaged to be furnished by him during the detailed engineering to the Owner. Such list should clearly indicate the purpose of submission of these drawings i.e. FOR APPROVAL or FOR INFORMATION ONLY. Similarly, all the drawings/ documents submitted by the Bidder during detailed engineering stage shall be stamped FOR APPROVAL or FOR INFORMATION prior to submission. The furnishing of detailed engineering data and drawings by the Bidder shall be in accordance with the time schedule for the project.
b)
c)
d) e)
f)
g)
h)
i)
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The review of these documents/ data/ drawings by the Owner will cover only general conformance of the data/ drawings/ documents to the specifications and contract, interfaces with the equipments provided by others and external connections & dimensions which might affect plant layout. The review by the Owner should not be construed to be a thorough review of all dimensions, quantities and details of the equipments, materials, any devices or items indicated or the accuracy of the information submitted. The review and/ or approval by the Owner / Project Manager shall not relieve the Bidder of any of his responsibilities and liabilities under this contract. j) After the approval of the drawings, further work by the Bidder shall be in strict accordance with these approved drawings and no deviation shall be permitted without the written approval of the Owner. All manufacturing, fabrication and execution of work in connection with the equipment / system, prior to the approval of the drawings, shall be at the Bidders risk. The Bidder is expected not to make any changes in the design of the equipment /system, once they are approved by the Owner. However, if some changes are necessitated in the design of the equipment/system at a later date, the Bidder may do so, but such changes shall promptly be brought to the notice of the Owner indicating the reasons for the change and get the revised drawing approved again in strict conformance to the provisions of the Technical Specification. Drawings shall include all installations and detailed piping layout drawings. Layout drawings for all piping of 65 mm and larger diameter shall be submitted for review/ approval of Owner prior to erection. Small diameter pipes shall however be routed as per site conditions in consultation with site authority/representative of Owner based on requirements of such piping indicated in approved / finalized Flow Scheme / Process & Instrumentation Diagrams and/or the requirements cropping up for draining & venting of larger diameter piping or otherwise after their erection as per actual physical condition for the entire scope of work of this package. Assessing & anticipating the requirement and supply of all piping and equipment shall be done by the Bidder well in advance so as not to hinder the progress of piping & equipment erection, subsequent system charging and its effective draining & venting arrangement as per site suitability. As Built Drawings After final acceptance of individual equipment/system by the Owner, the Bidder will update all original drawings and documents for the equipment/ system to as built conditions. o) Drawings must be checked by the Bidder in terms of its completeness, data adequacy and relevance with respect to Engineering schedule prior to submission to the Owner. In case drawings are found to be
k)
l)
m)
n)
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submitted without proper endorsement for checking by the Bidder, the same shall not be reviewed and returned to the Bidder for resubmission. The Bidder shall make a visit to site to see the existing facilities and understand the layout completely and collect all necessary data/drawings at site which are needed as an input to the engineering. The Bidder shall do the complete engineering including interfacing and integration of all his equipment, systems & facilities within his scope of work as well as interface engineering & integration of systems, facilities, equipment & works under Owners scope and submit all necessary drawings/ documents for the same. p) The Bidder shall submit adequate prints of drawing/data/document for Owners review and approval. The Owner shall review the drawings and return one (1) copy to the Bidder authorizing either to proceed with manufacture or fabrication, or marked to show changes desired. When changes are required, drawings shall be re-submitted promptly, with revisions clearly marked, for final review. Any delays arising out of the failure of the Bidder to submit/rectify and resubmit in time shall not be accepted as a reason for delay in the contract schedule. All engineering data submitted by the Bidder after final process including review and approval by the Project Manager/Owner shall form part of the contract documents and the entire works covered under these specification shall be performed in strict conformity with technical specifications unless otherwise expressly requested by the Project Manager in writing.
q)
8.04.00
Engineering Information Submission Schedule Prior to the award of Contract, a Detailed Engineering Information Submission Schedule shall be tied up with the Owner. For this, the bidder shall furnish a detailed list of engineering information alongwith the proposed submission schedule. This list would be a comprehensive one including all engineering data / drawings / information for all bought out items and manufactured items. The information shall be categorised into the following parts. a) Information that shall be submitted for the approval of the Owner before proceeding further, and Information that would be submitted for Owners information only. The Engineering Information Schedule shall be updated monthwise. The schedule should allow adequate time for proper review and incorporation of changes/ modifications, if any, to meet the contract without affecting the equipment delivery schedule and overall project schedule. The early submission of drawings and data is as important as the manufacture and delivery of equipment and hardware and this shall be duly considered while determining the overall performance and progress.
b) c) d)
8.05.00
Engineering Progress and Exception Report

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8.05.01
Report giving the status of each engineering information including a) A list of drawings/engineering information which remains unapproved for more than four (4) weeks after the date of first submission Drawings which were not submitted as per agreed schedule.
b) 8.05.02
The draft format for this report shall be furnished to the Owner within four (4) weeks of the award of the contract, which shall then be discussed and finalized with the Owner. Co-Ordination Meetings The Bidder shall be called upon to organize and attend monthly Design/ Coordination Meetings with the Owner/Owners representatives, Project Consultant during the period of contract. The Bidder shall attend such meetings at his own cost at mutually agreed venue as and when required and fully co-operate with such persons and agencies involved during the discussions. The Bidder should note that Time is the essence of the contract. In order to expedite the early completion of engineering activities, the Bidder shall submit all drawings as per the agreed Engineering Information Submission Schedule. The drawings submitted by the Bidder will be reviewed by the Owner as far as practicable within three (3) weeks from the date of receipt of the drawing .The comments of the Owner shall then be discussed across the table during the above co-ordination Meetings wherein best efforts shall be made by both sides to ensure the approval of the drawing. The Bidder shall ensure availability of the concerned experts / consultants/ personnel who are empowered to take necessary decisions during these meetings. The Bidder shall be equipped with necessary tools and facilities so that the drawings/documents can be resubmitted after incorporating necessary changes and approved during the meeting itself. Should any drawing remain unapproved for more than six (6) weeks after its first submission, this shall be brought out in the monthly Engineering Progress and Exception Report with reasons thereof. Any delays arising out of failure by the Bidder to incorporate Owners comments and resubmit the same during the TCM shall be considered as a default and in no case shall entitle the Bidder to alter the Contract completion date. Design Improvements The Owner or the Bidder may propose changes in the specification of the equipment or quality thereof and if the parties agree upon any such changes the specification shall be modified accordingly.
8.06.00 8.06.01
8.06.02
8.06.03
8.06.04
8.06.05
8.07.00
SS-M1: 12
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If any such agreed upon change is such that it affects the price and schedule of completion, the parties shall agree in writing as to the extent of any changing the price and/or schedule of completion before the Bidder proceeds with the change. Following such agreement, the provision thereof, shall be deemed to have been amended accordingly. 8.08.00 8.08.01 Material of Construction All materials used for the construction of the equipment shall be new and shall be in accordance with the requirements of this specification. Materials utilized for various components shall be those which have established themselves for use in such applications. Rating Plates, Name Plates & Labels Each main and auxiliary item of plant including instruments shall have permanently attached to it in a conspicuous position, a rating plate of noncorrosive material upon which shall be engraved manufacturers name, equipment, type or serial number together with details of the ratings, service conditions under which the item of plant in question has been designed to operate, and such diagram plates as may be required by the Owner. Each item of plant shall be provided with nameplate or label designating the service of the particular equipment. The inscriptions shall be approved by the Owner or as detailed in appropriate section of the technical specifications. Such nameplates or labels shall be of white non-hygroscopic material with engraved black lettering or alternately, in the case of indoor circuit breakers, starters, etc. of transparent plastic material with suitably coloured lettering engraved on the back. The name plates shall be suitably fixed on both front and rear sides. Items of plant such as valves, which are subject to handling, shall be provided with an engraved chromium plated nameplate or label with engraving filled with enamel. The name plates for valves shall be marked in accordance with MSS standard SP-25 and ANSI B 16.34 as a minimum. Hanger/ support numbers shall be marked on all pipe supports, anchors, hangers, snubbers and restraint assemblies. Each constant and variable spring support shall also have stamped upon it the designed hot and cold load which it is intended to support. Suitable scale shall also be provided to indicate load on support/hanger. Valves, steam traps and strainers shall be identified by Owners tag number of a metal tap permanently attached to non pressure parts such as the yoke by a stainless steel wire. The direction of flow shall also be marked on the body. Safety and relief valves shall be provided with the following : a) Manufacturers identification.
8.09.00 8.09.01
8.09.02
8.09.03
8.09.04
8.09.05
8.09.06
8.09.07
SS-M1: 13
JIINDAL J NDAL LTD.. LTD b) c) d) e)
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Nominal inlet and outlet sizes in mm. Set pressure in Kg/cm2 (abs). Blowdown and accumulation as percentage of set pressure. Certified capacity in Kg of saturated steam per hour or in case of liquid certified capacity in litres of water per minute.
8.09.08
All such plates, instruction plates, etc. shall be bilingual with Hindi inscription first, followed by English. Alternatively, two separate plates one with Hindi and the other with English inscriptions may be provided. All segregated phases of conductors or bus ducts, indoor or outdoor, shall be provided with coloured phase plates to clearly identify the phase of the system Tools and Tackles The Bidder shall supply with the equipment one complete set of all special tools and tackles and other instruments required for the erection, assembly, disassembly and proper maintenance of the plant and equipment and systems (including software). These special tools will also include special material handling equipment, jigs and fixtures for maintenance and calibration / readjustment, checking and measurement aids etc. A list of such tools and tackles shall be submitted by the Bidder along with the offer. The price of each tool / tackle shall be deemed to have been included in the total bid price. These tools and tackles shall be separately packed and sent to site. The Bidder shall also ensure that these tools and tackles are not used by him during erection, commissioning and initial operation. For this period the Bidder should bring his own tools and tackles. All the tools and tackles shall be of reputed make acceptable to the Owner.
8.09.09
8.10.00
8.11.00 8.11.01
Welding If the manufacturer has special requirements relating to the welding procedures for welds at the terminals of the equipments to be per formed by others the requirements shall be submitted to the Owner in advance of commencement of erection work. Colour Code for all Equipments/ Pipings/ Pipe Services All equipment/ piping/ pipe services are to be painted by the Bidder in accordance with Owners standard colour coding scheme, which will be furnished to the Bidder during detailed engineering stage. Protection and Preservative Shop Coating Protection
8.12.00 8.12.01
8.13.00 8.13.01
SS-M1: 14
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All coated surfaces shall be protected against abrasion, impact, discoloration and any other damages. All exposed threaded portions shall be suitably protected with either metallic or a nonmetallic protection device. All ends of all valves and piping and conduit equipment connections shall be properly sealed with suitable devices to protect them from damage. The parts which are likely to get rusted, due to exposure to weather, should also be properly treated and protected in a suitable manner. All primers/paints/coatings shall take into account the hot humid, corrosive & alkaline, subsoil or overground environment as the case may be. 8.13.02 Preservative Shop Coating All exposed metallic surfaces subject to corrosion shall be protected by shop application of suitable coatings. All surfaces which will not be easily accessible after the shop assembly, shall be treated beforehand and protected for the life of the equipment. All surfaces shall be thoroughly cleaned of all mill scales, oxides and other coatings and prepared in the shop. The surfaces that are to be finish-painted after installation or require corrosion protection until installation, shall be shop painted with atleast two coats of primer. Transformers and other electrical equipments if included shall be shop finished with one or more coats of primer and two coats of high grade resistance enamel. The finished colors shall be as per manufacturers standards, to be selected and specified by the Owner at a later date. 8.13.03 Shop primer for all steel surfaces which will be exposed to operating temperature below 95 degrees Celsius shall be selected by the Bidder after obtaining specific approval of the Owner regarding the quality of primer proposed to be applied. Special high temperature primer shall be used on surfaces exposed to temperature higher than 95 degrees Celsius and such primer shall also be subject to the approval of the Owner. All other steel surfaces which are not to be painted shall be coated with suitable rust preventive compound subject to the approval of the Owner. All piping shall be cleaned after shop assembly by shot blasting or other means approved by the Owner. Lube oil piping or carbon steel shall be pickled. Painting for Civil structures shall be done as per relevant part of technical specification. QUALITY ASSURANCE PROGRAMME The Bidder shall adopt suitable quality assurance programme to ensure that the equipment and services under the scope of contract whether manufactured or performed within the Bidders works or at his sub-Bidders premises or at the Owners site or at any other place of work are in accordance with the specifications. Such programs shall be outlined by the Bidder and shall be finally accepted by the Owner/authorized representative after discussions before the award of the contract. The QA programme shall
8.13.04
8.13.05
8.13.06
9.00.00 9.01.00
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be generally in line with IS/ISO-9001. A quality assurance programme of the Bidder shall generally cover the following: a) His organization structure for the management and implementation of the proposed quality assurance programme Quality System Manual Design Control System Documentation and Data Control System Qualification data for bidders key personnel. The procedure for purchase of materials, parts, components and selection of sub-Bidders services including vendor analysis, source inspection, incoming raw-material inspection, verification of materials purchased etc. System for shop manufacturing and site erection controls including process, fabrication and assembly. Control of non-conforming items and system for corrective actions and resolution of deviations. Inspection and test procedure both for manufacture and field activities. Control of calibration and testing of measuring testing equipment. System for Quality Audits. System for identification and appraisal of inspection status. System for authorising release of manufactured product to the Owner. System for handling, storage and delivery. System for maintenance of records, and Quality plans for manufacturing and field activities detailing out the specific quality control procedure adopted for controlling the quality characteristics relevant to each item of equipment/component.
b) c) d) e) f)
g)
h)
i) j) k) l) m) n) o) p)
9.02.00 9.02.01
General Requirements - Quality Assurance All materials, components and equipment covered under this specification shall be procured, manufactured, erected, commissioned and tested at all the stages, as per a comprehensive Quality Assurance Programme. An indicative programme of inspection/tests to be carried out by the Bidder for some of the major items is given in the respective technical specification. This is, however, not intended to form a comprehensive programme as it is the Bidders responsibility to draw up and implement such programme duly
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approved by the Owner. The detailed Quality Plans for manufacturing and field activities shall be drawn up by the Bidder and will be submitted to Owner for approval. Schedule of finalisation of such quality plans will be finalised before award. Monthly progress reports on MQP/FQP submission/approval shall be furnished on enclosed format No. QS-01-QAI-P-02/F1. 9.02.02 Manufacturing Quality Plan will detail out for all the components and equipment, various tests/inspection, to be carried out as per the requirements of this specification and standards mentioned therein and quality practices and procedures followed by Bidders/ Sub-Bidders/ sub-supplier's Quality Control Organisation, the relevant reference documents and standards, acceptance norms, inspection documents raised etc., during all stages of materials procurement, manufacture, assembly and final testing/performance testing. The Quality Plan shall be submitted on electronic media e.g. floppy or E-mail in addition to hard copy, for review and approval. After approval the same shall be submitted in compiled form on CD-ROM. Field Quality Plans will detail out for all the equipment, the quality practices and procedures etc. to be followed by the Bidders "Site Quality Control Organisation", during various stages of site activities starting from receipt of materials/equipment at site. The Bidder shall also furnish copies of the reference documents/plant standards/acceptance norms/tests and inspection procedure etc., as referred in Quality Plans along with Quality Plans. These Quality Plans and reference documents/standards etc. will be subject to Owners approval without which manufacturer shall not proceed. These approved documents shall form a part of the contract. In these approved Quality Plans, Owner shall identify customer hold points (CHP), i.e. test/checks which shall be carried out in presence of the Owners Project Manager or his authorised representative and beyond which the work will not proceed without consent of Owner in writing. All deviations to this specification, approved quality plans and applicable standards must be documented and referred to Owner along with technical justification for approval and dispositioning. No material shall be despatched from the manufacturers works before the same is accepted, subsequent to predespatch final inspection including verification of records of all previous tests/inspections by Owners Project Manager/Authorised representative and duly authorised for despatch by issuance of Material Despatch Clearance Certificate (MDCC). All material used for equipment manufacture including casting and forging etc. shall be of tested quality as per relevant codes/standards. Details of results of the tests conducted to determine the mechanical properties; chemical analysis and details of heat treatment procedure recommended and actually followed shall be recorded on certificates and time temperature chart. Tests shall be carried out as per applicable material standards and/or agreed details. The Bidder shall submit to the Owner Field Welding Schedule for field welding activities in the enclosed format No.: QS-01-QAI-P-02/F3. The field welding schedule shall be submitted to the Owner along with all supporting
9.02.03
9.02.04
9.02.05
9.02.06
9.02.07
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documents, like welding procedures, heat treatment procedures, NDT procedures etc. at least ninety days before schedule start of erection work at site. 9.02.08 All welding and brazing shall be carried out as per procedure drawn and qualified in accordance with requirements of ASME Section IX/BS-4870 or other International equivalent standard acceptable to the Owner. All welding/brazing procedures shall be submitted to the Owner or its authorised representative for approval prior to carrying out the welding/ brazing. 9.02.09 All brazers, welders and welding operators employed on any part of the contract either in Bidders/sub-Bidders works or at site or elsewhere shall be qualified as per ASME Section-IX or BS-4871 or other equivalent International Standards acceptable to the Owner. Welding procedure qualification & Welder qualification test results shall be furnished to the Owner for approval. However, where required by the Owner, tests shall be conducted in presence of Owner/authorised representative. For all pressure parts and high pressure piping welding, the latest applicable requirements of the IBR (Indian Boiler Regulations) shall also be essentially complied with. Similarly, any other statutory requirements for the equipment/systems shall also be complied with. On all back-gauged welds MPI/LPI shall be carried before seal welding. Unless otherwise proven and specifically agreed with the Owner, welding of dissimilar materials and high alloy materials shall be carried out at shop only. No welding shall be carried out on cast iron components for repair. All the heat treatment results shall be recorded on time temperature charts and verified with recommended regimes. All non-destructive examination shall be performed in accordance with written procedures as per International Standards. The NDT operator shall be qualified as per SNT-TC-IA (of the American Society of non-destructive examination). NDT shall be recorded in a report, which includes details of methods and equipment used, result/evaluation, job data and identification of personnel employed and details of co-relation of the test report with the job. All plates of thickness above 40mm & all bar stock/Forging above 40mm dia shall be ultrasonically tested. For pressure parts, plate of thickness equal to or above 25mm shall be ultrasonically tested. 9.02.16 The Bidder shall list out all major items/ equipment/ components to be manufactured in house as well as procured from sub-contractors (BOI). All the sub-Bidder proposed by the Bidder for procurement of major bought out items including castings, forging, semi-finished and finished components/ equipment etc., list of which shall be drawn up by the Bidder and finalised with the Owner, shall be subject to Owner's approval. The Bidders proposal
9.02.10
9.02.11
9.02.12
9.02.13 9.02.14
9.02.15
POWER POWER
shall include vendors facilities established at the respective works, the process capability, process stabilization, QC systems followed, experience list, etc. along with his own technical evaluation for identified sub-contractors enclosed and shall be submitted to the Owner for approval within the period agreed at the time of pre-awards discussion and identified in "DR" category prior to any procurement. Monthly progress reports on sub-Bidder detail submission / approval shall be furnished on enclosed on format no. QS-01QAI-P-02/F2. Such vendor approval shall not relieve the Bidder from any obligation, duty or responsibility under the contract. 9.02.17 For components/equipment procured by the contractors for the purpose of the contract, after obtaining the written approval of the Owner, the Bidders purchase specifications and inquiries shall call for quality plans to be submitted by the suppliers. The quality plans called for from the sub-Bidder shall set out, during the various stages of manufacture and installation, the quality practices and procedures followed by the vendors quality control organisation, the relevant reference documents/standards used, acceptance level, inspection of documentation raised, etc. Such quality plans of the successful vendors shall be finalised with the Owner and such approved Quality Plans shall form a part of the purchase order/contract between the Bidder and sub-Bidder. With in three weeks of the release of the purchase orders /contracts for such bought out items /components, a copy of the same without price details but together with the detailed purchase specifications, quality plans and delivery conditions shall be furnished to the Owner on the monthly basis by the Bidder along with a report of the Purchase Order placed so far for the contract. ** Owner reserves the right to carry out quality audit and quality surveillance of the systems and procedures of the Bidders or their sub-Bidders quality management and control activities. The Bidder shall provide all necessary assistance to enable the Owner carry out such audit and surveillance. The Bidder shall carry out an inspection and testing programme during manufacture in his work and that of his sub-Bidders and at site to ensure the mechanical accuracy of components, compliance with drawings, conformance to functional and performance requirements, identity and acceptability of all materials parts and equipment. Bidder shall carry out all tests/inspection required to establish that the items/equipment conform to requirements of the specification and the relevant codes/standards specified in the specification, in addition to carrying out tests as per the approved quality plan. Quality audit/surveillance/approval of the results of the tests and inspection will not, however, prejudice the right of the Owner to reject the equipment if it does not comply with the specification when erected or does not give complete satisfaction in service and the above shall in no way limit the liabilities and responsibilities of the Bidder in ensuring complete conformance of the materials/equipment supplied to relevant specification, standard, data sheets, drawings, etc. For all spares and replacement items, the quality requirements as agreed for the main equipment supply shall be applicable.
9.02.18
9.02.19
9.02.20
9.02.21
SS-M1: 19
POWER POWER
Repair/rectification procedures to be adopted to make the job acceptable shall be subject to the approval of the Owner/ authorised representative. The Bidder/Sub-Bidder shall carry out routine test on 100% item at Bidder/sub-Bidders works. The quantum of check/test for routine & acceptance test by Owner shall be generally as per criteria/sampling plan defined in referred standards. Wherever standards have not been mentioned quantum of check/test for routine / acceptance test shall be as agreed during detailed engineering stage.
9.03.00
QA Documentation Package The Bidder shall be required to submit the QA Documentation in two hard copies and two CD ROMs, as identified in respective quality plan with tick (?) mark.
9.03.01
Each QA Documentation shall have a project specific Cover Sheet bearing name & identification number of equipment and including an index of its contents with page control on each document. The QA Documentation file shall be progressively completed by the Suppliers subsupplier to allow regular reviews by all parties during the manufacturing. The final quality document will be compiled and issued at the final assembly place of equipment before despatch. However CD-Rom may be issued not later than three weeks.
9.03.02
Typical contents of QA Documentation is as below:a) b) Quality Plan Material mill test reports on components as specified by the specification and approved Quality Plans. Manufacturer / works test reports/results for testing required as per applicable codes and standard referred in the specification and approved Quality Plans. Non-destructive examination results /reports including radiography interpretation reports. Sketches/drawings used for indicating the method of traceability of the radiographs to the location on the equipment. Heat Treatment Certificate/Record (Time- temperature Chart) All the accepted Non-conformance Reports (Major/Minor) / deviation, including complete technical details / repair procedure). CHP / Inspection reports duly signed by the Inspector of the Owner and Bidder for the agreed Customer Hold Points. Certificate of Conformance (COC) wherever applicable.
c)
d)
e) f)
g)
h)
POWER POWER
i) 9.03.03
MDCC
Similarly, the Bidder shall be required to submit two sets (two hard copies and two CD ROMs), containing QA Documentation pertaining to field activities as per Approved Field Quality Plans and other agreed manuals/ procedures, prior to commissioning of individual system. Before despatch / commissioning of any equipment, the Supplier shall make sure that the corresponding quality document or in the case of protracted phased deliveries, the applicable section of the quality document file is completed. The supplier will then notify the Inspector regarding the readiness of the quality document (or applicable section) for review. a) If the result of the review carried out by the Inspector is satisfactory, the Inspector shall stamp the quality document (or applicable section) for release. If the quality document is unsatisfactory, the Supplier shall endeavor to correct the incompleteness, thus allowing to finalize the quality document (or applicable section) by time compatible with the requirements as per contract documents. When it is done, the quality document (or applicable section) is stamped by the Inspector. If a decision is made despatch, whereas all outstanding actions cannot be readily cleared for the release of the quality document by that time. The supplier shall immediately, upon shipment of the equipment, send a copy of the quality document Review Status signed by the Supplier Representative to the Inspector and notify of the committed date for the completion of all outstanding actions & submission. The Inspector shall stamp the quality document for applicable section when it is effectively completed. The submission of QA documentation package shall not be later than 3 weeks after the despatch of equipment.
9.03.04
b)
c)
9.03.05
Transmission Of QA Documentation On release of QA Documentation by Inspector, one set of quality document shall be forwarded to Corporate Quality Assurance Department and other set to respective Project Site of Owner. For the particular case of phased deliveries, the complete quality document to the Owner shall be issued not later than 3 weeks after the date of the last delivery of equipment.
9.04.00 9.04.01
Project Managers Supervision To eliminate delays and avoid disputes and litigation, it is agreed between the parties to the Contract that all matters and questions shall be referred to the Project Manager and without prejudice to the provisions of Arbitration clause in Section General Conditions of Contract, the Bidder shall proceed to comply with the Project Manager's decision.
POWER POWER
9.04.02
The work shall be performed under the supervision of the Project Manager. The scope of the duties of the Project Manager pursuant to the Contract, will include but not be limited to the following: a) Interpretation of all the terms and conditions of these documents and specifications: Review and interpretation of all the Bidders drawing, engineering data, etc: Witness or his authorised representative to witness tests and trials either at the manufacturers works or at site, or at any place where work is performed under the contract : Inspect, accept or reject any equipment, material and work under the contract. Issue certificate of acceptance and/or progressive payment and final payment certificates Review and suggest modifications and improvement in completion schedules from time to time, and Supervise Quality Assurance Programme implementation at all stages of the works.
b)
c)
d)
e)
f)
g)
9.05.00 9.05.01
Inspection, Testing And Inspection Certificates The word Inspector shall mean the Project Manager and/or his authorized representative and/or an outside inspection agency acting on behalf of the Owner to inspect and examine the materials and workmanship of the works during its manufacture or erection. The Project Manager or his duly authorized representative and/or an outside inspection agency acting on behalf of the Owner shall have access at all reasonable times to inspect and examine the materials and workmanship of the works during its manufacture or erection and if part of the works is being manufactured or assembled on other premises or works, the Bidder shall obtain for the Project Manager and for his duly authorized representative permission to inspect as if the works were manufactured or assembled on the Bidders own premises or works. The Bidder shall give the Project Manager/Inspector fifteen (15) days written notice of any material being ready for testing. Such tests shall be to the Bidders account except for the expenses of the Inspectors. The Project Manager/Inspector, unless the witnessing of the tests is virtually waived and confirmed in writing, will attend such tests within fifteen (15) days of the date on which the equipment is noticed as being ready for test/inspection failing which the Bidder may proceed with test which shall be deemed to have been made in the inspectors presence and he shall forthwith forward to the inspector duly certified copies of test reports in two (2) copies.
9.05.02
9.05.03
POWER POWER
9.05.04
The Project Manager or Inspector shall within fifteen (15) days from the date of inspection as defined herein give notice in writing to the Bidder, or any objection to any drawings and all or any equipment and workmanship which is in his opinion not in accordance with the contract. The Bidder shall give due consideration to such objections and shall either make modifications that may be necessary to meet the said objections or shall inform in writing to the Project Manager/Inspector giving reasons therein, that no modifications are necessary to comply with the contract. When the factory tests have been completed at the Bidders or sub-Bidders works, the Project Manager /Inspector shall issue a certificate to this effect fifteen (15) days after completion of tests but if the tests are not witnessed by the Project Manager /Inspectors, the certificate shall be issued within fifteen (15) days of the receipt of the Bidders test certificate by the Project Manager /Inspector. Project Manager /Inspector to issue such a certificate shall not prevent the Bidder from proceeding with the works. The completion of these tests or the issue of the certificates shall not bind the Owner to accept the equipment should it, on further tests after erection be found not to comply with the contract. In all cases where the contract provides for tests whether at the premises or works of the Bidder or any sub-Bidder, the Bidder, except where otherwise specified shall provide free of charge such items as labour, material, electricity, fuel, water, stores, apparatus and instruments as may be reasonably demanded by the Project Manager /Inspector or his authorized representatives to carry out effectively such tests on the equipment in accordance with the Bidder and shall give facilities to the Project Manager/Inspector or to his authorized representative to accomplish testing. The inspection by Project Manager / Inspector and issue of Inspection Certificate thereon shall in no way limit the liabilities and responsibilities of the Bidder in respect of the agreed Quality Assurance Programme forming a part of the contract. To facilitate advance planning of inspection in addition to giving inspection notice as specified at clause no 9.05.03 of this chapter, the Bidder shall furnish quarterly inspection programme indicating schedule dates of inspection at Customer Hold Point and final inspection stages. Updated quarterly inspection plans will be made for each three consecutive months and shall be furnished before beginning of each calendar month. All inspection, measuring and test equipment used by Bidder shall be calibrated periodically depending on its use and criticality of the test/measurement to be done. The Bidder shall maintain all the relevant records of periodic calibration and instrument identification, and shall produce the same for inspection by the Owner. Wherever asked specifically, the Bidder shall re-calibrate the measuring/test equipment in the presence of Project Manager/Inspector. Associated document for quality assurance programme:
9.05.05
9.05.06
9.05.07
9.05.08
9.05.09
9.06.00
SS-M1: 23
JIINDAL J NDAL LTD.. LTD 9.06.01 9.06.02
POWER POWER
List of items requiring quality plan and sub supplier approval. (Annexure-III). Status of items requiring Quality Plan and sub supplier approval. (AnnexureIV). Field Welding Schedule (Annexure-V). Manufacturing Quality Plan (Annexure-VI). Field Quality Plan (Annexure-VII).
9.06.03 9.06.04 9.06.05
10.00.00
PRE-COMMISSIONING AND COMMISSIONING FACILITIES FOR PLANT SYSTEM/SUBSYSTEM/EQUIPMENT IF INCLUDED IN BIDDERS SCOPE This is applicable if not specifically mentioned otherwise in the respective specification. a) As soon as the facilities or part thereof has been completed operationally and structurally and before start-up, each item of the equipment and systems forming part of facilities shall be thoroughly cleaned and then inspected jointly by the Owner and the Bidder for correctness of and completeness of facility or part thereof and acceptability for initial pre-commissioning tests, commissioning and start-up at Site. The list of pre-commissioning tests to be performed shall be as mutually agreed and included in the Bidders quality assurance programme as well as those included elsewhere in the Technical Specifications. The Bidders pre-commissioning/ commissioning/start-up engineers, specially identified as far as possible, shall be responsible for carrying out all the pre-commissioning tests at Site. On completion of inspection, checking and after the pre-commissioning tests are satisfactorily over, the commissioning of the complete facilities shall be commenced during which period the complete facilities, equipments shall be operated integral with sub-systems and supporting equipment as a complete plant. It will be the responsibility of the Bidder to assess and furnish a list of all commissioning spars required for successful commissioning of all the equipment covered under the contract. Such a list shall be furnished by the Bidder within 12 months from the date of LOA, separately for each equipment and shall be reviewed by the Owner and discussed for mutual agreement. The commissioning spares will be so identified as not to allow the trial operation to suffer for want of such commissioning spares. The identification of commissioning spares will not in any way relieve the Bidder of any of his responsibilities of satisfactory performance under the provisions of other conditions of contract. All the commissioning spares shall be deemed to be included in scope of the Bidder as a part of the respective equipment package at no extra cost to the Owner.
b)
SS-M1: 24
JIINDAL J NDAL LTD.. LTD c)
POWER POWER
All piping system shall be flushed, steam blown, air blown as required and cleanliness demonstrated using acceptable industry standards. Procedures to accomplish this work shall be submitted for approval to the Owner six months prior to the respective implementations. The Owner will approve final verification of cleanliness. The time consumed in the inspection and checking of the units shall be considered as a part of the erection and installation period. The check outs during the pre - commissioning period should be programmed to follow the construction completion schedule. Each equipment/system, as it is completed in construction and turned over to Owner's commissioning (start-up) Engineer(s), should be checked out and cleaned. The checking and inspection of individual systems should then follow a prescribed commissioning documentation [SLs (Standard Check List) / TS (Testing Schedule) / CS (Commissioning Schedule)] approved by the Owner. The Bidder during initial operation and performance testing shall conduct vibration testing to determine the base line of performance of all plant rotating equipment. These tests shall be conducted when the equipment is running at the base load, peak load as well as lowest sustained operating condition as far as practicable. Bidder shall furnish the commissioning organization chart for review & acceptance of Owner at least eighteen months prior to the schedule date of synchronization of 1st unit. The chart should contain : 1) 2) 3) Biodata including experience of the Commissioning Engineers. Role and responsibilities of the Commissioning Organisation members. Expected duration of posting of the above Commissioning Engineers at site.
d)
e)
f)
g)
10.02.00
Initial Operation a) On completion of all pre-commissioning activities / tests and as a part of commissioning the complete facilities shall be put on 'Initial Operation' during which period all necessary adjustments shall be made while operating over the full load range enabling the facilities to be made ready for the Guarantee Tests. The 'Initial Operation' of the complete facility as an integral unit shall be conducted for 720 continuous hours. During the period of initial operation of 720 hours, the unit shall operate continuously at full rated load for a period not less than 72 hours. The Initial Operation shall be considered successful, provided that each item/ part of the facility can operate continuously at the specified operating characteristics, for the period of Initial Operation with all operating parameters within the specified limits and at or near the predicted performacne of the equipment/ facility.
b)
c)
SS-M1: 25
JIINDAL J NDAL LTD.. LTD d)
POWER POWER
The Bidder shall intimate the Owner about the commencement of initial operation and shall furnish adequate notice to the Owner in this respect. Any loss of generation due to constraints attributable to the Owner shall be construed as Deemed Generation. An Initial Operation report comprising of observations and recordings of various parameters to be measured in respect of the above Initial Operation shall be prepared by the Bidder. This report, besides recording the details of the various observations during initial operation shall also include the dates of start and finish of the Initial Operation and shall be signed by the representatives of both the parties. The report shall have sheets, recording all the details of interruptions occurred, adjustments made and any minor repairs done during the Initial Operation. Based on the observations, necessary modifications/ repairs to the plant shall be carried out by the Bidder to the full satisfaction of the Owner to enable the latter to accord permission to carry out the Guarantee tests on the facilities. However, minor defects which do not endanger the safe operation of the equipment, shall not be considered as reasons for with holding the aforesaid permission.
e) f)
10.03.00
Guarantee Tests a) The final test as to prove the Functional Guarantees shall be conducted at Site by the Bidder in presence of the Owner. The Bidder's Commissioning, Start-up Purchasershall make the unit ready to conduct such test. Such test will be commenced, within a period of three (3) months after the successful completion of Initial Operations. Any extension of time beyond the above three (3) months shall be mutually agreed upon. These tests shall be binding on both the parties of the Contract to determine compliance of the equipment with the functional guarantee. For performance/ demonstration tests instrumentations, of accuracy class, to the approval of the Owner shall be used. The numbers and location of the instruments shall be as per the specified test codes. In addition the values of parameters shall be logged from the information system provided under Owner's Distributed Digital Control Monitoring and Information system. Test will be conducted at specified load points. Any special equipment, tools and tackles required for the successful completion of the Guarantee Tests shall be provided by the Bidder, free of cost. The Guarantee tests and specific tests to be conducted on equipments have been brought out in detail elsewhere in the specification.
b) c)
d)
e)
11.00.00
TAKING OVER Upon successful completion of Initial Operations and all the tests other than guarantee tests conducted to the Owner's satisfaction, the Owner shall issue
SS-M1: 26
POWER POWER
to the Bidder a Taking over Certificate as a proof of the final acceptance of the equipment. Such certificate shall not unreasonably be with held nor will the Owner delay the issuance thereof, on account of minor omissions or defects which do not affect the commercial operation and/or cause any serious risk to the equipment. Such certificate shall not relieve the Bidder of any of his obligations which otherwise survive, by the terms and conditions of the Contract after issuance of such certificate. 12.00.00 SAFETY ASPECTS DURING CONSTRUCTION AND ERECTION In addition to the requirements given in Erection Conditions of Contract (ECC) the following shall also cover: a) b) Working platforms should be fenced and shall have means of access. Ladders in accordance with Owners safety rules for construction and erection shall be used. Rungs shall not be welded on columns. All the stairs shall be provided with handrails immediately after its erection.
13.00.00
PACKAGING AND TRANSPORTATION All the equipments & spares shall be suitably protected, coated, covered or boxed and crated to prevent damage or deterioration during transit, handling and storage at Site till the time of erection. Each spare shall be clearly marked or labeled on the outside of the packing with its description. When more than one spare part is packaged in a single case, a general description of the contents shall be shown on the outside of such a case and other packages must be suitably marked and numbered for the purpose of identification. All cases, containers or packages, are liable to be opened for such examination as may be considered reasonable by the Engineer. In case of equipment supplied with grease/lubricants from imported origin, the supplied shall clearly indicate the indigenous equivalent of the grease/lubricant and source of supply so as to enable the Owner to procure these items from indigenous sources. While packing all the materials, the limitation from the point of view of the sizes of railway wagons available in India should be taken account of. The Bidder shall be responsible for any loss or damage during transportation, handling and storage due to improper packing. The Bidder shall ascertain the availability of Railway wagon sizes from the Indian Railways or any other agency concerned in India well before effecting dispatch of equipment. Before dispatch it shall be ensured that complete processing and manufacturing of the components is carried out at shop, only restricted by transport limitation, in order to ensure that site works like grinding, welding, cutting & pre-assembly to bare minimum. The Owner's Inspector shall have right to insist for completion of works in shops before dispatch of materials for transportation.
14.00.00
INSTRUMENTATION AND CONTROL
SS-M1: 27
POWER POWER
All instrumentation and control systems/ equipment/ devices/ components, furnished under this contract shall be in accordance with the requirements stated herein, unless otherwise specified in the detailed specifications. 14.01.00 All instrument scales and charts shall be calibrated and printed in metric units and shall have linear graduation. The ranges shall be selected to have the normal reading at 75% of full scale. All scales and charts shall be calibrated and printed in Metric Units. Gauge Glass 01. 02. 03. 04. 05. 06. 07. Type Glass Body material Pressure rating Temperature rating Bolts and nuts Accessories : : : : : : Reflex Toughened borosilicate. Resistant mechanical and thermal shocks. Carbon steel (Flanged Connection) Twice the maximum working pressure 300OC Rust proof alloy steel to
14.02.00 14.03.00
: Suitable ball check valves of SS-304/316 body, gaskets, companion flange etc.
14.04.00
level gauge (float & tape) 01. 02. 03. 04. 05. 06. 07. Type Float & Tape MOC Pulley material Guide wire Accuracy Indication Rating : : : : : : : Float and Tape AISI 316 Aluminium SS 316 Stainless steel +/- 2 mm On circular or vertical dial Twice the design pressure
SS-M1: 28
POWER POWER
ANNEXURE-I Sl. No. 1. 2. 3. 4. 5 Description of Manuals Drawings "FOR APPROVAL" Drawings "FOR INFORMATION" Drawings "FINAL DRAWING" Drawings "AS BUILT " DATASHEETS,DESIGN CALCULATIONS, PURCHASE SPECIFICATIONS, etc. and Other type of documents i) ii) iii) For Approval FINAL Analysis reports of equipments/piping/ structures components/systems employing software packages as detailed in the specifications a) b) c) 6. 7 8 9 10 11 12 13 14 15 16 17 Input Output Drawings/ Sketches 8 8 8 8 15 8 15 8 15 8 8 15 8 15 1 3CD ROMS 3CD ROMS 3CD ROMS 3CD ROMS 3CD ROMS 3CD ROMS 3CD ROMS 3CD ROMS 3CD ROMS 3CD ROMS 8 15 3 FLOPPIES 3 CD-ROMs No of Prints (Sets) 8 8 15 15 No. of CDROMs (sets) 3 FLOPPIES 3 FLOPPIES 3 CD-ROMs 3 CD-ROMs
Erection manual "DRAFT" Erection manual "FINAL" Operation & Maintenance manual "DRAFT" Operation & Maintenance manual "FINAL" Hand Book "DRAFT" Hand Book "FINAL" Commissioning and Performance Procedure manual "DRAFT" Commissioning and Performance Procedure manual "FINAL" Performance and Functional Guarantees test report Progress Reports Completion report QA programme including Organization for implementation and QA system manual (with revision-servicing) Vendor details in respect of proposed vendors including Bidders evaluation report. Manufacturing QPs, Field QPs, Field welding schedules and their reference documents like test procedures, WPS, POR etc. i) For review/comment
SS-M1: 29
18 19
3
JIINDAL J NDAL LTD.. LTD Sl. No. ii) 20
POWER POWER
Description of Manuals For final approval - 1 set floppies
No of Prints (Sets) 4 4 8 15 2 2 2
No. of CDROMs (sets) 1 set CD ROMS
Welding Manual, Heat Treatment Manuals, Storage & preservation manuals manuals Draft Final
4 sets 2 CD ROMS 1 CD ROM 2 CD ROMS 2 CD ROMS
21 22 23
Monthly Vendor Approval and QP approval status QA Documentation Package for items / equipment manufactured and dispatched to site QA Documentation Package for field activities on equipment/systems at site
SS-M1: 30
POWER POWER
ANNEXURE-II PRODUCT Product Design PLC Hardware organisation Operating system features Data base organisation Logic/loop algorithm Development of control logic & loop s/w & MMI application development MANDAYS Electric Power Supply System MANDAYS 10 Theory & design features 2 Manufacturing/assembly process Testing methodology 5 2 AREAS OF TRAINING REQUIREMENT Plant Visit Visit To Manufacturers Work Manufacturing process of PLC hardware Integration & testing facilities Operation & Maintenance Of Plant
SS-M1: 31
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ANNEXURE-III Project Package Supplier Bidder No. Sl. Item No. : : : : Stage : LIST OF ITEMS REQUIRING QUALITY PLAN AND SUBSUPPLIER APPROVAL SUB-SYSTEM: DOC. NO.: REV. NO.: DATE : PAGE : Sub-suppliers Sub-supplier approval status Details / category submission schedule
QP/ Insp. Cat.
QP No.
QP Sub. Schedule
QP approval schedule
Proposed sub-supplier
Place
OF Remarks
LEGENDS 1. SYSTEM SUPPLIER/SUB-SUPPLIER APPROVAL STATUS CATEGORY (SHALL BE FILLED BY the Owner) A For these items proposed vendor is acceptable to the Owner. To be indicated with letter A in the list alongwith the condition of approval, if any. DR For these items Detailed required for the Owner review. To be identified with letter DR in the list. NOTED For these items vendors are approved by Main Supplier and accepted by the Owner without specific vendor approval from the Owner. To be identified with NOTED. 2. QP/INSPN CATEGORY: CAT-I : For these items the Quality Plans are approved by the Owner and the final acceptance will be on physical inspection witness by the Owner. CAT-II : For these items the Quality Plans approved by the Owner. However no physical inspection shall be done by the Owner. The final acceptance by the Owner shall be on the basis review of documents as per approved QP. CAT-III : For these items Main Supplier approves the Quality Plans. The final acceptance by the Owner shall be on the basis certificate of conformance by the main supplier. UNITS/WORKS : Place of manufacturing Place of Main Supplier of multi units/works.
SS-M1: 32
POWER POWER
ANNEXURE-IV Project : Package : Bidder : Bidder No. : Sl. Item / Service No. Stage : STATUS OF ITEM REQUIRING QP& SUBSUPPLIER APPROVAL DOC. NO.: REV. NO.: DATE : PAGE : OF Proposed Place of Approval Sub-supplier Remarks Submanufacturing Status detail submission suppliers works schedule
QP/ Insp. Cat.
QP Sub. Date of Date of subcommt Schedule Approval mission Appl. schedule
Status Code C/II/I
SS-M1: 33
POWER POWER
ANNEXURE-V Project : Bidder : Bidder No. System :

Sl. No.
Stage : :
Dimensions
FIELD WELDING SCHEDULE (To be raised by the Bidder) Welding Code:

Process Type Electrode of of filler spec. welding Weld WPS. No. Min. preheat Heat treatment Temp. Holding time
DOC. NO.: REV. NO.: DATE : PAGE :

NDT method/ Quantum REF Spec. ACC No. Norm Ref.
OF
Remarks
DRG No. for Description Matl. Weld Location & of parts to Spec. Identification welded mark
NOTES:
SIGNATURE
SS-M1: 34
POWER POWER
ANNEXURE-VI MFGR.s MANUFACTURERS LOGO AND ADDRESS NAME MANUFACTURING QUALITY PLAN QP NO.: ITEM : REV.NO.: DATE: SUB-SYSTEM: PAGE: . OF. Class 4. Type Of Check 5. Quantum Of Check 6. Reference Document 7. PROJECT PACKAGE : :
CONTRACT NO. : MAIN-SUPPLIER: Acceptance Format Of Agency Norms Record M C N 8. 9. D* ** 10. Remarks 11.
Sl. No. 1.
Component & Operations 2.
Characteristics 3.
MANUFACTURER MAIN/ SUB-SUPPLIER SUPPLIER SIGNATURE
LEGEND: * RECORDS, INDENTIFIED WITH TICK ( ) SHALL BE ESSENTIALLY INCLUDED BY SUPPLIER IN QA DOCUMENTATION. ** M: MANUFACTURER/SUB-SUPPLIER FOR THE C: SUPPLIER/NOMINATED INSPECTION AGENCY, OWNER N: THE OWNER USE P: PERFORM W: WITNESS AND V: VERIFICATION. AS APPROPRIATE, CHP: THE OWNER SHALL IDENTIFIED IN COLUM N
DOC. NO.:
REV CAT..
REVIEWED APPROVED APPROVAL BY BY SEAL
SS-M1: 35
POWER POWER
ANNEXURE-VII MFGR.s LOGO SUPPLIERS ADDRESS NAME AND FIELD QUALITY PLAN ITEM : SUB-SYSTEM : Sl. No. 1. Activity And Operation 2. Characteristics / Instruments 3. Class# Of Check 4. Type Of Check 5. QP NO.: REV.NO.: DATE: PAGE: . OF. Quantum Of Check 6. Reference Document 7. PROJECT PACKAGE : :
CONTRACT NO. : MAIN-SUPPLIER: Acceptance Format Of Norms Record 8. 9. D* Remarks 10.
MANUFACTURER/ MAINSUB-SUPPLIER SUPPLIER SIGNATURE
LEGEND: * RECORDS, INDENTIFIED WITH TICK () SHALL BE ESSENTIALLY INCLUDED BY SUPPLIER IN QA DOCUMENTATION. LEGEND TO BE USED: CLASS #: A = CRITICAL, B=MAJOR, C=MINOR; A SHALL BE WITNESSED BY THE OWNER FQA, B SHALL BE WITNESSED BY OWNERS ERECTION / CONSTRUCTION DEPTT. AND C SHALL BE WITNESSED BY ERECTION SUPPLIER (A & B CHECK SHALL BE OWNER CHP STAGE)
DOC. NO.:
REV
FOR THE OWNER USE
REVIEWED APPROVED APPROVAL BY BY SEAL
SS-M1: 36
JIINDAL POWER J NDAL POWER LTD.. LTD
SUB-SCTION: M2 TECHNICAL SPECIFICATION FOR EMERGENCY DG SET
CONTENTS
CLAUSE NO. 1.00.00 2.00.00 3.00.00 4.00.00 5.00.00 6.00.00
DESCRIPTION INTENT OF SPECIFICATION CODES AND STANDARDS SYSTEM REQUIREMENTS DESIGN AND CONSTRUCTION INSPECTION & TESTING CLEANING, PROTECTION AND PAINTING
SUB-SECTION: M2 TECHNICAL SPECIFICATION FOR EMERGENCY DG SET

1.00.00INTENT OF SPECIFICATION This specification is intended to cover the design, performance requirements, construction features, manufacture, assembly, testing at manufacturer's works and delivery at site properly packed for transport, erection, commissioning and site testing of Emergency DG Set and accessories as specified hereunder. 2.00.00CODES AND STANDARDS 2.01.00 2.01.01 2.01.02 The design, manufacture and testing of the tanks shall comply with the requirements of one or more of the following standards as applicable. IS-10000/1980 Pt.I to XII : BS ISO 3046-1 2002 : Methods of test for Internal Combustion engines. Reciprocating Internal Combustion engines. Performance. Declaration of power, fuel and lubricating oil consumptions, and test methods. Additional requirements for engines for general use. Reciprocating Internal Combustion Engines. Performance. Test measurements. Specification for Reciprocating Internal Engines: Performance - Speed governing. Combustion
2.01.03
BS ISO 3046-3 2006 : BS-ISO-3046 Part 4/1997 BS ISO 3046 Part 5/2001 BS-ISO-3046 Part 6/1990
2.01.04
2.01.05
Reciprocating Internal Combustion Engines. Performance. Torsional vibration. Specification for Reciprocating Internal Combustion Engines: Performance - Specification for over speed protection. Recommended specification for Speed Governing of Internal Combustion Engine Generator units. Code for unfired Pressure Vessels. Shell and Tube Type Heat Exchanger.
2.01.06
2.01.07 2.01.08 2.01.09 2.01.10
IEEE-126/1983 : IS: 2825/1969 IS:4503/1967 : :
ASME Power Test Code PTC-17/1974 : Internal Combustion Engine.
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JIINDAL POWER J NDAL POWER LTD.. LTD 2.01.11 2.01.12 2.01.13 2.01.14
Codes of Diesel Engine Manufacturer's Association, USA (1972) IS-4722/ IEC-60034: Generator BS:5000 Part 99/1973 BS:822 Part 6/1988 : : Electrical Performance of rotating Electrical Machinery. Recommendations for Terminal Markings for Electrical machinery and apparatus.
2.01.15 2.01.16
BS Code of Practice CP:1014, protection of electrical equipment against climatic conditions. Various Indian/British Standards for material testing and identification. Other International standards like API/DIN/JIS/GOST etc. which may be equivalent or superior to those specified above.
2.02.00
The specific design, material requirement, manufacture etc. for the Atmospheric Tank for this project/system shall be guided by the requirements indicated in Data Specification sheets (Annexure-II) attached. In case of any contradiction between the aforesaid standards and this technical specification, particularly the data sheets, the stipulations in data sheets and Technical specifications shall generally prevail and shall be binding on the Supplier/Bidder. SYSTEM REQUIREMENTS The Diesel Generator system will consist of five (5) nos. of Diesel Generator Sets, to provide emergency power to units 1, 2, 3 & 4 in case of grid power failure and will deliver the power required by the plant for safe coasting down of the units. Out of above five (5) D.G. sets, D.G. Set-1, D.G. Set-2, D.G. Set-3 and D.G. Set-4 will normally be running for Unit-1, Unit-2, Unit-3 & Unit-4 respectively during emergency and D.G. Set-5 will be kept as common standby. Each D.G. Set shall feed power to the essential auxiliaries of each of units The essential loads of each T.G. unit shall be fed from Emergency MCC of each unit. Emergency MCC shall have tie connection with 415V Unit PMCC# 1A and 1B respectively. On sustained loss of normal A.C. supply to Emergency MCC, the normal incomer breaker in the Emergency MCC will be tripped automatically. The AMF Panel will generate signals to start the dedicated unitized DG and standby DG automatically On build-up of the rated voltage and frequency, the D.G breaker shall close automatically. After automatic closing of the D.G breaker, the incomer breaker of Emergency PMCC from DG shall also close automatically and thus restoring the emergency load of the unit either directly from the outgoing feeder of Unit Emergency PMCC. All DG sets will be controlled from the DG AMF control panel located in DG electrical room. The standby DG set shall also start automatically whenever main DG starts up i.e. starting signal will go to main as well as standby DG set whenever an emergency arises. This will ensure quicker availability of emergency power in the event of
2.03.00
3.00.00 3.01.00
3.02.00
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failure of main D.G. set to start. However, the incomer from the standby DG set shall close automatically only when the main DG fails to start. Once unitized DG started, the standby DG shall be made OFF manually. Each DG set will undergo periodic trial runs using a common Load Bank. Starting signal shall be derived from the voltage-monitoring relay connected to the Emergency MCC bus of respective unit. On build-up of the rated voltage and frequency, the incomer breaker of unitized DG PCC will be closed automatically. The outgoing breakers of D.G PCC will be kept normally closed. After the automatic closing of the incomer breaker at DG PCC end, the incomer breaker at Emergency MCC from DG PCC will be closed automatically and thus the emergency load of the unit will be fed. For further detail refer attached drawing Single Line Diagram: Emergency DG System (Drawing No.- K8B15-DWG-E-0119). During operation of any DG set, if a stop command is initiated or a protective device operates, that set will stop and will not restart even though the auto-start command persists, unless reset. On restoration of normal AC power supply, the operator will manually stop the DG set depending on the plant status. Under all the above operating conditions, pressing of the engine-mounted stop pushbutton will stop the DG set irrespective of whether normal power supply is restored or not. 3.03.00 Each DG Set shall be sized to supply total continuous emergency load amounting to 1600 KW at 0.8 pf (lag). Capacity and transient reactance of each DG is also to be selected fulfilling the following performance requirement: In the event of starting of motor of largest KW rating keeping all other loads running, the voltage at the largest KW rating motor terminal is to be maintained at 80% of rated voltage. The largest KW rating motor in the system is envisaged as 415 V, 132 KW (Steam Turbine Aux. Oil Pump # 2), running p .f. 0.85 (lag), running efficiency 0.85, starting p.f. 0.3 (lag), starting current 7.2 times (including tolerance) of full load current. Details of cables envisaged for DG system are as follows: From DG/DG PCC (Distance between DG to DG PCC is negligible) Emergency MCC To Emergency MCC Cable Size 8-1/CX630 sq.mm. FRLSH, XLPE Al cable /Ph. 1-3/CX300 sq.mm, FRLSH, XLPE Al cable Route Length 275M
Steam Turbine Aux. Oil Pump
168M
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DG PCC
# 2 Motor Load Bank Switchgear
4-1/CX630 sq.mm. FRLSH, XLPE Al cable
850 M
These data are tentative and for bidding purpose only. The actual data and any other information if required will be furnished to the successful bidder. Based on these tentative data Bidder is to furnish the calculations along with his bid for the DG sizing and the available voltage at the highest KW rating motor terminal during its starting keeping all other load running. The Diesel Generator System shall cater for the following essential loads: Sl. No. Rating (KW)
Description of Loads
Voltage
Qty. Per Unit W S
Remarks
Boiler 1 Air pre heater main driven motor 2 Air pre-heater guiding/support bearing oil system 3 Oil pump motor of PAF hydraulic lube oil station 4 Electric heater of PAF hydraulic lube oil station 5 PAF motor lube-oil pump 6 Electric heater of PAF motor lube oil station 7 Hydraulic oil station motor of FDF 8 Hydraulic oil station electric heater of FDF 9 Lube oil station motor of IDF 10 Lube oil station electric heater of IDF 11 Electrically operated furnace maintenance platform 12 Aux. oil pump motor 13 Seal Air Fan motor
415 415 415 415 415 415 415 415 415 415 415 415 415 415 415 415
37 2.2 2.2 2.5 2.2 2.2 2.2 2 1.1 2 5.1 30 132 15 9.3 7.5
2 4 1 1 1 3 1 1 2 6 1 1 1 1 1 7
0 0 1 0 1 0 1 0 0 0 0 0 0 0 0 1 for each mill for each PAF motor for each PAF motor for each FDF motor for each IDF motor (6kVA load) one for each unit one for each unit
14 DM Make-Up Pump 15 Scanner Air Fan motor Coal Bunker 16 Lube oil station oil pump motor of MSM
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JIINDAL POWER J NDAL POWER LTD.. LTD 17
Lube oil station electric heater of MSM Turbine House 18 Steam Turbine Turning gear Motor 19 Steam Turbine Lub Oil pmp motor 20 Steam Turbine Jacking Oil Pump Motor(normal) 21 BFP Turbine Jacking Oil Pump Motor 22 Hydrogen sealing oil standby pump motor 23 Aux. Oil Pump# 2 (MAV23AP001) 24 EH oil circulation pump motor 25 Steam Turbine main oil tank vapour extractor 26 BFP Vacuum Breaker Valve 27 Bearing chamber exhaust fans for hydrogen Generator 28 Primary Water Pump 2 (MKF12AP001) 29 Seal Oil Pump (MKW12AP001) 30 Alkaline Dosing Pump (MKF36AP001) Other device 31 Hydraulic coupler oil pmp motor 32 Bypass System Oil stn motor 33 Bypass system electric heater 34 Emergency CW fill puump - A (QHX33AE001) 35 Emergency CW fill puump - B (QHX33AE002) 36 Emergency CW Tank Inlet Isolation (CW-85) 37 Condenser Vacuum Breaker Valve 38 Recirculation Pump-1 Seal water UNIT C & I load list 39 Flame scanning Cooling fan AC motor Local control cabinet
415 415 415 415 415 415 415 415 415 415 415
12 37 55 45 3.7 30 132 2.2 0.75 1.5 1.0
7 1 1 1 1 1 1 1 1 1 1
1 0 0 1 1 0 1 0 1 1 1
415 415 240 415 415 415 415 415 415 415 415
37 15 0.02 5.5 4 2 5.5 5.5 0.09 1.5 4.0
1 1 1 1 1 1 1 1 1 1 1
0 0 1 0 1 0 0 0 0 1 0 one for each unit each oil station one for each unit one for each unit one for each unit
415
20
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JIINDAL POWER J NDAL POWER LTD.. LTD 40 Sub-Total-1
UNIT C & I load list 41 Boiler burner muzzle swing actuator local cabinet 42 Drum level TV For A & B side 43 Furnace Flame TV for A & B side 44 Gas air prehtr fire detn control cabinet 45 Gas Air prehtr gap adjust control cabinetcabinet For Side A & B 46 Drum level Bi-color Indicator for side A 47 Drum level Bi-color Indicator for side B 48 Local junction Box for Vaccum pump A 49 Local junction Box for Vaccum pump B 50 Boiler tube leakage System Cabinet 51 415V spare power 52 240V spare power 53 54 DCS including Data Acquisition System Sub-Total-2
240 240 240 415 415 240 240 240 240 240 415 240 415
0.3 5 5 3 8 1.5 1.5 1 1 4 1 1 34
2 1 1 2 2 1 1 1 1 1 1 1 1
0 0 0 0 0 0 0 0 0 0 0 0 0 40kVA estimated.
Miscellaneous Loads 55 UPS 415 120 1 0
56 57 58
Main Plant Battery charger Switchyard (battery charger + Emergency Lighting) Emergency Lighting Plant & aviation lighting
415 415
110.00 15.00
1 1
0 0
UPS capacity estimated as 150KVA & Power factor 0.8 Considering Ni-Cd battery
415
50.0
Includes aviation lighting for Chimney & Cooling Tower
59
Station Transf OLTC
415
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JIINDAL POWER J NDAL POWER LTD.. LTD 60 61
Main Stop Valve Stack Elevator
415
25
1 Common for both units and considered to be fed from DG of Unit#1
415
9.2
62 63 64
Turbine Elevator Boiler Elevator Technical Building elevator
415 415 415
22.5 22.5 7.5
1 2 1
0 0 0
4.00.00DESIGN AND CONSTRUCTION 4.01.00 4.01.01 Diesel Engine The Emergency Diesel Generator Set shall be capable of starting from cold condition on loss of normal A.C. supply and coming up to rated speed and voltage within the minimum time as specified elsewhere. During this time D.C. battery will take care of maintaining plant essential requirements. Type Diesel Engine Stationary type, two/four stroke with Vertical in line or V type cylinder arrangement and turbo charged/water cooled. The Diesel Generator shall be provided with acoustic enclosure and ventilation system as required. The Diesel Generator shall be installed outdoor under a shade. Rating a) b) c) d) e) f) Electrical output Ambient temperature Relative Humidity Noise level at works at one metre Distance from DG set. 2000 KVA 50 degree. 85 % 105 dB sound pressure
Noise level at one metre Distance 85 dB average sound pressure from DG acoustic enclosure. Fuel High speed Diesel Oil. However, engine shall be capable of running with Light diesel oil. 1500 rpm 12 hours continuous running, of which one hour at 10% overload at rated speed
g) h)
Speed Max. Duty
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JIINDAL POWER J NDAL POWER LTD.. LTD i) j) k) l) m) n) o) p) q) r) Governor Vibrations Starting
Electronic A1 type as per BS ISO -3046 Max. 250 microns peak to peak with anti-vibration pads Electrical self starting 990 litre Dry type air filter suitable for site conditions. Air cooled / Forced water cooled. IP-23 Battery Starting Brushless Required (through push button on AMF panel in local position & through push button on CCR desk in remote position
Fuel service tank Air intake system Cooling Type of Enclosure Engine Starting System Excitation System Manual starting of Engine through local/remote push button
4.01.02Main and Crank-Pin Bearings Removable precision-type which shall fit without scraping or shims.
4.01.03Cylinder Liners Replaceable close grained alloy iron liners, heat treated for proper hardness and of the wet or dry type. 4.01.04Engine Access Engine shall be arranged for convenient inspection and maintenance of crank and main bearings. 4.01.05Type of Combustion Air Supply to the Engine a) Exhaust gas driven turbo-charger shall be fitted to each bank and each turbo-charger shall have its own self-contained lubricating oil system. Air shall be normally supplied through intake filters and ducted to the turbo-charger via a silencer. Air from the turbo-charger compressor passes to the after cooler and then to the engine manifold. The cooler shall be of tubular construction with aluminium bronze tubes, mild steel shell and cast iron water boxes. It shall be cooled by engine driven water pump. The entire turbo-charging system including exhaust and intake manifolds, valve timing and arrangement of the cylinder head shall be designed for
b)
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optimum performance at high boost pressure with subsequent high specific engine power output. c) Arrangement to control air flow at different load shall be provided so that minimum velocity at any given load through the filter is maintained.
4.01.06Governing System (over speed protection) a) The governor shall be suitable for operation without external power supply, and shall provide adequate speed control in the event of failure of governor electrical motorized system. The Governor shall be provided with a motor operated speeder gear for remote adjustment of Generator frequency. The governor shall have necessary characteristics to maintain the speed substantially constant even with sudden variation in load. However a tripping shall be provided even if speed exceeds the maximum permissible limit. A mechanical over speed trip devices shall be provided to automatically shut-off fuel in case the speed exceeds 110% of the rated value. The trip shall also be manually operable for an emergency stop. The generator characteristics shall be suitably chosen considering load sharing between two generators in the event of parallel operation with other generator.
b)
c)
d)
4.01.07Ignition Engine shall run using heat of compression ignition. Engine shall start from cold by heat of compression only without any auxiliary preheating source, either injection or other ignition aids. 4.01.08Engine-Generator-Exciter-Auxiliary-Bedplate The engine, generator and exciter shall be mounted on a common bedplate. Auxiliary apparatus (accessory rack) is also to be mounted on the common bedplate. The bedplate supporting the engine and generator shall be fabricated of sufficiently heavy side members and cross-members to assure the maintenance of the proper alignment of the equipment. The Bidder shall provide properly designed vibration damping equipment for mounting between the bedplate and foundation. Furnish leveling shims, lifting eyes and provisions for jacking. 4.01.09Flywheel Bidder shall be responsible for determining and providing the necessary flywheel effect. The flywheel shall be properly statically and dynamically balanced and capable of rotating at 125 percent of rated speed without injury. Furnish fly-wheel guards. 4.01.10Flywheel Barring Provision
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Hand barring shall be provided to each engine over for inspection and maintenance. Barring will be accomplished from front end of engine using the crank shaft pulley. 4.01.11 Coupling and Guard Provide flexible coupling between the engine and generator, if required. Furnish coupling guard. 4.01.12 The Diesel Generator Sets shall meet the performance requirement as described in Clause No. 3.00.00 and frequency drop not exceeding 5% during its starting period. DG sets shall automatically start to meet the Emergency load requirement in event of power failure. The auto start signal shall be provided to DG control panel from the switchgear by owner. However, manual hand cranking starting arrangement shall be provided to start the Diesel engine in the event of automatic starting arrangement falls to start the engine. The bidder shall recommend in layout the space requirement. The Bidder shall have to take necessary approval of the installation from statutory authorities. The exhaust shall be discharged through a silencer and stack outside the shade at a sufficient height complying the pollution control board requirements. The generating set shall be installed inside the shade. Critical speed of the machine shall not be lesser than 120% of the normal speed. All couplings shall be capable of withstanding the maximum generator sudden short circuit torque. The Diesel Generator Sets shall be capable of safe, proper and continuous operation at all loads. Vibration, noise, mechanical and thermal stress shall be properly taken care of in the design of the equipment. The diesel engine shall be equipped with an electric starting system consisting of a starting motor, batteries, battery chargers with regulator and starting device. The desired nominal output at site referred to the alternator terminals and with machines operating under ambient conditions shall be computed by the Bidder as per the guidelines specified in Clause No. 3.00.00 of this section at 0.8 power factor at 415V+ 10%. The engine shall be capable of producing the maximum _ continuous output under the most adverse combination of ambient temperature, pressure and humidity at site and when required 10% greater output for a period of one hour in every twelve hours. The continuous engine brake horse power rating at the site condition shall be at least 15% greater than the maximum shaft horse power requirement of the generator at the rated KVA output to be computed by the Bidder at the specified power factor.
4.01.13
4.01.14
4.01.15 4.01.16 4.01.17 4.01.18
4.01.19 4.01.20
4.01.21
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JIINDAL POWER J NDAL POWER LTD.. LTD 4.01.22 4.01.23 4.01.24
The engine shall be de-rated in accordance with standard BS ISO 3046 for the difference in site conditions from standard conditions. The Diesel Generator Sets shall be housed in a shade adjacent to the Power House building. The Diesel Generator Set shall be running with High Speed diesel oil. However, the engine shall be capable of running with light diesel oil. All statutory regulation for firing and storing of high speed diesel oil/ light diesel oil shall be adhered to in preparing and locating the diesel generator sets and necessary approval/clearance from the statutory authority regarding the above shall be arranged by the Bidder.
4.01.25The engine shall be properly balanced so as to transmit only small unbalanced forces to the foundation. 4.02.00Cooling Water System 4.02.01General For engine cooling clarified water will be used. The engine shall be furnished with a complete closed loop cooling water system to adequately cool the engine jackets; exhaust manifold, lube oil, combustion air pre-coolers, intercoolers, and/or after-coolers as required and any other cooling requirements of the Bidder's design. The closed loop cooling water system shall be furnished complete including radiator, lube oil cooler; temperature regulators, expansion tank pressure gauges; thermometers; all control instrumentation; all piping including control valves; fittings; pipe and fabrication; engine-driven jacket water pump; combustion air cooler, intercooler, and any other cooling water pumps required by the engines design; and miscellaneous piping for a satisfactory operating system. Bidder shall furnish an engine cooling water system that provides jacket water outlet temperatures, manifold temperature, lube oil temperatures, combustion air temperatures, etc., safely within the engine manufacturer's recommended engine design temperature limits at the 100% load condition with air ambient temperature as high as 480C. 4.02.02Jacket Water Flow through the Engine All of the jacket water shall flow through the engine at all times and jacket water temperatures shall not be controlled by throttling of water flow to the engine. 4.02.03Cooling Mediums for Closed Systems Clarified water of quality as indicated in Annexure-II shall be used as cooling medium. To prevent corrosion and scaling inside the cooling passages corrosion and rust inhibitors shall be added. 4.02.04Vents
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Bidder shall furnish adequate venting to assure the removal of system air and filling completely with cooling medium for full cooling efficiency. 4.02.05 The cooling water system of each engine shall be provided with an expansion/head tank of adequate capacity placed at a suitable height. The tank shall be provided with fitting, vent and drain connections with isolating valves, gauge glasses, low level and high level alarm device.
4.02.06Radiator a) General The radiator shall be mounted on the engine bedplate and shall be cooled by air taken from ambient by an engine-driven pusher (blower) type fan. The fan shall push the air through the radiator to the outdoors. b) Cooling Air Cooling air shall range in ambient temperatures upto 480C with RH 100%. c) Fan Drive The radiator fan may be direct-connected to the engine or driven by vee belts. If a vee-belt is used, the belts shall be conservatively selected and adequate adjustment shall be furnished to assure proper belt tension. Belt guard shall be included. d) Each engine shall be located approximately one meter (1) away from the wall where RCC louvers/other means of cut-out shall be provided for exhausting the radiator hot air. Alternative to it, if any, as per Engine manufacturer's recommendation shall be provided by the Bidder so that the total output is unaffected.
4.02.05
Temperature Controls for Engine Cooling System Bidder shall provide proper and complete temperature control as required by the Bidder's design for the following : a) b) c) Jacket and exhaust manifold cooling. Lube oil cooling. Any other temperature control required by the Bidder for proper operation of his equipment.
4.02.06Engine-Driven Cooling Water Pumps Bidder shall furnish manufacturer's standard water pumps. 4.02.07High Temperature Engine Jacket Cooling Water Protection Bidder shall furnish temperature sensing device which will inaugurate an alarm on "high" jacket cooling water temperature. Furnish a second temperature sensing
SS-M2: 12
device which will inaugurate a trip and alarm if jacket water temperature rises to a "high-high" value. 4.02.08Cooling Water System Drains Bidder shall furnish sufficient drain valves so that the entire system can be completely drained. 4.02.09 Final painting of all equipment & structures in grades & colour as approved by the purchaser.
4.02.10Jacket Water Heating System During stand-by conditions, if necessary, the engine jacket water shall be kept warm by means of thermostatically controlled electric heaters to facilitate quick stating and rapid loading of the Engine. Location of the heaters shall be chosen so as to help natural convection during heating operation. 4.03.00 Fuel Oil System The fuel oil system for the DG set consists of high speed diesel (HSD) oil unloading & storage system including Fuel injection system from fuel oil storage tank to engine cylinder. 4.03.01 One (1) no. fuel oil storage tank of 990 litres capacity with accessories shall be provided for operation of each DG set. The tanks shall be located inside the shade. Tank shall be complete with level indicator marked in litres, two nos. of level switches, filling inlet with removable screen, an outlet, a drain plug, an air vent and necessary piping. The fuel tank shall be painted with oil resistant paint. All pipe joints shall be brazed/ welded. The fuel oil shall generally be unloaded from barrels by means of a hand pump, through a flow meter to be provided by the Contractor. The discharge from the above pump will go to Diesel Tank located inside the shade. The design and construction of the Pressure and Storage Vessel shall generally be as per Annexure-II (Data Specification Sheet) of this specification. The engine fuel system shall be furnished in accordance with the latest issue of "Indian Petro-chemical rules for Storage Handling & Use of Flammable Liquids. The fuel system shall afford an immediate supply of fuel to the engine to allow instantaneous starting. 4.03.02Fuel Injection Equipment Furnish mechanical injection of fuel oil into the engine cylinders. Injection pumps shall be positive displacement type, constant stroke and driven directly off engine. Injection pump and injection valves shall require no adjustment while in service and shall be capable of replacement in a few minutes by ordinary mechanics without special experience. Furnish two injection pumps and twelve injectors. 4.03.03Fuel to be Used
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Engine shall be fueled with High speed Diesel oil as per IS-1460. 4.03.04Fuel Lines to Engine Furnish between injection pumps and engine heavy seamless steel tubing of equal length to all cylinders to eliminate irregularities of fuel flow to the various engine cylinders. 4.03.05Fuel Oil Strainers and Filters a) Provide duplex full flow strainers of the metal edge or screen type between the engine-driven fuel oil transfer pump and the injection pumps. Strainers shall be cleanable without breaking any piping. Furnish strainers with manual bypass and isolating valves to allow servicing without engine shutdown. Provide injection pumps and injection valve assemblies without screens or filters that require cleaning. Furnish a Duplex strainer with manual bypass between the fuel oil day tank and engine-driven fuel oil pump. Strainer shall be cleanable with the engine running. The strainers shall be of Duplex type with basket type straining elements permitting easy removal and replacement. The open area ratio (i.e. straining area to the inlet area ratio) shall be at least 6:1.The strainers shall have 40 mesh screen of stainless steel construction with wire diameter of about 0.01 inch and open area of about 50%. Strainer body shall be made of cast iron of Gr. FG 200, IS-210 and basket shall be of stainless steel to AISI 304. Each strainer shall be provided with a pair of counter flanges and associated bolts, nuts and gaskets. Material of counter flange shall be of tested quality steel conforming to IS: 226. All strainers shall also be provided with oil drip plates beneath them for collection of oil. Bolts and nuts shall be as per IS: 1363. Gaskets shall be of minimum 3 mm thickness and made up of neoprene rubber. Furnish pressure gauges on the panel to indicate engine driven pump discharge and fuel header pressure. High differential pressure switches across each strainer and filter. Filter inlets/outlets shall be clearly marked.
b)
c) d)
e) f)
g) h) i)
4.03.06Fuel Oil Pumps (Engine Driven) Provide a direct engine-driven, sellf-priming positive displacement pump to pump fuel oil from the individual engine day tank to the injection pumps under all
SS-M2: 14
conditions of operation. Supply pressure shall be maintained constant by a relief valve and bypass system. 4.04.00 Lubrication System
4.03.01General A complete lube oil system shall be furnished by the Bidder to supply oil under pressure to the main and crank pin bearings, pistons pins, timing gears, cam shaft bearings, and rocker arm bearings. At peak load and an ambient air temperature of 480C, the maximum oil temperature leaving the engine shall not exceed the manufacturer's maximum safe value. The system shall be designed so that the bearings are lubricated and the engine is instantaneously ready to accept rated load within the specified temperature range. 4.04.02Filters Furnish manufacturer's standard lube oil filter system. Pressure gauges shall be provided in the inlets and outlets of all filters, High differential pressure alarm switches shall be furnished across each filter. The lube oil flow shall be continually strained and filtered. The filters shall be equipped with spring loaded bypass valves to prevent stoppage of lubricating oil flow in case of excessive plugging. The filters shall remove all particles down to 25 micron size and shall absorb water contamination from clean oil at normal operating temperature. Initial pressure drop across the filters shall not exceed 3 psi. 4.04.03Low Lub Oil Pressure Protection Furnish a pressure sensing device which will inaugurate an alarm on "Low" lub oil pressure. Furnish a second pressure sensing device which will inaugurate a trip and alarm if lub oil pressure drops to a "low-low" value. 4.04.04 Main Lub Oil Pump Provide engine-driven gear type positive displacement oil pump which shall furnish lub oil at a predetermined constant pressure. Lub oil pump shall be adequately sized. 4.04.05Lub oil Cooler Furnish manufacturer's standard shell and tube lube oil cooler. Furnish automatic oil temperature control as mentioned in clause no.: 5.01.03 of sub-section- M0. Provide temperature gauge at the outlet of oil cooler.
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Provide alarm contacts wired to the AMF panel annunciater for lub oil temperature high. 4.04.06 4.04.07 If engine needs lubrication during prolonged idle condition, Bidder to supply all necessary accessories like priming pump, timer relays etc. All necessary accessories like pressure gauge, temperature indicators, pressure relief valve, pressure switches for alarm and control shall be furnished by the bidder together with all interconnecting piping, fittings, supports, valves. etc.
4.05.00Exhaust System 4.05.01General The Bidder shall furnish a complete diesel engine exhaust gas system. 4.05.02 Muffler The Bidder shall furnish one residential type muffler for the engine. The muffler shall function by acoustic principles rather than throttling and shall not impair engine efficiency. Mufflers shall be mounted vertically. Companion flanges shall be furnished. Supports and appurtenances for mounting on building steel furnished by Others. 4.05.03 Flexible Exhaust System Metal Hose The Bidder shall furnish an 8" length of flexible seamless stainless steel metal hose to assure expansion protection and vibration isolation. 4.05.04 The exhaust line, muffler, etc. shall be of sufficient size so as not to place excessive backpressure on the engine that could prevent the engine from making its maximum rating. Exhaust pipe size shall be determined by the Bidder. Calculation shall be furnished with the offer. However, in any case it shall not be less than 12 inch dia. The system shall be designed based on D.G. room layout. Labour and material for exhaust pipe and installation by the Bidder. Necessary thermal insulation on exhaust system where required for personnel safety is to be furnished by the Bidder.
4.05.05
4.06.00Engine Starting System 4.06.01General A complete electric starting system shall be supplied by the Bidder. This system shall include starting motors, rack mounted 24V battery, battery charger, and associated wiring and cabling. 4.06.02 Auxiliary Electrical Supply The auxiliary supply voltage to the battery charger shall be 415V three phase, 50 Hz, and shall be arranged from the AMF panel by the bidder. The Bidder shall include the battery charger in a charger cabinet. Battery shall be capable of providing three (3) consecutive starts.
SS-M2: 16
4.06.03Starting Requirements The starting system shall supply the starting torque and crank the engine at a speed necessary to instantly and consistently start the engine when the jacket water temperature is kept at approximately the engine manufacturer's recommended value while shut down. 4.06.04Methods of Initiating the Starting System The starting system shall be furnished to operate (1) manually by operation of a control switch on the AMF panel and (2) automatically by remote contacts (by others). The control voltage shall be 24V D.C and arranged from the 24V battery/battery charger system by the bidder. 4.06.05Starting Procedures Each motor starter pinion shall make complete engagement with the flywheel ring gear and shall remain engaged until they are released by a centrifugal switch after the engine has reached a predetermined speed, operating under its own power (after stable ignition has taken place). With loss of ignition after the engine speed has already released the motor starter pinions, the engine shall come to rest before initiating restarting. Interlocking equipment shall be furnished to immediately sense when the engine has come to rest and upon this signal shall start recranking the engine. The starting system shall not crank the engine at a greater speed than the speed setting of the starter release centrifugal switch. 4.06.06 Starter Motor The starter motors shall be mounted on the engine and shall be as per NEMA Standards. Starter pinion shall automatically disengage flywheel at proper engine speed. 4.04.00 4.04.01 Piping, Valves & fittings Piping, Valves and fittings for oil line shall be as per Annexure-II to this section. For piping, valves and fittings for air and water refer Annexure-II (Data Specification Sheet) of this specification.
4.05.00Pumps Horizontal centrifugal pump (required for cooling water) design and construction shall be generally as per Annexure-II (Data Specification Sheet) of this specification. 4.06.00Instrumentation
SS-M2: 17
All electrical instruments and controls will be mounted on the local control panel, which will be installed near the engine. Non-electrical instruments for measuring pressure, temperature and liquid level may be mounted directly on the engine / engine mounted panel. Following instruments shall be provided: 4.06.01Pressure Indicators Fuel Oil Pressure (outlet of fuel pump) Lube Oil Pressure (outlet of oil pump) Lube Oil Pressure (outlet of oil filter) Cooling Water Pressure (outlet of water pump) Differential pressure across the lube oil filter & fuel oil strainers. 4.06.02Temperature Indicators Jacket cooling water temperature. Exhaust gas temperature Lube Oil (outlet of oil cooler) Cooling water (outlet of radiator) 4.06.03Level Indicators Level gauge for Fuel oil tank. Dip stick for lube oil level-marked for running and standing conditions. Sight glass for cooling water level in expansion tank. 4.06.04 4.06.07 All other instruments required for control, safety and smooth operation of the equipment. Separate indicators shall be provided for each of the following in local control panel: Separate indicators shall be provided for each of the following in local control panel: (i) Protection from engine side. Low Lube oil pressure (pressure switch) (Trip) High Lube oil temperature (temperature switch) (Trip) Low Air Pressure in Receiver (Alarm) Engine Over speed (Trip) Overload (Alarm) Engine fails to start (Alarm) Electrical Protective Relay Operated (Trip)
SS-M2: 18
JIINDAL POWER J NDAL POWER LTD.. LTD (ii)
Winding & Bearing Temperature high (Alarm) Cooling water pressure low (Trip) High Cooling water Temperature (Trip) Charger ON/OFF (Alarm) Abnormal voltage (under and over voltage) (Alarm) Alternator stator temperature high (Alarm) Fuel Level low in day tank (Alarm and trip) Electrical protective relays operated. Differential protection Voltage restrained over current protection
Annunciations & Indications Descriptions DG Available for start Emergency BUS on Normal supply Emergency BUS on DG supply Engine Running 24V DC supply Fail Alarm 24V DC Charger Group Alarm Engine failed to start Lub oil Pressure Low (pressure switch) Lub oil temp high (temp switch) Jacket water temp high (temp switch) Engine over speed Jacket water level low (level sw-float type) Fuel oil level low (level switch) Generator Protection Operated Generator Relay operated DG group Alarm Engine Tripped DG Incomer CB Tripped Local Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Remote Yes
SS-M2: 19
Winding Temperature High Alternator stator temp. high Generator bearing temp high Abnormal voltage (under and over) i)
Yes Yes Yes Yes
For alarm and annunciation, a window based alarm annunciation system with clustered bright LED lamps and a Hooter shall be provided. Four (4) nos. push buttons shall be furnished for Accept, Reset, Silence & Test. On occurrence of fault, the hooter shall sound and a window indication lamp shall flash. On pressing accept push button, hooter shall stop but the lamp shall continue to glow steady. On pressing reset push button, the lamp shall stop glowing but if the fault persists, the hooter shall not sound and the lamp shall glow steadily. Necessary auxiliary relays, push buttons, hooter, indication LED lamps etc. shall be furnished, as required, to achieve the above function. The bidder shall furnish the Alarm annunciation list in his proposal. However, the separate windows facia shall be provided for the following annunciations, as a minimum. a) b) c) d) e) f) g) h) i) j) k) l) Lub oil temperature high Lub oil level low Lub oil pressure low Jacket cooling water temperature high Fuel oil tank level low Cylinder head temperature high Engine running Engine tripped DG Fail to Start Generator winding temperature high & very high Generator bearing temperature high & very high Engine exhausts temperature high
m) D.G. set over-speed n) o) p) All electrical faults (Master trip relay operated as well as supervision of master trip relay operated) Negative sequence of phase - alarm. Battery earth faults
SS-M2: 20
JIINDAL POWER J NDAL POWER LTD.. LTD q) r) s) t) u) v)
Generator breaker auto trip Battery charger - `A' failure. Battery charger -`B' failure. Generator PT Fuse Failure. Generator Frequency Low. Generator Over-voltage.
Item Nos. (e), (g), (h) and (i) will be repeated in Common Control Room. Provision for annunciating engine faults (non-trip) type in unit control room shall also be made by the Bidder. For proper functioning of D.G. emergency power supply system necessary surveillance drill shall be undertaken periodically for trial operation of the D.G. on no load. Necessary pressure switches, level switches, thermostats, flow switches, auxiliary relays, etc. required for the above alarms and annunciation system shall be furnished under the scope of this section. The Successful Bidder shall take prior approval from the Owner regarding make and technical particulars of such accessories to be used. 5.00.00 INSPECTION & TESTING Please refer to Sub-section: M3 Quality Assurance & Inspection Requirements. 6.00.00 CLEANING, PROTECTION AND PAINTING Please refer to Sub-section: M4 Technical Specification for Surface Preparation & Painting.
SS-M2: 21
SUB-SECTION: M3 QUALITY ASSURANCE PLAN
CONTENTS CLAUSE NO. 1.00.00 2.00.00 3.00.00 4.00.00 5.00.00 6.00.00 DESCRIPTION INTRODUCTION DEFINITIONS QUALITY ASSURANCE PROGRAMME GENERAL REQUIREMENT QUALITY ASSURANCE DOCUMENT INSPECTION, TESTING AND INSPECTION CERTIFICATES GUIDELINES OF MAKING NON- CONFORMANCE REPORT INSPECTION AND TESTING
7.00.00 8.00.00
ATTACHMENTS EXHIBIT-A EXHIBIT-B MANUFACTURING QUALITY PLAN FIELD QUALITY PLAN
SUB-SECTION: M3 QUALITY ASSURANCE PLAN

1.00.00 INTRODUCTION The purpose of these requirements is to provide uniform general requirements for implementation of Quality Assurance Programme for projects being executed by M/s Jindal Power Limited. The scope of these requirements covers the pre-requisites of the Bidder / Suppliers Quality Assurance System applicable for all phases of contract execution including design, procurement, manufacture, testing, erection and commissioning and other services and further establish specific factors for which control shall be carried and put into continuing operation by the Bidder / Supplier to ensure that all supplies and services comply with the contract requirements. These requirements apply to products or systems designed, developed and/or manufactured under closely controlled conditions, the technical requirements of which are specified principally in terms of performance and/or safety and requiring the Bidder / Supplier to be responsible for design, development, manufacture and when appropriate, installation and commissioning. In these circumstances, reliability and other quality characteristics can only be ensured by the Bidder / Supplier exercising control over all phases of work, over his total organization engaged on the defined task and by providing procedures which ensure adequate monitoring of this system and products including those obtained from outside his own organization. The required/specified reliability and other characteristics of quality should initially be designed in and then built in and it is emphasized that satisfactory product and system performance can be achieved only through strict control of all design, manufacturing and erection/installation processes as well as test and inspection.
2.00.00
DEFINITIONS For the purpose of these requirements, the following definitions shall apply:
Quality
- The totality of features and characteristics (attributes) of a product or service that bears on its ability to satisfy a given need - All those planned or systematic actions necessary to provide adequate confidence that an item or a facility shall perform satisfactorily in service. - A document setting out the specific quality practices and procedures relevant to a particular component, part of material. - Those quality assurance actions, which provide a means to control and measure the characteristics of an item, process, or facility to, established requirements.
Quality Assurance
Quality Plan
Quality Control
SS-M3: 1
JIINDAL POWER J NDAL POWER LTD.. LTD Quality Audit
- An activity to determine through investigation, the adequacy of, and adherence to established procedures, instructions, specifications, codes, and standards and other contractual requirements, and the effectiveness of implementation. - Overall management and procedures for the execution of a specific contract or project. - A document specifying the general quality policies and practices of an organization. - The monitoring activity by the purchaser, his representative of an independent organization acting on his behalf, of a Bidder / Suppliers quality control organization and methods. - A comparison between a standard or measuring equipment, instrument or items of equipment with a standard of higher accuracy to detect, correlate, adjust and document the accuracy of the instrument or equipment item being compared or tested. - The officer authorized by the Purchaser/ Client placing the order for the work with the Bidder / Supplier or such other officers as may be authorized and appointed in writing by the Company to act as the Engineer for the purpose of the Contract. - "Hold Points" are stages in process, which are indicated in the Quality Plans beyond which the work shall progress only with the Engineer's written consent in respect of the relevant items. - The process of measuring, examining, testing, gauging or otherwise comparing one or more characteristics of the product or service with the specified requirements. - Shall mean the Engineer and/or his authorized representative and/or an outside inspection agency acting on behalf of the Purchaser/ Client to inspect and examine the materials and workmanship of the works during its manufacture or erection/construction and/or other duties as required by Quality Plan or standard code. - An appraisal to determine whether or not a management system is capable of producing a quality control or service and generating evidence to support decisions of acceptability. - The Clients of the project who have contracted the job to Purchaser.
Quality Programme
Quality Manual
Quality Control Surveillance
Calibration
Engineer
Hold Point
Inspection
Inspection Engineer/ Inspector
Evaluation
Client
SS-M3: 2
JIINDAL POWER J NDAL POWER LTD.. LTD 3.00.00 3.01.00
QUALITY ASSURANCE PROGRAMME To ensure that the equipment and services under the scope of contract whether manufactured or performed within the Bidder / Suppliers works or at his subvendor's premises or at site or at any other place of work are in accordance with the specifications, the Bidder / Supplier shall adopt suitable Quality Assurance Programme and submit the same for approval of Purchaser/ Client, to control such activities at all points, as necessary. Such programmes shall be outlined by the Bidder / Supplier and shall generally cover the following: i) His organization structure for the management, both for Shop & Site and implementation of the proposed quality assurance programme. Quality System Manual. The procedure for purchase of materials, parts, components and selection of sub-vendor's services including vendor analysis, source inspection, incoming raw-material inspection, verification of materials purchased etc.
ii) iii)
iv)
System for shop manufacturing and site erection control including process controls and fabrication and assembly controls. Control of non-conforming items and system for corrective actions. Inspection and test procedure both for manufacturing and field activities. Control on calibration and testing of measuring and test equipment. System for handling storage, packing and delivery at site. Records & documentation control system. Furnishing of quality plans for manufacturing and field activities detailing out the specific quality control procedure adopted for controlling the quality characteristics relevant to each item / equipment / component.
v) vi) vii) viii) ix) x)
4.00.00 4.01.00
GENERAL REQUIREMENTS All materials, components and equipment covered under the contract including bought outs shall be procured, manufactured and tested at all the stages, as per a comprehensive Quality Assurance Programme. It is the Bidder/Suppliers responsibility to draw up and implement such programme duly approved by the Purchaser/ Client. All items/equipment in the scope of the contract may be classified into categories according to the criticality or other attributes of items/ equipments. A detailed proposal addressing vendor approvals and quality control of all such items/ equipment shall be proposed to Purchaser/ Client for approval.
4.02.00
SS-M3: 3
The detailed quality plans for shop manufactured items and for field activities including civil works (if applicable) shall be drawn up by the Bidder / Supplier separately. All shop quality plans and field quality plans shall be submitted to Purchaser/ Client for approval prior to start of manufacturing activities and site activities respectively. The quality plans for the items manufactured by the Bidder / Supplier in-house shall be submitted not later than 7 days after the LOI/ placement of order whichever is earlier. The quality plan for the items that are bought out items for the Bidder / Supplier shall be submitted as per the mutually agreed schedule. 4.03.00 4.04.00 The Bidder / Supplier prior to the award of contract shall draw up such schedule. Manufacturing quality plans shall detail out various tests/inspections to be carried out as per the requirement of the specification and standards mentioned therein and quality practices and procedures followed by Bidder / Suppliers /his sub vendors quality control department, the relevant reference documents and standards, acceptance norms, inspection documents generated etc. during various stages of manufacturing right from material receipt stage to material dispatch including final testing/performance testing at shop for all items/ equipment / components. Typical format of manufacturing quality plan is enclosed as Exhibit-A. Field quality plans shall detail out for all equipment, the quality practices and procedures etc. to be followed by the erectors site quality control department, during various stages of site activities right from receipt of materials/equipment at site to commissioning stage. Typical format of field quality plan is enclosed as Exhibit-B. The Bidder / Supplier shall also furnish copies of the reference documents/plant standards/ acceptance norms/ tests and inspection procedure etc., as referred in quality plans along-with quality plans. These quality plans and reference documents/ standards etc. shall be subject to Purchaser/ Clients approval without which manufacturing and or field activities shall not proceed. These approved documents shall form a part of the contract. In these approved manufacturing and field quality plans, Purchaser/ Client shall identify hold points, i.e. test/checks which shall be carried out in presence of the Purchaser/ Clients Engineer or his authorized representative and beyond which the work shall not proceed without consent of Purchaser/ Client / its authorized representative in writing. The above procedure shall be applicable to the Bidder / Suppliers bought out equipment/ items also. All the items classified as mentioned above shall be procured from the sub-vendors approved by Purchaser / Client. For the same the Bidder / Supplier shall propose a list of sub vendors for bought out items for approval from Purchaser/ Client. The list of sub-vendors shall be discussed with the Bidder / Supplier prior to award of contract and all the sub-vendors which are already approved with Purchaser/ Client shall be identified and the Bidder / Supplier shall be informed regarding approval or otherwise for those sub-vendors. All such approvals shall be in line with the vendor approvals obtained by Purchaser from Purchaser/ Client for the subject project. In case, the Bidder / Supplier desires approval of any sub-vendor offered by him, not approved with Purchaser/ Client, then the Bidder / Supplier shall submit his technical evaluation assessment report of the sub-vendor along with all details, which shall include:
4.05.00
4.06.00
4.07.00
SS-M3: 4
Documentary evidence which demonstrate that the proposed sub vendor meets the eligibility criteria as stipulated in the tender documents Manufacturing facilities. Testing facilities. Quality Management System including certification, if any. Past Experience details in line with the qualification criteria.
The details of the sub-vendors offered by him shall be submitted not later than 7 days after the LOI/ Placement of order whichever is earlier and shall be frozen. Request for additional vendors shall not be entertained from the Bidder / Supplier after the vendor list is finalized and frozen. Delays arising out of such exercises shall be entirely to the account of Bidder /Supplier and shall not relieve him from any obligation, duty, or responsibility under the contract. 4.08.00 All deviations to specifications, approved quality plans and applicable standards observed during various stages of contract execution shall be documented in Shop Non-Conformance Record and the deviations observed at site shall be documented in Site Non-Conformance Record. Major deviations are to be referred to Purchaser/ Client / Consultant along-with technical justification for approval. The Bidder / Supplier shall submit to the Purchaser/ Client/ Consultant field-welding schedule for field welding activities for approval/ information. The field welding schedule shall be submitted to Client/ Consultant along-with all qualified supporting procedures, like WPS, PQR and welder qualification, heat treatment procedures, NDT procedures etc. at least forty five days before schedule start of erection work at site. No material shall be dispatched from the bidder / supplier /manufacturer's works before the same is accepted subsequent to pre-dispatch inspection including verification of records of all previous tests/ inspections by Purchaser/ Client /Authorized representative and duly authorized in writing by Purchaser for dispatch in case of customer hold point (CHP) items / equipment. In case of Non CHP items, material shall be dispatched from the manufacturer's works only after all internal test and inspection reports (in requisite number of copies) submitted to Purchaser/ Client / Consultants for approval are approved and duly authorized in writing by Purchaser for dispatch. All materials used or supplied shall be accompanied by valid and approved material certificates, tests and inspection reports. These certificates and reports shall indicate the heat numbers or other such acceptable identification numbers of the material. The material certified shall also have the identification details stamped on it.
4.09.00
4.10.00
4.11.00
SS-M3: 5
JIINDAL POWER J NDAL POWER LTD.. LTD 4.12.00
All material used for equipment shall be of tested quality as per approved technical specifications/ quality plans /relevant codes & standards. Details of the tests conducted to determine the mechanical/ Electrical properties, chemical analysis and details of heat treatment procedure recommended and actually followed shall be recorded on certificates and time temperature chart. Tests shall be carried out as per applicable material standards and/or approved procedures. Purchaser/Client/his nominated representative reserves the right to carry out quality audit / quality surveillance of the systems and procedures of the Bidder / Suppliers or their sub-vendor's quality management and control activities. The Bidder / Supplier shall provide all necessary assistance to Purchaser/Client/his nominated representative to carry out such audit/ surveillance. The Bidder/ Supplier shall carry out inspection and testing during manufacture in his works and that of his sub-vendor's and at site to ensure the mechanical accuracy of components, compliance with drawings, conformance to functional and performance requirements, identity and acceptability of all materials parts and equipment. He shall carry out all tests/inspection required to establish that the items/equipment conform to requirements of the specification and the relevant codes / standards specified in the specification, in addition to carrying out tests as per the approved quality plans. The Bidder/ Supplier shall be responsible for providing controlling, calibrating, and maintaining measuring and test equipment required by him/his sub-contractor/subvendor which are suitable for demonstrating compliance of supplies within contract requirement at shop and at site. All the measuring instruments shall be calibrated at periodic intervals determined by Bidder/ Supplier / sub-vendor on the basis of his suitability, purpose and usage, as per the system adopted by him for calibration of such measuring and test equipment. However, in no case, shall the interval between successive calibrations be more than 12 months. Measuring and test equipment may be calibrated by Bidder / Supplier/sub-vendor in their own labs using controlled written procedures subject to Bidder /Supplier/subvendor having satisfactory calibration facilities and procedures acceptable to Client. In absence of above, all measuring and test equipment shall be calibrated at a third party lab acceptable to Client. However, in all cases the master gauges used for calibration of equipment shall be periodically calibrated at Government approved/ recognized laboratory acceptable to Client. All measuring and test instruments shall have valid calibration certificates and calibration data shall be made available to Client/his nominated representative on demand. Quality surveillance/approval of the results of the tests and inspection shall not, however, prejudice the right of the Purchaser/ Client to reject the equipment if it does not comply with the specification when erected or does not give complete satisfaction in service and the above shall in no way limit the liabilities and responsibilities of the Bidder / Supplier in ensuring complete conformance of the materials/equipment supplied to relevant specification, standard, data sheets, drawings etc.
4.13.00
4.14.00
4.15.00
4.16.00
4.17.00
4.18.00
SS-M3: 6
4.19.00
For all spares and replacement items, the quality requirements as agreed for the main equipment supply shall be applicable. Major repair/rectification procedures to be adopted to make the job acceptable shall be subject to the approval of the Client/ Consultant. All tests shall be carried out to the satisfaction of the Purchaser/ Client / Consultant either in his presence or as agreed by Client. All reports/ protocols, site and shop inspection reports shall be developed specific to the requirements of the project which is acceptable to Purchaser / Client. The same shall be applicable to erection testing and commissioning reports and protocols also. Approval of any concession shall be the prerogative of the Client/ Consultant and approval of concession for a particular case shall not be set as a precedent. Type tests when called for shall be made on equipment, which has previously passed its routine tests. Painting: The final colors and identification systems for the equipment shall be generally in accordance with approved paint schedule / accepted procedure and shall confirm to the technical specification. Welding And Non-Destructive Testing General Requirements Bidder / Supplier shall submit the following documents in requisite copies for review and approval of Client/ Consultant at least FOUR weeks prior to commencing fabrication/ manufacturing. All such submissions shall be made in ENGLISH language only. i) Welding procedures together with the relevant procedure qualification records. Non destructive testing procedures. Heat treatment procedures. Other special procedure as applicable proposed to be used during project execution
4.20.00
4.21.00
4.22.00
4.23.00
4.24.00
4.25.00 4.25.01
ii) iii) iv)
Welding procedures and welders' qualifications shall be in accordance with the latest revision of ASME Boiler & Pressure Vessel Code Section IX or equivalent standard acceptable to Purchaser/ Client a) The welding procedures submitted for approval of Purchaser/ Client / Consultant shall include all details required by ASME Boiler & Pressure Vessel Code Section IX, both essential and non-essential variables for the particular welding process together with a detailed sketch of the weld joint.
SS-M3: 7
b)
The Bidder / Supplier shall maintain for review, or if requested shall submit to the Purchaser/ Client documentary evidence of the competency of all welders employed on the contract. Where documentary evidence does not exist welders' qualification tests will be required to be done in presence of Purchaser/ Clients representatives. If in the opinion of the Purchaser/ Client the welders are not carrying out the work in a satisfactory manner, the Purchaser/ Client reserves the right to call for samples of welding for examination and test. The Bidder / Supplier shall bear all costs for carrying out such tests. However in case of welders employed at site, welders qualification shall be done as per the guidelines of applicable standards for each welder in presence Client/ his nominated representative. For the purposes of identification, the Bidder / Supplier as part of the Quality Assurance System shall retain the welders name and/or suitable identification. These documents shall be made available to the Client/ his nominated representative on demand. Stamping or hammering of alloy material is not permitted. Non-removable, permanent metal name plates/ identification plates shall identify all items of alloy steel, which needs to be identified. All such labels shall be fixed at clearly visible location. All surfaces for welding shall be clean and free from paint, oil, grease, rust, scale, or other material detrimental to welding. All butt weld preparations shall be done by machining, grinding, machine or manual flame cutting with subsequent grinding. The use of temporary attachments welded to components shall be avoided wherever possible. If used, the attachments shall be removed by flush grinding after they have served their purpose and the area of attachment shall be examined by the method specified/ approved for permanent fillet welds in the system. Where post weld heat treatment is required by the fabrication specification the heat treatment charts showing temperature time shall be retained by the Bidder / Supplier. The charts shall indicate the heating and cooling rates, holding temperature, time and shall clearly identify the component(s) or weld(s) heat-treated. All such documents shall be made available to the Client/ his nominated representative on demand. Welding in the fabrication shop or at Site shall be done under the supervision of a qualified welding engineer only. The Purchaser/ Client reserves the right to examine and witness acceptance tests, prior to and following weld repairs and subsequent post weld heat treatment, mechanical tests etc, at the material Bidder / Supplier works. Weld repair procedures are subject to approval of the Client.
c)
d)
e)
f)
g)
h)
i)
j)
SS-M3: 8
JIINDAL POWER J NDAL POWER LTD.. LTD k)
NDT of castings, wrought iron products and weldments shall be carried out in accordance with the appropriate ASME/ International standards acceptable to Purchaser/ Client except where otherwise specified by the Client. The techniques of ultrasonic, radiographic, magnetic particle, liquid penetrant and leak detection methods applicable to all the principle items of the system shall be subjected to the approval of the Client. NDT operators shall be qualified in accordance with an agreed nationally accredited scheme such as the Personnel Certification in Non-destructive testing (PCN) scheme and shall be certified to level II or higher of that system. Alternative NDT qualifications equivalent to NDT level II may be submitted to the Purchaser/ Client for approval. Where in-house qualification systems are employed these will be subject to quality audit by the Client. The Bidder / Supplier shall submit a document relating the weld procedure; weld finish, acceptable criteria and the extent & method of non-destructive testing for each weld or group of welds. The Bidder/Supplier shall institute and maintain a record of all approved nondestructive tests and these records shall be readily available for verification by the Client/ Consultant. Bidder/Supplier shall submit all welding, heat treatment and manufacturing procedures for the approval of Client/ Consultant. Where only partial inspection is required, the location of the joints selected for testing shall be as agreed by the Purchaser/ Client/ Consultant. Should any of these welds prove to be defective on inspection, the number of welds to be tested in that system shall be twice that originally selected. Should any of the second increment welds prove to be defective, then 100 % of the welds in that system / group shall be tested.
l)
m)
n)
o)
p)
q)
r)
4.26.00 4.26.01
Castings, Forgings and Wrought Iron Products All castings, forgings and wrought iron products shall be subjected to chemical analysis, material tests and inspections in accordance with the applicable national and international standards except where otherwise agreed by the Purchaser/ Client / Consultant. Inspection should be scheduled in order to detect defects as early as possible, to avoid unnecessary delay in manufacture and delivery of the plant. Failure to Pass Tests If any item / equipment fail to pass any such test, the Bidder / Supplier shall rectify or replace the same and, unless Purchaser/Client agrees to dispense with repetition of the test, shall repeat the test following a further notice as describer under section 4.0. The cost and expense of any such retest shall be borne by the Bidder/Supplier himself.
4.27.00 4.27.01
SS-M3: 9
JIINDAL POWER J NDAL POWER LTD.. LTD 4.28.00 4.28.01
Tests On Electrical Equipment In Manufacturers Works All tests shall be carried out in the presence of the Purchaser/ Client unless otherwise agreed in writing. All instruments used shall have valid calibration certificates and the same shall be shown to Purchaser/ Client / Consultant on demand. The Bidder / Supplier shall provide measuring and test equipment required for inspections and tests. The above requirements are only indicative. Bidder /Supplier shall be completely responsible to draw on his own the applicable quality and statutory requirements for the equipment and items being supplied by him so that the stated and implied needs of the equipment/ items / systems are completely met. QUALITY ASSURANCE DOCUMENTS The Bidder / Supplier shall be required to submit hard copies (number of copies as agreed in the contract) of the following Quality Assurance documents: i) ii) Material mill test reports of components/ items. The quality assurance plan, inspection and check lists, test certificates, stage and final inspection report, dimensional reports, test procedures, verification sketches, documents used for guidance during inspection other than national and international standards, Witness reports, factory test results and other documents generated during or after inspection. Non-destructive examination interpretation reports. results reports including radiography
4.30.00
5.00.00 5.01.00
iii)
iv)
Type test results if conducted for the equipment supplied for the project or certified test result for an identical or essentially similar equipment, which satisfy Client/ Consultant. All the accepted deviations including complete technical details. As built drawings and sketches. Compliance certificate stating clearly that the supplied product/ service confirms to the technical specification requirements in totality. Soft copies of the drawings, documents, QAPs and FQPs.
v) vi) vii)
viii) 6.00.00 6.01.00
INSPECTION, TESTING AND INSPECTION CERTIFICATES The Engineer or his authorized representative acting on behalf of the Client, shall have access at all reasonable times to inspect and examine the materials and workmanship of the works during its manufacture or erection/construction including those parts which are being manufactured or assembled on others premises or works. The purpose of these visits may be for progress monitoring, investigating, inspecting and observing the execution of the works, including witnessing the tests.
SS-M3: 10
Bidder / Supplier shall arrange all necessary permits and approvals required for all such visits of Purchaser/ Client / his nominated representative from concerned authorities. Such approvals shall be arranged both for self manufactured items /equipments and as well as for items / equipments being manufactured at sub vendors works. 6.02.00 The Bidder / Supplier shall give Inspection authority/inspector advance written notice for inspection (advance notice period shall be as agreed in the contract) of any material being ready for testing at Shop. Such tests shall be to the Bidder / Suppliers account except for the expenses of the inspector's. The Engineer/ Inspector or his authorized representative, unless the witnessing of the tests is waived, shall attend such shop tests. All such inspection notice/ requests shall be made on the inspection call format of Purchaser only. The Purchaser/ Client will endeavor to schedule the inspection and tests so as to avoid undue risk of delaying the work. In the event of postponement of the inspection, tests and re inspection, or the necessity to make re-tests due to unsatisfactory results of the original tests, or other reasons attributable to the Bidder / Supplier, the Bidder / Supplier will bear all costs for new tests and the costs incurred by the Purchaser/ Client or his nominated representative in re-inspecting the non conforming item or its replacement. When the factory tests have been completed at the Bidder/Suppliers or sub-Bidder / Suppliers works, the Engineer shall issue a certificate / inspection report to this effect. Failure of the Engineer/inspector to issue such a certificate shall not prevent the Bidder / Supplier from proceeding with the works. The completion of these tests, or the issue of the certificates shall not bind the Purchaser/ Client to accept the equipment should it, on further tests or after erection be found not to comply with the contract. The Purchaser/ Client will make acceptance or rejection of the equipment and/or components as promptly as practicable following any inspection or test involvement. However, failure to inspect and accept or reject equipment and/or components shall neither relieve the Bidder/Supplier from responsibility for such items, which may not be in accordance with the specified requirements, nor impose liability for them on the Client. In all cases where the contract provides for tests whether at the premises or works of the Bidder / Supplier or any sub-vendor, the Bidder / Supplier, except where otherwise specified shall provide free of charge such items as labour, materials, electricity, fuel, water, stores, apparatus, instruments, connections / arrangements including statutory approvals (wherever required) as may be reasonably demanded by the Engineer/Inspector or his authorized representatives to carry out effectively such tests on the equipment. The inspection by Engineer or his authorized representative and issue of Inspection Certificate thereon shall in no way limit the liabilities and responsibilities of the Bidder / Supplier in respect of the agreed quality assurance programme forming a part of the contract.
6.03.00
6.04.00
6.05.00
6.06.00
6.07.00
SS-M3: 11
The inspection and tests by the Purchaser/ Client of any components or lots thereof does not relieve the Bidder / Supplier of any responsibility whatever regarding defects or other failures which may be found before the end of the warranty period. 6.08.00 To facilitate advance planning of inspection in addition to giving inspection notice as mentioned above, the Bidder / Supplier shall furnish ONE MONTH LOOK AHEAD SCHEDULE for shop testing indicating schedule dates of inspection at hold point and final inspection stages at least by 20th of the preceding month. No materials shall be put to work until all tests, analysis and inspections have been made and certified copies of reports of test and analysis or certificates have been accepted and released by the Purchaser/Client. The Purchaser/Client shall have complete authority to accept or reject any equipment or part thereof considered unsatisfactory and/or not in accordance with the specified agreed requirements. Any non-conformances observed by Purchaser/ Client during inspection stage shall be brought to the notice of the Bidder / Supplier. Re-inspection shall not be notified until all the deviations, non-conformance is either attended or appropriately disposed off by the Bidder / Supplier. Above quality assurance requirements shall also be applicable to the bought out items of the Bidder / Supplier. In the event of materials not made ready for inspection of Purchaser/Client by Bidder/Supplier on the requested / mutually agreed date for any reasons attributable to Bidder/Supplier, man day costs of inspection engineers of all concerned agencies who are involved in such inspection witness shall be charged to the Bidder / Supplier. GUIDELINES FOR MAKING NON-CONFORMANCE REPORT Any deviation from specifications/quality plans/applicable standards is referred as Non-Conformance and shall be documented. When a non-conformance is noticed the material shall be segregated and identified by the Bidder / Supplier as per his procedures. The manufacturer shall generate the non-conformance report (NCR) and send it to the Bidder / Supplier in case manufacturer is not the Bidder/ Supplier. In the NCR generated, it shall be clearly specified whether the activity has stopped or activity shall proceed upto certain stage only pending disposal of deviations. The Bidder / Supplier shall classify the deviations as major or minor as per the guidelines given below:i) Major Deviation
6.09.00
6.10.00
6.11.00
6.12.00
6.13.00
7.00.00 7.01.00
7.02.00
7.03.00
7.03.01
7.03.02
SS-M3: 12
Major deviation is defined as departure from specifications, which affects performance, reliability, safety, interchangeability and erection, commissioning or working life of the equipment/product. ii) Minor Deviation All other deviations not classified as major deviations shall be classified as minor deviations. 7.04.00 The non conformance report shall be duly filled in by the Bidder / Supplier giving the description of non-conformance, proposed dispositions with justifications and steps to prevent recurrence and submit it to Purchaser/ Client /its authorized representatives for disposal of deviations. Purchaser/ Client / its authorized representatives shall inform the Bidder / Supplier regarding the disposal of the deviations as given in the format. All items rejected shall be segregated and shall not be destroyed (wherever applicable) till completion of supplies from that manufacturer for the contract. INSPECTION & TESTING Type Tests The bidder shall carry out the type tests as listed in the LIST OF TESTS TO BE CONDUCTED on the equipment mentioned therein. The Bidder shall indicate the charges for each of these type tests separately and the same shall be considered for the evaluation of the Bids. The type test charges shall be paid only for the test(s) actually conducted successfully under this contract and upon certification. The type tests shall be carried out for which minimum 15 days notice shall be given by the Bidder. The Bidder shall obtain the approval for the type test procedure before conducting the type test. Irrespective of the requirement of conducting the type tests under this contract, the Bidder shall submit the reports of the type tests listed in the LIST OF TESTS TO BE CONDUCTED and carried out within last five years from the date of bid opening. These reports should be for the tests conducted on the equipment similar to those proposed to be supplied under this contract and the test (s) should have been either conducted at an independent laboratory or should have been witnessed by a client. Further the Bidder shall only submit the reports of the type tests as listed in LIST OF TESTS FOR WHICH REPORTS HAVE TO BE SUBMITTED and carried out within last five years from the date of bid opening. These reports should be for the tests conducted on the equipment similar to those proposed to be supplied under this contract and the test(s) should have been either conducted at an independent laboratory or should have been witnessed by a client. All acceptance and routine tests as per the specification and relevant standards shall be carried out. Charges for these shall be deemed to be included in the equipment
7.05.00
7.06.00
8.00.00 8.01.00 8.01.01
8.01.02
8.01.03
8.01.04
8.01.05
SS-M3: 13
JIINDAL POWER J NDAL POWER LTD.. LTD price. 8.01.06
All other tests as mentioned in approved Quality Assurance Plan and as per relevant Design Code shall be carried out. Gauges, Switches, Instruments etc: Accuracy, calibration, repeatability, material, dimension, functional tests and other checks shall be carried out as per relevant standard. Painting Painting of all surfaces shall be checked for shade (by shade card), coating thickness (DFT) and adhesion test/peal off test. Coating thickness meter and cross hatch tester respectively at random. Performance test. All tests shall be carried out as per relevant codes and standards and as specified in the data sheet. TYPE TESTS: Bidder to submit the Type test certificates for the type tests (as per applicable standards) conducted on similar equipment, which is not older than five years to the review and approval of Purchaser. However, if these certificates are not acceptable to purchaser, bidder may have to repeat these type tests in presence of Purchaser. There shall be no delivery and cost implications to Purchaser on account of these type tests. SITE TESTS After completion of erection at site, performance test and hydraulic test to 1.5 times of design pressure shall be conducted (on the complete assembly) rectification of all defects shall be carried out by the Bidder at no extra cost to the Purchaser. The performance tests shall be conducted at site to demonstrate guaranteed performance and rectification of all defects shall be done satisfactorily. If any equipment fails to meet the guaranteed performance, the performance test shall be repeated after rectifications / replacements are made till guaranteed performance is demonstrated satisfactorily by the Bidder. The Bidder in the presence of the Purchaser or his representative shall conduct the performance test. All tests shall be carried out as per relevant codes and standards and as specified in the data sheet.
SS-M3: 14
JIINDAL POWER LTD.. J NDAL POWER LTD
DIESEL GENERATORS DIESEL ENGINE Performance test as per BS-5514/or equivalent IS/ISO-Standard including Governing Test for 3 hours at full load and one hr. at 10% UT (On forging and piston Bonding) TESTS/CHECKS All other tests (if applicable) as per Spec./relevant Standard
ITEMS/COMPONENTS Crank shaft Y Y Y Y Cylinder blocks/heads Y Y Liner/ Radiator Y Y Rotating/moving parts other Y Y than crank shaft Piston Y Y Y Diesel Engine Y Y Y Y Y Y Note: This is an indicative list of tests / checks. The manufacturer is to furnish a detailed Quality Plan indicating the practice and procedure along with relevant supporting documents.
SS-M3: 15
Fuel consumption, rated power measurement, rate speed
Functional/Operation Test
Hydraulic/water fill test
Material Test
Assy./fit up
Dimension
Balancing
DP/MPI
ALTERNATOR TESTS/CHECKS Make/Type/Rating/TC/General Physical Inspection Hydraulic/Leak/Pressure Test Welding/Brazing (WPS/PQR)
ITEMS/COMPONENTS Plates for stator frame, end shield, spider etc. Shaft Magnetic Material Rotor Copper/Aluminium Stator copper SC Ring Insulating Material Tubes for Cooler Sleeve Bearing Stator/Rotor, Exciter Coils Castings, stator frame, terminal box and bearing housing etc.
Y Y Y Y Y Y Y Y Y Y Y
Y Y Y Y Y Y Y Y Y Y
Y Y Y Y Y Y Y Y Y Y Y
Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y
Y Y Y Y Y Y Y Y Y Y Y Y Y
SS-M3: 16
Tan delta, shaft voltage & polarization index test
Electrical Characteristics
Magnetic Characteristics
Thermal Characteristics
Mech/Chem. Properties
All tests as per IS-4722
Dynamic Balancing
NDT/DP/MPI/UT
Heat Treatment
Metallography
Dimensional
Over speed
Vibration
Run Out
Visual
ALTERNATOR TESTS/CHECKS Make/Type/Rating/TC/General Physical Inspection Hydraulic/Leak/Pressure Test Welding/Brazing (WPS/PQR)
ITEMS/COMPONENTS Fabrication & machining of stator, rotor, terminal box Wound stator Wound Exciter Rotor complete Exciter, Stator, Rotor, Terminal Box assembly Accessories, RTD, BTD, CT, AVR. Brushes, Diodes, Space heater, antifriction bearing, cable glands, lugs, gaskets etc. Alternator ( IS 4722)
Y Y Y Y Y Y
Y Y Y Y Y Y Y
Y Y Y Y Y Y Y
SS-M3: 17
Tan delta, shaft voltage & polarization index test Y1
Electrical Characteristics
Magnetic Characteristics
Thermal Characteristics
Mech/Chem. Properties
All tests as per IS-4722
Dynamic Balancing
NDT/DP/MPI/UT
Heat Treatment
Metallography
Dimensional
Over speed
Vibration
Run Out
Visual
Note: 1. 2.
This is an indicative list of tests / checks. The manufacturer is to furnish a detailed Quality Plan indicating the practice and procedure along with relevant supporting documents during QP finalisation. Make of all major bought out items will be subject to approval. Y1= for HT Machines only. FINAL ASSEMBLY No load test for one hour of the DG set assembly
TESTS/CHECKS Hydraulic/Leak/Pressure test All routine test as per Spec/IS Check completeness WPS/PQR/Welding
ITEMS/COMPONENTS Base frame Fuel Tank Battery (IS 1691) Battery Charger Control Panel Assembled DG Set Notes: 1. 2.
Y Y
Y Y
Y Y
Y Y
Y Y
Y Y Y Y
This is an indicative list of tests / checks. The manufacturer is to furnish a detailed Quality Plan indicating the practice and procedure along with relevant supporting documents. Make of all major Bought Out Items will be subject to approval.
SS-M3: 18
Clearances & Alignment Y
NDT/DP/MPI/UT
Functional Tests
Material Test
Dimension
JIINDAL POWER J NDAL POWER LTD.. LTD SL. NO. COMPONENET & OPERATION
MANUFACTURING QUALITY PLAN FOR -----------------------------MANUFACTURER: CHARATERISTIC S CLASS TYPE OF CHECK
EXHIBIT A PROJECT: PACKAGE: ITEM: QUATUM OF CHECK 6 REFER ENCE DOCU MENT 7 ACCEPTA NCE NORMS 8 FORMAT OF RECOR D 9
Q.P. NO & REV: DATE : PAGE : AGENCY M 10 C O 11 REMARK S
LEGEND: M: MANUFACTURER/SUB CONTRACTOR C: EPC CONTRACTOR O: OWNER/ CONSULTANT P: PERFORM V: VERIFY W: WITNESS
MANUFACTURER SEAL AND SIGN
CONTRACTOR SIGN AND SEAL
NAME & SIGN OF APPROVING AUTHORITY & SEAL
SS-M3: 19
JIINDAL POWER J NDAL POWER LTD.. LTD FIELD QUALITY PLAN FOR -----------MANUFACTURER: & CHARATERISTICS
---------------
JIINDAL POWER J NDAL POWER LTD.. LTD SL. NO. COMPONENET OPERATION
PROJECT: PACKAGE: ITEM: REFERENCE STANDAR D 6 FORMAT OF RECORD AGENCY C O
FQP. NO & REV: DATE : PAGE : REMARKS
TYPE OF CHECK
EXTENT OF CHECK
1 1
2 RECEIPT MATERIAL
3 OF
IN PROCESS CHECKS
FINAL CHECKS
MANUFACTURER SEAL AND SIGN CONTRACTOR SIGN AND SEAL NAME & SIGN OF APPROVING AUTHORITY & SEAL
LEGEND: M: MANUFACTURER/SUB CONTRACTOR C: EPC CONTRACTOR O: OWNER/ CONSULTANT P: PERFORM V: VERIFY W: WITNESS
SS-M3: 20
POWER POWER
SUB-SECTION: M4 PAINTING SPECIFICATION & PAINTING SCHEDULE
POWER POWER
SUB-SECTION: M4 PAINTING SPECIFICATION & PAINTING SCHEDULE

1.00.00 INTENT OF SPECIFICATION This section defines the technical requirements for surface preparation selection and application of paints on equipment, vessels, machinery, piping, ducts etc. However, manufacturers shall follow their standard procedures for painting their equipment. The Bidder shall submit a detailed painting procedure for approval of Employer / Employees Representative after the award of contract.
2.00.00 2.01.00
GENERAL INFORMATION The colour scheme of the entire Plant, covered under this specification shall be approved by the Purchaser in advance before application. Exterior and interior indicated herein pertain to outdoor and indoor whereas inside and outside pertain to internal and external surfaces of a particular item. All insulated piping shall have aluminum sheet jacketing. All interior and exterior piping, insulated and uninsulated shall have approved colour bands painted on the pipes at conspicuous places throughout the system, as approved by Purchaser. In areas where there is danger of spotting automobiles or other finally finished equipment or building by wind borne particles from paint spraying, a Purchaser approved method shall be adopted. Manufacturer's specific recommendation, if any, shall be followed during application of paints. The Tenderer shall follow relevant Indian and International Standards wherever possible in cleaning of surface, selection of paints and application. The following surface and material shall require painting : (a) All un-insulated carbon steel and alloy steel equipment like columns, vessels, drums, storage tanks, heat exchangers etc. All un-insulated carbon steel and low alloy piping, fitting and valves (including painting of identification marks). All pipe structural steel supports, walkways, platforms, hand rails, ladders etc.
2.02.00
2.03.00
2.04.00
2.05.00
2.06.00
2.07.00
(b)
(c)
2.08.00
The following surfaces and material shall not require painting;

SS-M4: 1
JIINDAL J NDAL LTD.. LTD (a) (b) (c) (d)
POWER POWER
Non-ferrous materials Austenitic stainless steel Plastic and for plastic coated materials Insulated surface of equipment and pipes except color coating wherever required Painted equipment like blowers, pumps, valves, etc., with finishing coats in good condition and with matching color-code.
(e)
3.00.00
Codes and Standards Painting of equipment shall be carried out as per the specifications indicated below and shall conform with the relevant IS specification for the material and workmanship. The following Indian Standards may be referred for carrying out the painting work: IS :5: IS : 1303 [S :2379 IS :2395 IS: 2338 Colors for ready mixed paints and enamels Glossary of terms relating to paints Color code for identification of pipelines. Code of practice for finishing of concrete, masonry and plaster surfaces (Parts I and II) Code or practice for finishing of wood and wood based materials (Parts I & II) Ready mixed paint, brushing, bituminous , black, lead free, acid, alkali, water and heat resisting Ready mixed paint, air drying, red oxide zinc chrome, and priming Ready mixed paint, brushing, zinc chrome, priming Enamel, synthetic, exterior (a) Undercoating (b) Finishing SIS : 55900 Swedish standard for blasting
IS: 158
IS: 2074
IS: 104 IS: 2932
SS-M4: 2
POWER POWER
Surface Preparation The surface shall be prepared in a manner suitable for coatings. Chemical derusters or rust conveners shall not be applied. Acid cleaning is subject to approval of Purchaser / Purchaser representative.
4.01.00
Blasting The surface of the part / component shall be blasted before the coating material is applied. Unless otherwise specified in the documents, the surface shall satisfy the following requirements after blasting: Blasting according to SIS 055900, Gr. Sa-2.5. Depending on production flow, weldable, ethyl zinc silicate shop primer, dry film thickness 15-25 microns shall be used.
4.02.00
Manual Rust Removal Manual rust removal shall be allowed for welded zones and for touching up installed components.
4.03.00
Cleaning Removal of impurity Impurity Removal (a) Dust, loose deposits (b) Adhesive deposits (c) Oils, greasy impurities (d) Salt deposits Impurity Removal Vacuum-cleaning, brushing Power brushing Wet blasting, use of detergent additives by agreement Rinsing
(e) Markings (e.g, felt tip pen) Organic solvents to manufacturer's specifications e.g., Trichloro trifluoro ethane and solvents containing acetone (renew solvent and rag frequently), 5.00.00 5.01.00 Processing General Application Conditions The primer shall be applied to properly prepared surfaces only. The specifications of the coating material manufacturers shall be observed. The minimum temperature shall be +5C and the relative humidity shall not
DOCUMENT NO.: K8B15-SPC-M-0023, REV -1 SS-M4: 3 DEVELOPMENT CONSULTANTS PVT. LTD.
POWER POWER
exceed 8GV The temperature of the work piece shall be atleast 3C above dew point. 5.02.00 Application Procedure The primer shall be applied by means of brush or by spray. The lop coats shall be applied by means of brush, roller or by spray. At points where coating application is interrupted, the individual layers shall be adequately stepped to ensure proper layer sequence when coating operations are resumed. 5.03.00 Touching Up Before each layer is applied, previous coating shall be touched up where necessary by rust removal and cleaning, according to manufacturer's specifications. The final top coat shall be reapplied completely, if required. 5.04.00 Uncoated Surfaces Moving parts of machines (e.g., stems, shafts, sliding and locating bearings), nameplates, instruments and sealing surface shall not be coated. Welds shall be left free of coating upto a distance of 30 mm on each side of the weld edge until erection and weld examinations, if any, have been completed. 5.05.00 Bond Strength The pull-off stress determined using the pull-off test method for adhesion shall be not less than 1.5 N/mm2, according lo ISO 4624.
6.00.00
Surface Conditions of Coating Surfaces The coating surface shall have a uniform film thickness, shade and gloss and shall be free from inclusions, sags and wrinkles,
7.00.00 7.01.00
Coating Systems General Requirements for Coating Systems Coating materials according to SSPC, BS 5493 or DIN 55 928 shall be used. Intermediate coats are to be pigmented with micaceous iron oxide, The materials shall be matched with each other so that they are compatible. Coatings deviating this specification shall be subject to approval. Standards of surface preparation and painting shall give a time to first maintenance of 10 years.
7.02.00
Standard Coating System (External Coatings)
SS-M4: 4
JIINDAL J NDAL LTD.. LTD (a)
POWER POWER
For painting of civil structures in general and other steel structures not covered below shall be carried out as specified in the Civil Section of the specification. Galvanised iron and steel requiring paint finish at site
(b) At site
Surface Treatment: Mechanical cleaning from contaminants by means of washing or steam jetting and sweep blasting with fine sand or etching (T Wash).
Touch-up mechanical damages: De rusting St 3 and application of high build epoxy primer DFT 80 microns.
Finish coating: Analogous to standard painting scheme.
7.03.00
Painting of indoor components such as valves, pumps, motors, electrical parts, tanks etc. At works Surface preparation: Blasting according to SIS 055900: Gr. Sa 2.5. Depending on production flow, a weldable, inorganic ethyl zinc silicate shop primer dry film thickness 15-25 microns, may be used. Prime coat: Two (2) layers of zinc phosphate epoxy, total dry film thickness 75 microns. At site Thorough cleaning to remove oil, grease, dirt and any oilier contaminants. Derusting of all mechanical damages according to SIS 055900 Grade ST3. Touch up with 1 pack inorganic ethyl zinc silicate, dry film thickness 50 microns. Finish coat: Two (2) layers of a 2 pack epoxy poly amide glossy, according to colour specification, dry film thickness 60 microns. Total system dry film thickness 135 microns.
SS-M4: 5
POWER POWER
Remarks: Equipment coated with a standard application system can be accepted if the quality of this application system is corresponding with the quality of the above mentioned system.
7.04.00
Painting of Outdoors equipment (external surfaces) such as piping, valves, pumps, motors, electrical parts, tanks, tie. Weather exposure, weather resistance, temperature up to 120C Surface Preparation: Blasting according to SIS 055900: Gr. Sa 2.5. Depending on production flow, a weldable, inorganic ethyl zinc silicate shop primer dry film thickness 15-25 microns, may be used. Prime Coat: Two (2) layers of zinc phosphate epoxy, total dry film thickness 75 microns. Intermediate Coat: One (1) layer 2 pack high build epoxy polyamide Mio, dry film thickness 100 microns. Finish Coat: One (1) layer of a 2 pack aliphatic polyurethane glossy minimum dry film thickness 50 microns. Total system dry film thickness 225 microns.
7.05.00 (a)
Special Coating System (External Coatings) Parts exposed to temperatures above 120C, up to 200C not insulated :
At works Surface Preparation:
Blasting according standard SIS 55900 Gr. Sa 2.5 and ISO 8501-1: 1988. Depending on production flow, a weldable, inorganic ethyl zinc silicate shop primer, dry film thickness 15-25 microns, may be used. Prime coat:
Inorganic ethyl zinc silicate, dry film thickness 75 microns. At site
SS-M4: 6
POWER POWER
Pre-Treatment: Derusting of all mechanical damages, according to ISO 8501-1: I988, grade St 3 Touch-up with 1 pack inorganic ethyl zinc silicate, dry film thickness 50 microns. Removal of all decontaminants from prime coat.
Intermediate Coat: 1 pack silicon acrylic, dry film thickness 35 microns.
Final coat: 1 pack silicon acrylic, dry film thickness 35 microns. Total system dry film thickness 145 microns. Final coat according to colour code.
(b)
Parts exposed to temperatures above 200C, up to 400C, not insulated: At works Surface Preparation: Blasting according to ISO 8501-1: 1988 grade Sa 2.5. Depending on production flow, a weldable, inorganic ethyl zinc silicate shop primer, dry film 15-25 microns, shall be used. Prime coat: Inorganic ethyl zinc silicate, dry film of thickness 75 microns, At site Pre-treatment Derusting of all mechanical damages, according standard Sa 2.5 to ISO 8501-1: 1988. Touch-up with coating system according to manufacturer's recommendations.
(c)
Insulated Paris, continuously exposed to condensing water or parts exposed to temperatures: For parts that are provided with insulation on site
i)
Insulated parts, exposed to condensing water At works Surface Preparation :

POWER POWER
Blasting according standard Sa 2.5 lo ISO 8501-1: 1988. Depending on production flow, a weldable, inorganic ethyl zinc silicate shop primer, dry film thickness 15-25 microns shall be used. Prime coat: Inorganic ethyl zinc silicate, dry film thickness 75microns. ii) Insulated parts exposed to temperatures Parts, exposed to temperatures up to <400 C at works Surface Preparation: Blasting according to standard Sa 2.5 to ISO 8501-1: 1988. Depending on production flow, a weldable, inorganic ethyl zinc silicate shop primer, dry film thickness 15-25 microns shall be used. Parts, exposed to temperatures above 400C at works (Steam pipes, pressure lubes and parts for the HRSG, such as heating surfaces, heaters and super heaters reheaters, etc.) Surface preparation: Blasting according standard Sa 2.5 to ISO 8501-1: 1988. Temporary primer: Varnish (d) Intermittent exposure due to condensing water/chemicals (Indoors) At works Surface preparation: Blasting according to standard Sa 2.5 to ISO 8501-1: 1988. Depending on production flow, a weldable, inorganic ethyl zinc silicate shop primer, dry film thickness 15-25 microns may be used. Prime Coat: Two layers of zinc phosphate epoxy primer total dry film thickness greater than or equal to 75 microns. At site Pretreatment:
SS-M4: 8
POWER POWER
Derusting of all mechanical damages, according standard Sa 3 to ISO 8501-1: 1988, touch-up with 2 pack high build epoxy with volume solid content of more than 85%, DFT 75 microns. Intermediate Coat: 2 pack high build epoxy, dry film thickness 50 microns. Finish coat: 2 pack epoxy according to colour appearance, dry film thickness of 50 microns. Total system dry film thickness 205 microns. When exposed to weathering, weather resistance finish coat shall be applied. (e) Water exposure Surfaces permanently or predominantly in contact with water At site / works Pretreatment: Removal of all welding pearls. Blasting according standard Sa 3 to ISO 8501-1: 1988 Coat: 4 coats 2 pack coal-tar-epoxy, dry film thickness 125 microns each. Total system dry film thickness 500 microns. Touch-up after erection as required. 7.06.00 (a) Buried / underground piping system Where pipelines are buried, underground protection shall be provided for the piping system as indicated in any one of the methods given below:
i)
Coal tar primer, coal tar enamel, inner wrap of fibre glass, final outer wrap of enamel impregnated fibre glass. Total thickness of coating shall not be less than 4.0 mm. With anti-corrosive tape of minimum 4mm thick conforming to IS-10221 and AWWA C 203-93. Pipe surfaces shall be cleaned by shot or sand blasting before application.
ii)
(b)
SS-M4: 9
POWER POWER
Tests to be carried out after application i) ii) Bond / Adhesion test Holiday lest
8.00.00 8.01.00
INTERNAL COATINGS Tanks (Internal Surfaces) as specified in relevant sections of specification. Industrial, deionised, demineralised and potable water upto 60C pH range: 4.5 - 9.5. Blasting according to ISO 8501-1: 1988, Gr. Sa 2.5 Prime coat: Two layers of zinc phosphate epoxy primer total DFT greater than or equal to 75 microns. Pretreatment: Derusting of all mechanical damages, according to standard Sa 3 to ISO 8501-1:1988, touch up with 2 pack high build epoxy with volume solid content of more than 85%, DFT 75 microns. Intermediate coat : 2 pack high build epoxy, dry film thickness 80 microns. Finish coats: 2 pack solvent free epoxy paint dry film thickness 150 microns per coat. In case of service or potable water tanks, the coating material selected shall not taint the water. QA / QC procedure, including pinhole inspection shall be submitted for approval by Purchaser.
8.02.00
Rubber Lining of Pipes, Valves and Tanks as specified in relevant sections At works Pretreatment: Blasting according standard 2.5 to ISO 8501-1 : 1988.
SS-M4: 10
POWER POWER
Rubber lining:
Hard-rubber 5mm for DM water applications, thickness greater than or equal to 3 mm for others. In case of failure of rubber lining for both pipes and vessels, the rubber lining shall be replaced by COROCOAT. 9.00.00 9.01.00 Painting for Electrical Items All the steel work shall be thoroughly cleaned of rust, scale, oil, grease, dirt and swarf by pickling, emulsion cleaning, etc. The sheet steel shall be phosphated / oven dried and then painted with two coats of zinc rich primer paint. After application of the primer, two coats of finishing synthetic enamel paint shall be applied. The colour of the finishing coats inside shall be glossy white and exterior of the treated sheet steel shall be shade 631 of IS-5 / RAL 7032 for all switchboard/MCC/ Distribution boards, control panels, etc. All electrical equipment shall be given tropical and fungicidal treatment and outdoor equipment shall be provided with rain hood to prevent entry of rain water into the equipment. Documentation Engineering submittals shall identify the painting/coating and lining systems to be applied in the shop and the field. Data to be provided shall include the surfaces to be painted, the painting/coating system manufacturers name and product designation, the degree of surface preparation, dry film thickness, finish colour, and material safety and data sheets (MSDS).
9.02.00
10.00.00
11.00.00
EQUIPMENT DATA The Tenderer shall submit complete list of paints and primers proposed, giving detail information, such as, chemical composition, drying time etc. and also unit rates of each type of paint shall be furnished.
SS-M4: 11
O.P. Jindal Super Thermal Power Project (4 x 600 MW)
TECHNICAL SPECIFCATIONS OF ELECTRICAL EQUIPMENT
CONTENT
SUB - SECTION DESCRIPTION
E0
GENERAL ELECTRICAL SPECIFICATION
E1
A C MOTOR
E2
POWER CONTROL CENTER (PCC) & AMF CONTROL CUM ANNUNCIATION PANEL GENERATOR
E3
E4
BATTERY & BATTERY CHARGER
E5
ERECTION, TESTING & COMMISSIONING
SUB SECTION - E0 GENERAL ELECTRICAL SPECIFICATION
CONTENT CLAUSE NO. 1.00.00 2.00.00 3.00.00 4.00.00 5.00.00 DESCRIPTION SCOPE OF WORK TERMINAL POINTS EXCLUSION FROM SCOPE OF WORK CODES & STANDARDS ` CO-ORDINATION WITH STATUTORY BODIES AND OUTSIDE AGENCIES DEVIATIONS SERVICE CONDITIONS SYSTEM PARAMETRS AND VARIATIONS DESIGN CRITERIA PAINTING AND TROPICAL PROTECTION TEST / WITNESSING THE TEST / TEST CERTIFICATE LOAD BANK CABLING GROUNDING TESTS SPARE PARTS DRAWINGS, DATA AND MANUALS PAGE NO. 1 2 3 3
3 4 4 4 4 5 5
6.00.00 7.00.00 8.00.00 9.00.00 10.00.00 11.00.00
12.00.00 13.00.00 14.00.00 15.00.00 16.00.00 17.00.00
6 6 7 8 8 8
SUB-SECTION E0 GENERAL ELECTRICAL SPECIFICATION FOR DIESEL GENERATOR 1.00.00 1.01.00 SCOPE OF WORK This specification is intended to cover design, manufacture, assembly, testing at manufacturer's works, supply & delivery, properly packed for transport F.O.R. site of supply and installation, testing, commissioning and putting into successful commercial operation of plant emergency DG system comprising five (5) nos. diesel generators, excitation system equipment, motors, AMF panels, water immersed load bank, load bank switchgear, and all other equipment and accessories, as required. The scope shall include the equipment described herein under but not limited to these only. Any item, which is not specifically mentioned in this specification but necessary for safe and efficient operation of the Diesel Generator system, shall be provided by the Bidder. Broad scope of supply and installation of electrical equipment are listed below and they are further detailed in relevant sections of this specification. DG power control center (PCC) for unit as well as stand by DG (supply of DG PCC by Owner as a free issue item), Load bank switchgear, AMF control cum annunciation panels. Load Bank Electric motors Battery & Battery charger Diesel generator & accessories Installation, testing and commissioning of above electrical equipment, cabling (supply of cable by Owner as a free issue item) and above grade grounding work including supply of grounding material, cable termination kits, glands, lugs, pre fabricated cable trays / racks, steel supports, structures and all other erection consumables, hardware, material and accessories, labor, tools and tackle etc. as required. The scope of supply shall also include the following with respect to each electrical equipment: Fittings and accessories as required. Recommended spare parts for three (3) years of satisfactory operation One (1) set of special tools and tackle as applicable for individual equipment. All relevant drawings, data and instruction manuals
1.02.00
1.03.00
1.03.01
1.03.02 1.03.03 1.03.04 1.03.05 1.03.06
1.04.00
1.04.01 1.04.02 1.04.03 1.04.04
E0: 1
1.05.00
Further, the scope of work shall include complete design and detail engineering of electrical equipment / system under DG package. Following minimum document / drawings shall be submitted by the Bidder as part of above scope Complete engineering Bill of Material Detail single line diagram of 415V DG PCC, Load bank power control center. Design calculation and sizing of electrical equipment. Control schemes / wiring diagrams of Load Bank PCC, AMF panel, Load bank and for other equipment / system. DDCMIS I/O list LV power and control cable schedule and interconnection charts. Electrical and cable routing layout of Diesel Generator building, showing, cable tray/ trench, cable routes etc. Civil assignment drawings shall be prepared by others based on the above layout drawings submitted by the Bidder. Grounding layout drawings for over ground earthing of equipment. Installation, testing, commissioning, operation and maintenance manual. All relevant civil inputs such as foundation plan and loading of each electrical equipment, co ordinates of insert plates for building steel / concrete etc. The work is subject to all the terms and conditions detailed in the document listed below, which shall form part of this specification as if bound together. a. b. c. d. Tender Notice Commercial Evaluation Format ITB and Draft Contract Agreement Proposal Exhibits
1.05.01 1.05.02 1.05.03 1.05.04
1.05.05 1.05.06 1.05.07
1.05.08 1.05.09 1.05.10
1.06.00
1.07.00 1.08.00 1.09.00 2.00.00 2.01.00
In the event of any discrepancy with listed documents, the stipulation of this specification shall govern. Furnishing complete information with regard to requirement (type & rating) of Local Push Button Station (LPBS) for procurement of Owner. Preparation of cable tray/trench layout of DG electrical building including interconnection with DG sets. TERMINAL POINTS Laying and termination of 415V power supply cable from Emergency MCC to 415V DG PCC shall be carried out by Owner. All further power cabling from 415V DG PCC to various other loads pertaining to DG system including supply, laying and termination of cables, cable trays, supports and accessories shall be included in the scope of Bidder. As regards control cable, interface cabling between DG system and equipment outside DG electrical building shall be included under the scope of Owner. Terminals required for such interfaces shall be wired up and terminated at a junction box located at a
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2.02.00
convenient location in DG electrical building by the Bidder for further cabling by Owner. Apart from above, all other control and special cabling within DG system including supply and installation of cable trays supports and accessories shall be included under the scope of Bidder. 2.03.00 3.00.00 3.01.00 3.02.00 3.03.00 3.04.00 3.05.00 3.06.00 3.07.00 4.00.00 4.01.00 Structure / equipment grounding shall be carried out by the bidder through risers, from Owners below ground earth mat. EXCLUSION FROM SCOPE OF WORK Illumination system Fire fighting system Intercommunication system Supply of Power, Control & Instrument cable Supply of Local Push Button Station (LPBS) Supply of DG PCC s & Emergency MCC Underground Earth Grid CODES AND STANDARDS The equipment offered under this package shall comply with the relevant Indian Standards, IEC or British Standards or applicable National / International Standards. In case any discrepancy arises, the most stringent one shall be followed. Equipment conforming to any other national standard, which ensures equivalent or better quality, may be accepted. In such case, copies of the English version of the standard adopted shall be furnished along with the proposal. The successful Bidder shall be responsible for obtaining necessary approval and making whatever additions/modifications considered necessary by the electrical Inspectors and other statutory authorities to bring the installation in conformity with the above Rules / Regulations. All electrical installation work shall comply with the provisions of the Indian Electricity Act and the Indian Electricity Rules as amended upto date and relevant IS codes of practice. CO-ORDINATION WITH STATUTORY BODIES AND OUTSIDE AGENCIES The Bidder shall be fully responsible for carrying out all coordination and liaison work with Electrical Inspectors (including approval), Factory Inspector, and other statutory bodies for implementation of the work. Applications on behalf of the Owner, for submission to the Electrical Inspector and other statutory bodies along with necessary drawings etc. shall be prepared by the Bidder. Approved drawings and certificates shall be submitted to the Owner/Consultant well ahead of schedule so that the actual commissioning of equipment does not get delayed for want of inspection and approval by the Inspector and other statutory bodies.
4.02.00
4.03.00
4.04.00
5.00.00 5.01.00
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6.00.00 6.01.00
DEVIATIONS The scope of supply, installation and commissioning work considered by the Bidder shall be clearly spelt out in the offer. Any intended omissions or deviations must be clearly stated giving reference to clause no. of tender specification. Otherwise, it shall be construed that there is no deviation in Bidders offer and the same is in strict compliance with the tender specification. SERVICE CONDITIONS The equipment will be installed in hot, humid and tropical atmosphere, highly polluted at places with coal dust and/or fly ash. Unless otherwise noted, electrical equipment/system design shall be based on the service conditions and auxiliary power supply given in the annexure of this specification. Where the equipment are to operate in the vicinity of high temperature zone, or installed outside and exposed to direct sun rays, suitable de rating shall be taken into consideration for higher ambient temperature and rigorous weather conditions, as applicable. SYSTEM PARAMETRS AND VARIATIONS System parameters for utility systems are detailed below.
7.00.00 7.01.00
7.02.00
7.03.00
8.00.00 8.01.00
System Volt. & Frequency a) b) 415V 10%, 3Ph, 4 wire, 50 Hz 5% Control, indication, space heater, panel interior lighting, receptacles and general power
Fault Level 50 KA (1 sec) 110V 10%
Grounding Solidly earthed 1Ph, 50 Hz, 5%
Combined voltage and frequency variation 10% (absolute sum) c) 220 V DC () 15% to (+) 10%, 2 wire 25 KA Unearthed
In case power supply in addition to those indicated above is required for some of Bidders equipment, the Bidder shall make his own arrangement by providing necessary conversion, rectification and transformation equipment. 9.00.00 9.01.00 DESIGN CRITERIA For continuous operation at specified ratings, temperature rise of all electrical equipment shall be limited to permissible values stipulated in relevant standard and / or this specification
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9.02.00
9.03.00
All electrical equipment and components thereof shall be capable of withstanding the mechanical forces and thermal stresses of listed short circuit current with out any deterioration or damage to the material. Selection of component for motor starters shall comply with coordination type-II as per IS-13947 / IEC-947. Bidder shall furnish electrical component selection chart for Owners approval. All electrical equipment, accessories and wiring shall have fungus protection involving special treatment of insulation and metal against fungus, insects and corrosion. PAINTING AND TROPICAL PROTECTION Painting / coating system shall provide an optimum life expectancy of 10 years from the time of original painting. The optimum life of a painting/coating system shall be considered the time until first maintenance painting / touch up should occur with 3 to 5 percent breakdown of the top coat, before active rusting begins. Surfaces of equipment, which are inaccessible after assembly, shall be protected for the life of the equipment. All surfaces shall be sand blasted, pickled and grounded as required to produce a smooth, clean surface free of scale, grease and rust before painting. After cleaning, the surfaces shall be given a phosphate coating followed by 2 coats of high quality rust resistant primer and stoved after each coat. This shall be followed by two coats of epoxy finish painting of approved color shade. Sufficient quantity of touch-up paint shall be furnished for application at site. Exact color shade shall be informed to the successful Bidder during detail engineering. Structural steel members to be galvanized shall be pickled after completion of fabrication process. Pickling shall remove scale, rust, grease, and other impurities. Steel shall be hot-dip galvanized in accordance with ASTM A123 or equivalent. For bolted connections, where either member to be bolted is galvanized, erection and structural bolts shall be galvanized in accordance with ASTM A153. All equipment, accessories and wiring shall have fungus protection involving special treatment of insulation and metal against fungus, insects and corrosion Ventilated equipment shall have fine mesh / screened louvers to prevent entrance of pests and dusts. TEST/ WITNESSING THE TEST / TEST CERTIFICATE The successful Bidder shall carry out all routine tests and any other special tests as per relevant standards or as may be agreed with the Owner or required by the electrical inspector for various equipment. Type test certificates of identical type and rating of equipment shall be furnished for approval of Owner / consultant, otherwise type test shall be carried out by the Bidder within the contracted price and delivery period. Certificates of type tests performed before five (5) years are not acceptable. Tests shall be performed in presence of Owner's representative, if so desired by the Owner. The successful Bidder shall give at least fifteen (15) days advance notice of the date when the tests are to be carried out. Three (3) copies each of the routine and type test certificate shall be submitted by the Bidder for approval of Owner before dispatch of the equipment from works. No
9.04.00
10.00.00 10.01.00
10.02.00
10.03.00
10.04.00
10.05.00
. 11.00.00 11.01.00
11.02.00
equipment shall be dispatched to site before getting approval of test certificates from Owner. 11.03.00 After completion of erection work at site, different equipment / system of the installation shall be tested by the Bidder, with an advance notice to the Owner. The Bidder shall prepare pre-commissioning test pro forma of each equipment/work/system indicating their data. The pro forma shall be submitted to Owner for approval. Reference shall also be made to manufacturers requirement / recommendation and procedure to be followed for site tests. List of site tests to be performed with respect to individual equipment / system are given elsewhere in the specification. The test result of any installation or equipment or its parts, if considered unsatisfactory by the Owner, the installation/equipment and its accessories shall be properly rectified and tested again by the Bidder free of cost to the satisfaction of the Owner. LOAD BANK The load bank shall be water immersed. The tank for the load bank shall be adequately sized and a make-up tank shall be supplied for complementing the water requirement during load testing. The water level shall be controlled automatically through level controller such that the load fluctuation is limited to +/-2.5%. The step loading shall be possible by changing the level such that constant loading is possible at 25%, 50%, 75% and 100%. The electrodes provided shall be corrosion proof as it will remain dipped in water with terminal connection for cables supplied by the bidder. Bidder shall furnish with details of load bank and the control philosophy in their offer. The Bidder shall supply the switchboard as per attached single line diagram. Interlock shall be provided in order to ensure only one DG is connected with the load bank at any point of time. CABLING 415V power cables, laid in tray shall be in touching formation in single layer. Single core power cables shall be laid in trefoil formation and shall have 2D distance (center-to-center) between two trefoils. 415V power cables, if directly buried in ground (at a depth of 1000mm from ground level), shall be laid in touching formation in single layer. Single core power cables shall be laid in trefoil formation and shall have 150mm distance (center-to-center) between two trefoils. The highest voltage grade cable shall be laid in the topmost tray and other voltage grade cable in the lower trays in descending order. The order of cable laying starting from top of the tray is given below. a. b. c. 13.04.00 415 V AC / 220V DC power cables Control cables Instrumentation and signal cable
12.00.00 12.01.00
12.02.00
13.00.00 13.01.00
13.02.00
13.03.00
All control cables and instrumentation cables shall be laid in multi layers touching each other.
13.05.00 13.06.00
Adequate space will be provided to facilitate installation of cable system and to allow routine inspection and modification after installation. Cable tray and conduit systems shall be electrically continuous and grounded. Further they shall be so constructed as to prevent drainage of water into equipment or building. A.C. and D.C. circuits shall not be run in same cable. Further separately fused circuits shall be run in separate cables. Cables for redundant equipment/system shall be run in separate trays. All openings in the floor and wall for cable access shall be sealed after installation of the cable system with non-inflammable materials. GROUNDING All electrical equipment enclosures, supporting structures, conduit and tray system shall be effectively grounded. Electrical equipment shall be provided with two separate and distinct grounding pads, each complete with tapped hole, galvanized bolt and spring washer for connection to station ground conductors Above Grade Grounding a. Enclosures of all electrical equipment such as PCC, AMF panel, LPBS etc. shall be earthed by two separate and distinct earth connections. Risers shall be brought through the ground floor and connected to the building steel and the selected equipment. The grounding system shall be extended by way of risers and conductors installed in cable tray. The earth connectivity leads from individual equipment shall be connected to the nearest conductor running in the topmost tray of the cable raceway system in the vicinity. Taps from runway conductor shall be taken to each section of other trays at an interval of about 30m. The runway conductor is connected to the below ground grounding system at every available building column within plant building and through risers at approximately 20m interval in outdoor trestle / trenches. Galvanized steel flats shall run as main earth conductor along building columns / walls and securely fixed to the same by welding / clamping at intervals not exceeding 1500 mm. All structures, alternate columns and stairs, metallic handrails, etc. shall be earthed at least at one point. Fence within the ground grid shall be bonded to the plant grid system at regular interval not exceeding ten (10) meters. Above grade ground conductor connections shall be welded except at the equipment end, where the connections are bolted.
13.07.00
13.0816.00
14.00.00 14.01.00
14.01.01
b.
c.
d.
14.01.02
Following minimum sizes of grounding material shall be used: Sl. No 1. 2. 415V motors
Item 415V DG PCC, Load bank switchgear
Material Galvanized flat
Size 50x6mm GS flat
O.P. Jindal Super Thermal Power Project (4 x 600 MW) Size 50x6mm GS flat 35x6mm GS flat 25x3mm GI flat 8SWG GI wire 50 x 6 mm GI flat 8 SWG GI wire 50 x 6 mm GI flat
Sl. No
Item Above 125KW up to 160KW Above 22KW up to 125KW Above 5.5KW up to 22KW Up to 5.5KW
Material Galvanized flat Galvanized flat Galvanized flat GI wire Galvanized flat GI wire Galvanized flat
3. 4. 5.
AMF Control & annunciation panel Push Button stations, welding receptacles and single phase DB Steel structure, cable trays, fence, rails
For further details of grounding system refer GROUNDING NOTES and DETAILS (doc. No. K8B15-DWG-E-0600) attached. 15.00.00 15.01.00 TESTS Upon completion, each equipment shall be subject to standard routine tests as per I.S. In addition, any special test called for in the main package specification shall be performed. As required copies of routine tests certificates shall be submitted for approval prior to despatch of the concerned equipments from works. Type test certificates, if called for by the Owner, shall be furnished for approval. SPARE PARTS For each electrical equipment the Bidder shall submit a recommended list of spare parts for five (5) years' continuous operation along with their item wise price. Commissioning spares, as required during commissioning of electrical equipment shall be considered as included in Bidders scope. DRAWINGS, DATA AND MANUALS Drawings, data and manuals for the different equipment shall be submitted as indicated below: 17.01.00 Along with the bid a) b) c) d) e) f. List of different equipment Single line diagram Technical leaflets and general constructional details Foundation plan and loading Type test report of similar equipment List of deviations, if any.
15.02.00
15.03.00 16.00.00 16.01.00
17.00.00
g.
List of makes of various items / components shall be submitted for Owners approval.
17.02.00
After award of the Contract for approval a) Dimensional general arrangement drawing of Load Bank PCC, AMF control cum annunciation panel, load bank and other electrical equipment (A) Foundation plan and loading data of each equipment (A) Final electrical load list.(A) Bill of quantities (R) Single line diagram, Control schematic and wiring diagram (A) Synchronizing scheme (A) Complete electrical layout of DG electrical building showing disposition of electrical equipment, cable tray arrangement, sectional view of building, interconnection with DG sets.(A) Cable Schedule & Interconnection diagram. (A) Erection and maintenance manual. (R) Control & Operational Philosophy (R)
b) c) d) e) f) g)
h) i) j)
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SUB SECTION - E1 TECHNICAL SPECIFCATION OF A.C. MOTOR
CONTENT
CLAUSE NO. 1.00.00 2.00.00 3.00.00 4.00.00 5.00.00 6.00.00 7.00.00 8.00.00 9.00.00 10.00.00 11.00.00
DESCRIPTION SCOPE STANDARDS SERVICE CONDITIONS TYPE AND RATING PERFORMANCE SPECIFIC REQUIREMENTS ACCESSORIES TESTS MANDATORY SPARE PARTS DRAWINGS, DATA & MANUALS DESIGN DATA
PAGE NO. 1 1 1 1 2 3 5 6 7 8 9
TECHNICAL SPECIFICATION FOR A.C MOTORS 1.00.00 1.01.00 SCOPE This section covers the general requirements of the drive motors for Diesel Generator system equipment for 4x600MW O.P. Jindal Super Thermal Power Plant at TAMNAR, RAIGARH, CHHATISHGARH Motors shall be furnished in accordance with both this general specification and the accompanying driven equipment specification. In case of any discrepancy, the driven equipment specification shall govern. STANDARDS All motors shall conform to the latest applicable IS, IEC and CBIP Standards/Publications except when otherwise stated herein or in the driven equipment specification. Major standards, which shall be followed, are listed below other applicable Indian Standards for any component part even if not covered in the listed standards shall also be followed: IS-325 IS-12615 IEC-34 3.00.00 3.01.00 SERVICE CONDITIONS The motors will be installed in hot, humid and tropical atmosphere, highly polluted at places with coal dust and/or fly ash. Unless otherwise noted, electrical equipment/system design shall be based on the service conditions and auxiliary power supply given in the annexure to this specification. For motor installed outdoor and exposed to direct sunrays, the effect of solar heat shall be considered in the determination of the design ambient temperature. TYPE AND RATING A.C. Motors Motors shall be general purpose, constant speed, squirrel cage, three/single phase, induction type. All motors shall be rated for continuous duty. They shall also be suitable for long period of inactivity.
1.02.00
1.03.00 2.00.00 2.01.00
2.02.00
3.02.00
3.03.00
4.00.00 4.01.00 4.01.01
4.01.02
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4.01.03
The motor name-plate rating at 50 Deg.C shall have at least 15% margin over the input power requirement of the driven equipment at rated duty point unless stated otherwise in driven equipment specification or in general electrical specification. The motor characteristics shall match the requirements of the driven equipment so that adequate starting, accelerating, pull up, break down and full load torques are available for the intended service. Motors rated up to 160kW shall be suitable for operation at a voltage level of 415 volt. PERFORMANCE Running Requirements Motor shall run continuously at rated output over the entire range of voltage and frequency variations as given in the annexure The motor shall be capable of operating satisfactorily at full load for 5 minutes without injurious heating with 75% rated voltage at motor terminals. Starting Requirements LT Motor shall be designed for direct on line starting at full voltage. Starting current shall not exceed 6 times full load current for all auxiliaries. The motor shall be capable of withstanding the stresses imposed if started at 110% rated voltage. Motor shall start with rated load and accelerate to full speed with 80% rated voltage at motor terminals. a) The motor shall be capable of five starts in an hour, the motor initially being at a temperature not exceeding the rated load operating temperature. The motor shall be capable of the motor shall be capable of two starts in succession with coasting to rest between starts and the motor initially at rated operating temperature, all at full load.
4.01.04
4.01.05 5.00.00 5.01.00 5.01.01
5.01.02
5.02.00 5.02.01
5.02.02
5.02.03
5.02.04
b)
5.02.05
Pump motor subject to reverse rotation shall be designed to withstand the stresses encountered when starting with non-energized shaft rotating at 125% rated speed in reverse direction. Stress During Slow/ Fast Auto Bus Transfer The motor may be subjected to sudden application of 150% rated voltage during bus transfer, due to the phase difference between the incoming voltage and motor residual voltage. The motor shall be designed to withstand any torsional and/or high current stresses, which may result, without experiencing any deterioration in the normal life and performance characteristics. Locked Rotor Withstand Time
5.03.00 5.03.01
5.03.02
5.04.00
5.04.01
The locked rotor withstand time under hot condition at 110% rated voltage shall be more than motor starting time by at least 2.5 seconds for motors upto 20 seconds starting time and by 5 seconds for motor with more than 20 seconds starting time. Starting time mentioned above is at minimum permissible voltage of 80% rated voltage. Hot thermal withstand curve shall have a margin of at least 15% over the full load current of the motor to permit relay setting utilising motor rated capacity. SPECIFIC REQUIREMENTS Enclosure All motor enclosures shall conform to the degree of protection IPW-55 unless otherwise specified. Motor for outdoor or semi-outdoor service shall be of weather-proof construction. For hazardous area approved type of increased safety enclosure shall be furnished. Motor shall be designed on 50 degC ambient temperature. Motor shall be suitable for bi-directional rotation. Cooling The motor shall be self ventilated type, either totally enclosed fan cooled (TEFC) or closed air circuit air cooled (CACA). Winding and Insulation All insulated winding shall be of electrolytic copper. Motors shall have class F insulation but limited to class B temperature rise. Windings shall be impregnated to make them non-hygroscopic and oil resistant. Tropical Protection All motors shall have fungus protection involving special treatment of insulation and metal against fungus, insects and corrosion. All fittings and hardware shall be corrosion resistant. Bearings Motor shall be provided with antifriction bearings, unless sleeve bearings are required by the motor application. Vertical shaft motors shall be provided with thrust and guide bearings. Thrust bearing of tilting pad type (Mitchel or Kingsbury) is preferred.
5.04.02 5.04.03
6.00.00 6.01.00 6.01.01
6.01.02 6.01.03 6.01.04 6.02.00 6.02.01
6.03.00 6.03.01 6.03.02 6.03.03 6.04.00 6.04.01
6.04.02 6.05.00 6.05.01
6.05.02
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6.05.03 6.05.04
Bearings shall be provided with seals to prevent leakage of lubricant or entrance of foreign matters like dirt, water etc. into the bearing area. Sleeve bearings shall be split type, ring oiled, with permanently aligned, close running shaft sleeves. Grease lubricated bearings shall be prelubricated and shall have provisions for in-service positive lubrication with drains to guard against over lubrication. Oiled bearing shall have an integral self cooled oil reservoir with oil ring inspection ports, oil sight glass with oil level marked for standstill and running conditions and oil fill and drain plugs. Lubricant shall not deteriorate under all service conditions. The lubricant shall be limited to normally available types with IOC equivalent. All LT motors upto 30 KW rating shall be provided with ball bearings. Bearings shall be insulated as required preventing shaft current and resultant bearing damage. Noise & Vibration The noise level shall be as per NEMA. The peak amplitude of the vibration shall be within IS specified limits. Motor Terminal Box Motor terminal box shall be detachable type and located in accordance with Indian Standards clearing the motor base- plate/ foundation Terminal box shall be capable of being turned 360 Deg. in steps of 90 Deg., unless otherwise approved. The terminal box shall be split type with removable cover with access to connections and shall have the same degree of protection as motor. The terminal box shall have sufficient space inside for termination/connection of XLPE (415V) insulated armoured aluminium cables. Terminals shall be stud or lead wire type, substantially constructed and thoroughly insulated from the frame. Not more than two wires shall be connected to any terminal. 20% of total terminal used in each terminal block shall be provided as spare. The terminals shall be clearly identified by phase markings, with corresponding direction of rotation marked on the non-driving end of the motor. The terminal box shall be capable of withstanding maximum system fault current for a duration of 0.25 sec. Motor terminal box shall be furnished with suitable cable lugs and double compression brass glands to match with cable used.
6.05.05
6.05.06
6.05.07
6.05.08 6.05.09
6.06.00 6.06.01 6.06.02 6.07.00 6.07.01
6.07.02
6.07.03
6.07.04
6.07.05
6.07.06
6.07.07
6.07.08
6.07.09 6.07.10
The gland plate for single core cable shall be non-magnetic type. Additional epoxy insulator with bus bar shall be provided for connection of 2 or more cables per phase, if required during detail engineering without any extra cost. Grounding The frame of each motor shall be provided with two separate and distinct grounding pads complete with tapped hole, GI bolts and bimetallic washer. The grounding connection shall be suitable for accommodation of ground conductors as follows : Motor above 90 KW Motor above 30 KW up to 90 KW : Motor above 5 KW up to 30 KW Motor upto 5 KW : : : 50 x 6 mm GS Flat 50 x 6 mm GS Flat 50 x 6 mm GS Flat 25x 3 mm GS Flat
6.08.00 6.08.01
6.08.02
6.08.03 6.09.00
The cable terminal box shall have a separate grounding pad. Rating Plate In addition to the minimum information required by IS, the following information shall be shown on motor rating plate: a) b) c) d) e) f). g) h) I) j) k) Temperature rise in Deg.C under rated condition and method of measurement. Degree of protection. Bearing identification no. and recommended lubricant. Location of insulated bearings. Motor frame Size Starting limitations Direction of rotation and voltage sequence Insulation System class designation Service factor/duty. For motors connected to an external lubricant re circulating system, or with an integral forced lubrication system, oil pressure and oil flow shall be mentioned. Motors designed for hazardous application: -Location class and group designation shall be mentioned - Maximum operating temperature value or operating temperature code number shall be mentioned.
7.00.00 7.01.00
ACCESSORIES General Accessories shall be furnished, as listed below, or if otherwise required by driven equipment specification or application.
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7.02.00 7.02.01 7.02.02
Space Heater Motor of rating 30 KW and above shall be provided with space heaters, suitably located for easy removal or replacement. The space heater shall be rated 240 V, 1 phase 50 Hz and sized to maintain the motor internal temperature above dew point when the motor is idle. Accessory Terminal Box All accessory equipment such as space heater, temperature detector, current transformers etc., shall be wired to and terminated in terminal boxes, separate from and independent of motor (power) terminal box. Accessory terminal box shall be complete with double compression brass glands and pressure type terminals to suit owner's cable connections. Drain Plug Motor shall have drain plugs so located that they will drain the water, resulting from the condensation or other causes from all pockets of the motor casing.
7.03.00 7.03.01
7.03.02
7.04.00
7.05.00
Lifting Provisions Motor weighing 25 Kg. or more shall be provided with eyebolt or other adequate provision of lifting.
7.06.00
Dowel Pins The motor shall be designed to permit easy access for drilling holes through motor feet or mounting flange for installation of dowel pins after assembling the motor and driven equipment.
7.07.00
Painting Motor including fan, if any, shall be painted with corrosion proof epoxy paints as per shade RAL 7032.
8.00.00 8.01.00
TESTS Upon completion, each motor shall be subject to standard routine tests as per I S. In addition, any special test called for in the driven equipment specification shall be performed. Type tests shall be carried out on a representative sample of motor of each type & rating as per requirement of relevant IS. Type test certificate for L.T. Motor shall be furnished for approval. Type test certificate on any equipment, if so desired by the owner, shall be furnished. Otherwise, the equipment shall have to be type tested, free of charge, to prove the design.
8.02.00
8.03.00
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The following type tests shall be performed on a representative sample of motor of each type & rating, even if type test certificates of these tests are submitted by the Bidder for Owners approval: a) b) Measurement of stator resistance (and rotor resistance on slip ring motors). No load running of motor and reading of voltage, current, power input and speed. Locked rotor reading of voltage, current, power input and values of torque of motor. Full load reading of voltage, current, power input and slip. Temperature rise test.
c)
d) e) 9.00.00
MANDATORY SPARE PARTS Refer elsewhere mentioned din the specification.
10.00.00
DRAWINGS, DATA & MANUALS Drawings, data & manuals for the motors shall be submitted as indicated below:
10.01.00
Along with the bid a) b) c) d) List of the motors Individual motor data sheet as per format of the proposal data sheets. Scheme & write up on forced lubrication system, if any Type test report (as per IS)
10.02.00
After Award of the Contract (A): Approval category; a) b) c) d) e) f) g) (R) : Reference category
Dimensional General Arrangement drawing (A) Foundation Plan & Loading (A) Cable end box details (A) Space requirement for rotor removal (R) Thermal withstand curves hot & cold (R) Starting and speed torque characteristics at 80% & 100% voltage (R) Complete motor data (A)
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h) i) 10.03.00
Erection & Maintenance Manual (R) Test reports (A)
10.04.00
The Owner may also review the documents marked (R) if found necessary. The Bidder shall note that the approval of drawings & documents by the owner does not relieve him of his contractual obligation. The Bidder may note that the drawings, data and manuals listed herein are minimum requirement only. The bidder shall ensure that all other necessary write ups, curves and information required to fully describe the equipment are submitted with the bid
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O.P. Jindal Super Thermal Power Project (4 x 600 MW) Table-A
SYSTEM PARAMETRS AND VARIATIONS System parameters for utility systems are detailed below. Sl No. System Volt. & Frequency Fault Level Grounding
a) b) c)
11000 V 10%, 3Ph, 3 wire, 50 Hz 5% 3300 V 10%, 3Ph, 3 wire, 50 Hz 5% 415V 10%, 3Ph, 4 wire, 50 Hz 5%
40 KA (3 sec) 40 KA (3 sec) 50 KA (1 sec)
Non effectively earthed Non effectively earthed Solidly earthed
Combined voltage and frequency variation 10% (absolute sum) d) 220 V DC () 15% to (+) 10%, 2 wire Voltage levels Following voltage levels shall be adopted for power station auxiliaries: Voltage (V) No. of phases & frequency 3Ph, 50 Hz. 5% 1Ph, 50 Hz, 5% 1phase, 50 Hz, 5%. 25 KA Unearthed
Energy network apparatus AC motors (rated up to and including 160 KW), power receptacles and three phase AC loads Control & indication for contactor operated 415 V motor feeders Space heaters rated up to and including 1200 watt
Grounding
415V 10%
Solidly earthed Solidly earthed Solidly earthed
110V 10% 240V 10%
E1: 9
SUB - SECTION E2 TECHNICAL SPECIFCATION OF
LOAD BANK POWER CONTROL CENTER (PCC) & AMF CONTROL CUM ANNUNCIATION PANEL
CONTENT
CLAUSE NO. 1.00.00 2.00.00 3.00.00 4.00.00 5.00.00 DESCRIPTION SCOPE OF SUPPLY DESIGN CRITERIA SPECIFIC REQUIREMENTS TESTS DRAWINGS, DATA AND MANUALS PAGE NO. 1 1 1 8 9
TECHNICAL SPECIFICATION FOR LOAD BANK POWER CONTROL CENTER & AMF CONTROL CUM ANNUNCIATION PANEL
1.00.00 1.01.00 SCOPE OF SUPPLY This section covers the general requirement of DG Power Control Center (DG PCC), DG Motor Control Center (DG MCC) and AMF control cum annunciation panel to be provided under DG package. a. b. 1.02.00 1.03.00 2.00.00 2.01.00 Load bank Power control center One (1) set AMF Control cum Annunciation Panel Five (5) sets
One (1) set of special tools and tackle. All relevant drawings, data and instruction manuals. DESIGN CRITERIA Power Control Center (PCC) & Motor Control Center (MCC) shall be used to provide power for 415 / 240V AC auxiliary services and shall be fed from Emergency MCC. PCC shall house TPN air circuit breaker / MCCB as incomer and TPN MCCB / SPN MCB as out going feeder. Motor feeders rated 30 KW and above shall be provided with motor space heater supply and ammeter (in one phase only). AMF control cum annunciation panel shall provide all the features for control, indication & annunciation pertaining to DG system PCC & MCC shall be provided with 20% spare outgoing feeders of each type and rating, subject to minimum one (1) number. Selection of component for motor starters shall comply with coordination type-II as per IS-13947 / IEC-947. Bidder shall furnish electrical component selection chart for Owners approval. For PCC, MCC and AMF control cum annunciation panel all provisions and accessories shall be furnished for termination and connection of cables, including removable undrilled gland plate, cable support arrangement, crimp type tinned copper lugs, double compression brass glands with tapered washer and terminal blocks. SPECIFIC REQUIREMENT Construction PCC, MCC shall be metal clad, floor mounted, fully draw-out type and of unitized modular construction, continuous line up of dead front, free-standing, vertical, double front configuration and fabricated from 2 mm thick CRCA sheet steel. PCC shall be
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provided with ACB, whereas MCC shall have MCCB/MCB depending upon the rating & type of outgoing feeder. PCC & MCC enclosure shall be dust and splash proof, conforming to a degree of protection IP-54. The design shall be fully compartmentalized with metal/insulating partitions between compartments. The working height shall be limited within 450 mm to 1800 mm from finished floor level. Each control module shall be housed in a separate compartment, complete with an individual front access door. Each vertical section shall have a removal back cover. All doors and covers shall be gasketed. A full height vertical cable chamber with cable supports shall be provided in each section to facilitate unit wiring. The chamber shall be liberally sized to accommodate all cables and shall have removable cover at the front for access. A horizontal wireway, extending the entire length, shall be provided at the top of each PCC for inter panel wiring. The main buses and connections shall be of high conductivity Aluminium/Aluminium o alloy, sized for specified current ratings with maximum temperature limited to 85 c o o (i.e., 35 C rise over 50 C ambient). All bus connections shall be silver plated. Bimetallic connector shall be furnished for connection between dissimilar metals. Busbars and connections shall be fully insulated for working voltage with adequate phase/ground clearances. Insulating sleeves for busbars and shrouds for joints shall be provided. Bus insulators shall be flame retardant, track-resistant type with high creepage surface. Busbars shall be colour coded for easy identification and so located that the sequence R-Y-B shall be from left to right, top to bottom or front to rear when viewed from the front of the assembly. Drawout type control module shall have self-aligning power/control disconnects. All disconnects shall be silver plated to ensure good contacts. Control Module shall house the control components for a circuit such as switch, fuse, contactors, relays, push buttons, lamps etc. as detailed in the bill of materials. Drawout type control modules of same size and type shall be electrically and physically interchangeable. Air Circuit Breaker Circuit breaker shall be three pole with neutral, single throw, air-break type with with stored energy, trip-free mechanism and shunt trip. Circuit breaker shall be drawout type, having service, test & isolated position with positive indication for each position. Circuit breakers of identical rating shall be physically and electrically interchangeable. For motor wound mechanism, spring charging shall take place automatically after each breaker closing operation. One
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open-close-open operation of the circuit breaker shall be possible after failure of power supply to the motor. Each breaker shall be provided with three (3) adjustable overload release and three (3) adjustable instantaneous short circuit trips. The release characteristic shall be suitable for co-ordination with down-stream fuses. Mechanical safety interlock shall be provided to prevent the circuit breaker from being racked in or out of the service position when the breaker is closed. Automatic safety shutters shall be provided to cover up the stationary disconnects when the breaker is withdrawn. Each breaker shall be provided with an emergency manual trip, mechanical ON-OFF indication, operation counter and mechanism charge/discharge indicator. Each circuit breaker shall be provided with the following :a. b. Position/Cell switch with 4 NO + 4 NC contacts. Auxiliary switch with 6 NO + 6 NC contacts.
f.
3.01.13
MCCB (Moulded Case Circuit Breaker) a. Moulded case circuit breaker shall be three pole, single throw, air break type having trip free mechanism with quick make & break type contacts. Each MCCB shall be provided with in-built releases. The inbuilt protection release shall have voltage/current setting for under voltage, over current, short circuit and earth fault. Each moulded case circuit breaker shall have current limiting feature. Moulded case circuit breakers of identical rating shall be physically and electrically interchangeable. MCCB shall be provided with 2NO and 2NC electrically separate auxiliary contacts. MCCB shall be provided with front drive mechanism with panel door interlock with defeat features. ON-OFF position shall be displayed. MCCB used for 50KW & above motor rating shall have additional E/F release protection.
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3.01.14
Fuse / MCB a. Fuses shall be HRC, preferably link type, with a minimum interrupting capacity equal to the short circuit current of the LT system. Fuses shall be furnished complete with fuse bases and fittings of such design as to permit easy and safe replacement of fuse element.
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Visible indication shall be provided on blowing of the fuse. The fuse on incoming feeder wherever provided, shall be chosen to provide discrimination with feeder fuses. MCB shall be trip free, with manual close/open mechanism. Automatic tripping provision for over load and short circuit shall also be provided. MCB shall be rated for full fault level of the system. MCB shall be provided with required number of auxiliary contacts as per circuit requirement.
3.01.15 3.01.15.01
A.C. Starter Contactors a. The contactors shall be three pole, air break type designed for duty class III Category AC3 with non-bouncing silver/ silver alloy contacts. Contactors for reversible motors shall be of AC-4 duty. Each contactor shall be provided with two (2) normally open and two (2) normally closed auxiliary contacts rated 10 A at 240V A.C. Reversing contacts shall be electrically and mechanically interlocked. Contactors with delayed dropout feature shall be provided for some essential auxiliaries. These contactors shall not dropout on power failure if the voltage is restored within 3 seconds.
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Thermal Overload a. Thermal overload relays shall be three element, positive acting, ambient temperature compensated with adjustable settings. Single phase preventer relay shall be provided, preferably as an inbuilt feature of thermal overload. Relays shall be manual reset type with one changeover contact. Resetting of relays shall be possible with compartment door closed. Relays may be direct acting or C.T. operated, depending on current rating. C.T.s shall be included in the scope of supply.
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3.01.16 3.01.16.01
Control and Indication 415V drives within the DG area, except for manually operated drives shall be operable from DDCMIS in Central Control Room. Remote control commands (start/stop) shall be generated in DDCMIS and issued through interposing relays mounted in respective PCC. The interposing relays shall be rated 24V DC. For Circuit Breaker The circuit breaker shall be wired up for local & remote operation. Each breaker cubicle shall be equipped with following: -
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One (1) TEST-NORMAL selector switch stay put type with pistol grip handle and key interlock. Two (2) heavy-duty oil tight, push buttons for TRIP & CLOSE in TEST position only. Three (3) indicating lights on front of compartments: GREEN RED AMBER 3.01.16.03 Breaker Open Breaker Closed Breaker Trip/Trip Circuit Trouble
For Starter Module Motor Feeder Local-Remote selection Start/Stop in TEST position only. ON (Red)/OFF (Green)/Trip/Overload (Amber) indication ON (Red)/OFF (Green)/Trip/Overload (Amber) indication
Outgoing Feeder 3.01.17 a. Meters
All indicating instruments (96 x 96 mm) shall be switchboard type, with 250` scale, anti-glare glass and accuracy class of 2% full scale. Each meter shall have zero adjuster on the front. Motor ammeter shall have an extended suppressed end-scale range to indicate starting current (6 to 8 times full load current). Current Transformer Current Transformer shall be cast resin type with accuracy Class 1.0 for metering and 5P20 for relaying. All secondary connections will be brought out to terminal blocks where wye or delta connection will be made. Separate shorting links shall be provided at the terminal block for shorting and grounding CT secondary terminals inside panel. VA burden of the CTs shall be adequate (15VA minimum) for connection to remote transducers for Owners DCS Voltage Transformer (VT) Voltage Transformers shall be cast-resin, drawout type and shall have an accuracy class of 1.0. Voltage Transformer mounted on breaker carriage is not acceptable. Voltage rating for the transformer shall be 1.2 continuous and 1.5 for 30 seconds. High voltage windings of voltage transformer shall be protected by current limiting fuses. The voltage transformer and fuses shall be completely disconnected and visibly grounded in fully draw-out position.
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Low voltage fuses, sized to prevent overload, shall be installed in all ungrounded secondary leads. Fuses shall be suitably located to permit easy replacement while the switchgear is energized. VA burden shall be adequate for connection to remote transducers for Owners DCS. Relays Relays shall be numerical multifunction type in draw-out design with built-in testing facilities Small auxiliary relays may be in non draw-out execution The relays shall be rated for operation on 110V secondary voltage and 1A secondary current. Meters Indicating instruments (96 x 96 mm) shall be switchboard type, with 90o scale, antiglare glass and accuracy class of 2% full scale. Each meter shall have zero adjuster on the front. Motor ammeter shall have extended suppressed end-scale range to indicate starting current (6-8 times full load). A.C. meters shall generally be rated for 1A secondary current and 110V secondary voltage. AMF control cum annunciation panel AMF Control cum Annunciation Panel shall be metal enclosed, consisting of a number of vertical panels mounted side-by-side, in which case, they shall be bolted together to form a compact unit. Where two panels meet, the joints shall be smooth, close-fitting, and unobtrusive. The panels shall be free-standing, floor-mounted, totally enclosed type with 2 mm thick CRCA steel conforming to degree of protection IP-54. The panels shall have rear door. Doors shall have concealed type hinges and padlocking arrangement. Doors shall be grounded by flexible copper braid. All doors and removable covers shall be provided with neoprene rubber gaskets all round and latches sufficiently strong to hold them in alignment when closed. The panels shall be provided with channel / angle base plates with anti-vibration pad and stainless steel kick-plates. The annunciator system shall be solid-state type with fast and slow blinking option. Each annunciator group shall be independent, complete with its own power supply, acknowledge-reset-test buttons and other necessary accessories. Hooter for audible alarm shall be common for each control panel assembly. Each annunciator group shall be provided with a common alarm relay for group alarm annunciation in remote control room. The common alarm relay will operate on actuation of any alarm point of the group.
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g.
The annunciator shall be non-integral type with hardware box mounted separately for easy access and maintenance. Secondary Wiring The PCC, MCC and AMF Control cum Annunciation Panel shall be fully wired at the factory to ensure proper functioning of control, protection and interlocking schemes. All spare contacts of relays, push buttons and other devices shall be wired upto terminal blocks. Wiring shall be done with flexible, 1100V grade, PVC insulated switchboard wires with stranded Copper conductors of minimum 2.5 mm2. Each wire shall be identified, at both ends, with permanent markers bearing wire numbers as per Contractor's wiring diagrams. Terminal Blocks Terminal blocks shall be 1100V grade box-clamp type with marking strips similar to 2 ELMEX 10 mm or equal. Not more than two wires shall be connected to any terminal. Spare terminals equal in number to 20% active terminals shall be furnished. Cable Terminations PCC, MCC and AMF Control cum Annunciation Panel shall be designed for cable entry both from bottom. Sufficient space shall be provided for ease of termination and connection. Cables shall be XLPE insulated, armoured and overall PVC sheathed as detailed elsewhere in the specification. All provisions and accessories shall be furnished for termination and connection of cables, including removable gland plates, cable supports, crimp type tinned Copper/Aluminium lugs, double brass compression glands with tapered washer and Terminal blocks. Gland plates shall be minimum 4 mm thick. The gland plate for 1/C power cables shall be of non-magnetic material and the supporting arrangement shall be such as to prevent flow of eddy current. Ground Bus A ground bus, made of copper, rated to carry maximum fault current, shall extend full length of the PCC and panel. The ground bus shall be provided with two-bolt drilling with G.I. bolts and nuts at each end to receive 50 x 6 mm G.S. flat. Each stationary unit shall be connected directly to the ground bus. The frame of each circuit breaker and draw out V.T. unit shall be grounded through heavy multiple
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contacts at all times except when the primary disconnecting devices are separated by a safe distance. d. C.T. and V.T. secondary neutrals shall be earthed through removable links so that earth of one circuit may be removed without disturbing other. All hinged doors shall be earthed through flexible copper braid. Nameplates Nameplates of approved design shall be furnished at each cubicle front and back and at each instruments & device mounted on or inside the cubicle. The material shall be lamicoid or approved equal, 3 mm thick with white letter on black background. The nameplate shall be held by self-tapping screws. Caution notice on suitable metal plate shall be affixed at the back of each vertical section. Space heaters, Plug sockets and Illumination Each vertical section shall be provided with thermostat controlled space heaters and 5A, 3 pin plug socket. In addition, motor feeder (rated 30kW and above) cubicle shall be wired-up for feeding the motor space heater through suitable rated auxiliary NC contact of the breaker. Appropriate lighting equipment and fixtures rated for 240V AC shall be provided in each panel for adequate internal of the panel. Cubicle heater, motor heater, socket and lamp circuits shall have individual switch fuse units. TESTS PCC, MCC and AMF local control cum annunciation panel shall be completely assembled, wired, adjusted and tested at the factory prior to shipment to ensure accuracy of wiring, correctness of control scheme and proper functioning of all components Routine Tests The tests shall include but not necessarily limited to the following: a. Wiring continuity tests, high voltage tests, insulation measurement test both before and after high voltage test, and functional tests to ensure accuracy of wiring operation of the control/ protection/metering schemes and individual equipment. Test report including procedure and drawing shall be furnished. All MCCB. MCB, meters, relays and other devices shall be tested.
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Type Tests
Certified reports of type tests carried out at works shall be furnished in requisite number of copies for approval of the Owner. Otherwise, the equipment shall have to be type tested free of charge within the delivery schedule, to prove the design. 4.04.00 The equipment shall be dispatched from works only after receipt of Owner's written approval of the test reports. DRAWINGS, DATA & MANUALS To be submitted with the Bid a. General arrangement and cross-sectional drawings showing constructional features, space required in front for withdrawals, power & control cable entry points etc. Technical particulars sheet duly filled in Schedule of Materials Single line diagram Type test reports Technical leaflets of Instrument transformers, meters, indicating lamp, switch, push-button, MCCB, MCB, selector switches etc.
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5.02.00
To be submitted for Approval and Distribution (A) : Approval Category ; (R) : Reference Category a. Outline dimensional drawings showing general arrangement, space requirements and cable entry points of PCC, MCC and AMF local control cum annunciation panel (A) Cross-section with parts list (A) Foundation plan & loading, clearly showing panel fixing arrangement, floor opening for cable entry etc. (R) Foundation drawing Single line diagram (A) Control schematics showing terminal and wire numbering (A) Wiring diagram showing all equipment and devices in their relative physical positions and all wiring up to the terminal blocks. (A)
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SUB - SECTION E3 TECHNICAL SPECIFCATION OF GENERATOR & ACCESSORIES
CONTENTS
CLAUSE NO.
DESCRIPTION
PAGES
1.00.00 2.00.00 3.00.00 4.00.00 5.00.00
GENERATOR CODES & STANDARDS CONTROL & INSTRUMENTATION TESTING AND INSPECTION PERFORMANCE GUARANTEE
1 6 6 11 13
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PAINTING
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SECTION: E3 TECHNICAL SPECIFICATION OF GENERATOR & ACCESSORIES 1.00.00 1.01.00 GENERATOR The generator shall be of totally enclosed or screen protected drip proof and self air cooled type. The Generator shall be driven by the diesel engine as described in this Specification (Sub-Section M0 & M1) and shall match the same in all respects. The generator shall also conform to IEC-34/IS-4722 or equivalent. Alternator vibration level shall not exceed the values as defined in IS:12075. Alternator shall be able to withstand vibration level of 9 mm/sec. as per BS 5000 Part III, Rating There shall be five (5) nos. Diesel Generator sets and each generator shall be star connected synchronous generator and shall have a continuous rating of 2000 KVA (min) at 0.8 p.f. (Lag), 1500 rpm. At 415V, 50 Hz, 3 phase, Terminal Voltage & Frequency The generator shall be capable of delivering rated output at rated p.f. With: a) b) 1.04.00 1.04.01 The terminal voltage differing from the rated value by not more than 10%. The frequency differing from the rated value by not more than 5%.
1.02.00 1.02.01
1.03.00
Short Circuit Condition The generator shall be capable of withstanding for three (3) seconds, without injury, a 3 short circuit as its terminal when operating at rated KVA, p.f. and a voltage at 5% over rated voltage, with fixed excitation. The machine shall also be capable of withstanding, without injury or damage any other short circuit at its terminal for three (3) seconds duration or less, provided the machine phase currents under fault conditions are such that the negative phase sequence current (I2) expressed in terms of per unit stator current, at rated KVA, and the duration of fault in seconds (t) are limited to values which gives an integrated product (I2)2 x t equal to or more than 20 and also the maximum asymmetrical phase current shall not exceed the maximum phase current obtained from a three (3) phase short circuit specified under clause 3.13 of IS-5422 i.e., at rated voltage at machine. The negative sequence continuous capacity shall be minimum 10%. Short Time Overload The Generator shall be capable of withstanding on test, without injury for not less than fifteen (30) seconds a current of 50% in excess of its rated current after having attained the thermal equilibrium corresponding to rated load, the terminal voltage being maintained as near as the rated values possible. Low Power Factor Operation & Transient Reactance Drop Limitation due to Large Motor Starting Load
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1.06.00
1.06.01
At the time of switching emergency loads of the plant there is necessity for reaccelerating or restarting of certain number of important induction motor loads in addition to the lighting loads. The leads to large reactive power operation and the restart up of machines may result in low power factors say, 0.2 to 0.3 lagging. The generator and its regulation equipment must be capable to supply the load including starting current of the loads at the low power factor as mentioned above. To limit the voltage dip due to Transient Reactance of Generator, the value of the Transient Reactance shall be limited within 13 (thirteen) to 15 percent for the alternator at its own base specified herein. However the bidder shall justify any other value considered in their offer with valid calculations. Short Circuit Ratio Short Circuit Ratio (S.C.R.) of the Generator at rated KVA and rated KV shall not be less than 0.5. Over Speed The generator shall withstand without mechanical injury an over speed of twenty (20) percent for a period of two (2) minutes. Insulation & Temperature rise of Windings and Core The generator stator and rotor windings and all connections including main and neutral leads shall have Class-F insulation meeting the temperature rise limitations for Class-B set forth for air cooled machines in IS:4722-1968. The temperature rise of the stator core and mechanical parts in contact with or adjacent to winding shall not exceed the limits specified in the aforesaid I.S. specification (IS: 4722). Ambient temperature shall be considered as 50 Deg.C. General Construction All parts of the generator shall be capable of withstanding electrical, mechanical, thermal and other stresses experienced in normal operation and also on abnormal conditions such as short circuit and over speed.
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1.07.00 1.07.01 1.08.00 1.08.01 1.09.00 1.09.01
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1.11.00
Stator Terminals The line and neutral ends of phase winding of the generator shall be brought out on six (6) suitably located terminals. The neutral terminals shall be arranged for star connection.
1.12.00 1.12.01
Neutral Earthing The neutral of the stator winding of the alternator is to be grounded through NGT. For detection of ground fault, primary of one single phase VT shall be connected across neutral of the alternator and ground. Secondary of the VT will be connected to one neutral displacement relay (voltage operated) as per enclosed single line diagram. Necessary CTs shall be provided in the neutral side before star formation for phase differential protection. This shall be provided in the alternator terminal box. Protection
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The generator protection shall be provided by using numerical programmable protection relay. The relay shall have following protection features. Over current protection Voltage controlled over current protection Phase differential protection (As additional feature) Over voltage Under voltage Over frequency Under frequency Reverse power protection Field failure protection Earth fault protection Overload Alarm on one phase Additionally the relay shall have measurements for various electrical three phase parameters, event recorder, PT fuse failure monitoring, and a communication port for communicating to Owners SCADA systems. Breaker failure protection shall be provided. Separate multifunction numerical relay shall be used for trip circuit monitoring and protection lockout and other auxiliary relays. The relay shall have flags and hand reset buttons. All relays shall be drawout type with testing provision. It shall be mounted in the AMF panel. The numerical relays shall be supplied with programming software. All protections shall have alarm and trip settings and output relays that can be programmed. Current and voltage elements shall be for three phases. Control supply shall be 220V DC. 1.14.00 Relays All the protective relays shall be of draw out design with built-in testing facilities or with facilities for testing the relay by inserting test plug and Test plug shall also be furnished. Small auxiliary relays may be in non-drawout execution and may be mounted within the cubicle. All the protective relays indicated above shall be mounted on AMF panel located near the D.G. set. 1.14.02 1.14.03 1.15.00 Relays shall be rated for operation on 1A C.T. secondary current and 110V P.T. secondary voltage. All the relays shall conform to latest revision of IS-3231. Current Transformers
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1.15.01
Cast Resin type current transformers shall be provided for phase as well as neutral side of the generator. All secondary connection shall be brought out to terminal blocks where wye (Y) or delta connection will be made. The C.T. ratio, accuracy class, ISF, VA burden (for protective and metering C.Ts) and knee point voltage (for class PS C.Ts.) shall be indicated.
1.15.02 1.15.03 1.16.00 1.16.01
All the metering and protective C.Ts. shall conform to the latest revision of IS-2705. Except, metering all other CTs shall be located in Alternator Terminal Box. Voltage Transformers. Three single phase 415/ 3 / 110/ 3 V, Star/Star Cl.1.0 3P and one single phase 300/100V Cl. 1.0 3P shall be provided with each D.G. set V.A. burden shall be selected by the Bidder for which necessary calculation shall be furnished to the Owner for approval. Voltage transformer shall be cast resin, drawout type. High voltage windings of voltage transformers shall be protected by current limiting fuses. The voltage transformer and fuses shall be completely disconnected and visibly grounded in fully drawout position. Low voltage fuses, sized to prevent overload, shall be installed in all in all ungrounded leads. Fuses shall be located to permit easy replacement while the switchgear is energized. V.T. shall conform to latest revision of IS-3156. Temperature Detectors Duplex type three (3) wire resistance element temperature detector shall be installed at the following locations: a) Six elements of platinum each having a D.C. resistance of 100 Ohms at 0 Deg.C suitably distributed at locations where highest temperatures may be expected in stator winding. One (1) element in each bearing. The R.T.Ds shall comply with the latest edition of IS-2828.
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b) c) 1.17.02
The supplier shall provide for each of the generators one (1) winding temperature indicator along with selector switch for checking the temperature at different points of stator winding and also two (2) bearing temperature indicators suitable for the above detectors. The indicators and selector switches shall be suitable for flush mounting on AMF panel. Space Heaters Suitably rated 240V, single phase, 50 Hz, space heaters located in lower part of alternator shall be provided to maintain the internal temperature above the dew point to prevent moisture condensation on the insulation during shut-down. Excitation System
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1.19.00
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1.19.01
Generator shall be provided with complete excitation system capable of supplying the excitation current of the generator under all conditions of output from no load to full load and capable of maintaining voltage of the generator constant at any value within 5% of the rated voltage. The type of insulation of the armature field winding of the exciter shall be Class-F and the temperature rise above 50 Deg.C ambient shall not exceed the values specified in IS-4722 for different parts corresponding to Class-B. Shaft driven A.C. brushless type exciter shall be provided. The pilot exciter shall be PMG exciter with permanent magnet field and the stator will have hifh frequency three phase winding as an input to AVR system. The excitation system shall be provided with field forcing to sustain the voltage during fault condition. Voltage Regulator An automatic, high speed, static/microprocessor based non-dead band type voltage regulator shall be furnished. The regulation system shall be provided with equipment for automatic and manual control. Necessary equipment shall be furnished for the following: a) b) c) To prevent automatic rise of field voltage in case of failure of potential supply. To initiate transfer from automatic to manual control of excitation on fuse failure in the generator potential signal. To initiate transfer from automatic to manual control of excitation on fuse failure in the generator potential signal.
1.19.02
1.20.00 1.20.01
1.20.02 1.20.03 1.20.04
The regulator shall regulate from generator current and potential signals. The above equipment shall be housed in self standing sheet metal cubicle, and shall be completely tested and wired. The regulation equipment shall function between the frequencies 47 and 53 Hz and shall assure to maintain a constant voltage in steady operating condition between no load to full load. The excitation and voltage regulation should be designed so as to cause necessary de-excitation in case of any short circuit. The details of excitation wiring diagram shall be furnished with the offer. AVR shall have fault signals volt free contact. The AVR shall have features for over excitation and under excitation protection, under frequency (V/f) controls. The detail write-up shall be enclosed with bid.
1.21.00 1.21.01
Terminal Box Separate terminal boxes shall be provided for phase and neutral side of leads. The terminal boxes shall be dust proof, weather proof phase segregated double walled (metallic as well as insulated barriers) having degree of protection of IP-54 as per IS: 13947. Suitable Alternator Terminal box fabricated from minimum 14 SWG MS sheet duly painted shall be provided towards power output side as well as towards neutral side. Each termination box shall be equipped with copper busbar to be supported on epoxy resin support insulator having minimum 1.1kV voltage grade, to accommodated CTs. Bus bar shall be suitable to withstand short circuit level of 50kA for 1 sec. and rating shall be at least 25% higher than the rated capacity. Space heater with thermostat
control for each box shall be provided. Double compression glands for power & single compression glands for control cables shall be provided for DG set scheme. 2.00.00 2.01.00 CODES AND STANDARDS The design, manufacture and testing of the equipment covered by this specification, shall, unless specifically mentioned otherwise, conform to the latest editions of the following standards and codes along with all addendum as applicable: i) a) b) c) d) e) f) g) 3.00.00 3.01.00 3.01.01 ASME and ANSI Power Test Code. Heat Exchange Institute (USA) Standards. AIEE Standards. Instrument Society of American Standards, Various Indian Standards for material and tests. BS:2613 : Electrical Performance of rotating Electrical Machinery. BS Code of Practice CP:1014, protection of electrical equipment against climatic conditions. IS Specification for rotating Electrical Machines.
CONTROL & INSTRUMENTATION Start-Up & Control Each Auto Mains Failure (AMF) panel shall have the provision for automatic and manual starting of Diesel Engine and Generator set through a suitable 4 position Auto-ManualTest-off Selector Switch located in AMF panel. In Test position D.G. set can be started from AMF panel without closing of incomer breaker to Emergency MCC. In Automatic position of selector switch the set shall start only when the starting impulse is received as described elsewhere. Starting command is generated in respective AMF panel by taking PT inputs from emergency MCC. In Manual position of the selector switch, the generator set can be started both from UCR and AMF panel manually. The generator shall be connected to respective DG PCC bus through 415V circuit breaker when the bus is in Dead Bus Condition. In normal condition the above selector switch. All relays, meters, timers, indicating lamps, controls switches etc. necessary to achieve the system described elsewhere shall be included in AMF panel. The DG set shall have facility to stop both from CCR and AMF panel. To facilitate manual starting of D.G. from remote, a local/remote selector switch shall also be provided on each AMF panel. The necessary interface hardwires for starting/stopping from remote shall be provided. The AMF panel shall also be equipped with control and interlock of starting, sequence starting, timers, protection relays and instruments as per enclosed drawing and other requirements specified elsewhere in the specification. The supply and erection of remote control panel in central control room is under scope of this specification. The control panel shall house the requisite timers and under voltage relays (which shall be quoted as control item) in
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addition to required push buttons, indicating lamps, annunciators, switches required for the system. In each AMF panel one power supply section shall be provided (along with 415/240V, 1 phase, 50 Hz, adequately rated auxiliary transformer) for supplying auxiliary power to Generator space heaters, AMF panel space heaters, The AMF panel controls and ACB controls shall be 220V DC to be provided by Owner. However the engine controls shall be derived from dedicated battery supply at 24v DC. The DC supplies shall be suitable for +10% and 15% supply variation. The AMF panel will house the ACB and two isolators interlocked as shown in the SLD of adequate rating. The in panel rating of the equipments shall be more than the maximum current output. 3.01.02 Readiness to Start A master relay shall be provided to monitor the following requirements to be met before the set can be started and an indicating lamp on the AMF panel shall be provided to indicate when all the requirements are met. Necessary provision shall be made so that indication can be provided on one of Owners remote control panels also. 3.01.03 D.G. Board Bus at Dead Bus Condition. Incoming circuit breaker at D.G. Board from corresponding D.G. Set is open. Pre-requisite conditions for D.C. Supply required for engine starting is satisfied. Pre-requisite conditions for jacket cooling water for safety are satisfied. Pre-requisite conditions for lubricating oil pump/system, fuel oil systems, pre-lube systems, for safety are satisfied. Generator field breaker (if provided) is open. No volt field flashing circuit, if provided, is available. None of the tripping signal enumerated in this specification is present.
Manual Control of Speed & Voltage The manual control of the engine speed & generator voltage shall be provided through suitable Raise-Lower control switches on the AMF panel furnished by Bidder. Remote control provision shall be provided.
3.01.04
Control of Jacket Cooling Water Temperature The engine jacket water will bypass the cooling water heat exchanger in the standby condition. In order to enable quick starting and loading of the diesel generator jacket water shall be kept warm by thermostat controlled electric heaters. Automatic control for maintaining the jacket water temperature within specified limits during running of the diesel engine shall be furnished.
3.01.05
Control of Lubricating Oil Temperature Automatic temperature controller and control system shall be furnished for lubricating oil cooler also.
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3.02.00
Tripping Any one or more of the following defects shall cause the running diesel generator to be tripped and re-start shall be prevented until the fault/faults are removed and manual resetting is done. a) Failure to start-up under cases where a D.G. set fails to start in first attempt, two additional attempts should be allowed to be made to start the machine automatically before finally blocking the machine. In the event of maintenance of a particular D.G. set, the common standby set will be selected as dedicated D.G. set in place of D.G. set under maintenance under an emergency situation. Selection of the standby set to act for a particular unit shall be possible from Central Control Room (CCR). D.G. set, which has failed to start even on successive attempts and finally blocked shall be possible to restart after the faults are removed and manual resetting is done. Engine and generator protection shall be made independent. Troubles in the alternator will lead to tripping of incomer breaker to DGPCC and field breaker first and Engine thereafter with a delay time to safeguard engine parameters. b) c) d) e) f) Protection from Engine side as detailed elsewhere. Alternator stator temperature very high Electrical protective relays operated. Differential protection Voltage restrained over current protection
3.03.00 3.03.01
Indication & Annunciation For alarm and indication, a hooter and individual indication lamps shall be provided. Three nos. push buttons shall be furnished for Accept, Reset & Test. Detailed list of Alarms and Annunciations are indicated elsewhere. All the annunciations will be repeated in Central Control Room (CCR). Necessary pressure switches, level switches, thermostats, flow switches, auxiliary relays, etc. required for the above alarm and annunciation system shall be furnished under the scope of this specification. The successful Bidder shall take prior approval from the Owner regarding make and technical particulars of such accessories to be used. Annunciation system supply failure alarm & indication shall also be provided. Potential free contacts for following conditions of each D.G. set shall be provided by the bidder for use of the Owner for data logging: a) D.G. Start Command Actuated.
3.03.02
3.03.03 3.03.04
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b) c) d) e) f) g) h) i) 3.04.00 3.04.01 3.04.02
D.G. ON D.G. Differential Protection Operated D.G. U/V Protection Relay Operated D.G. Incomer Breaker Close D.G. Incomer Breaker Trip DG Feeder Breakers to Emergency Switchgear Trip. Standby DGDB Tie Breaker Trip DGDB Bus V.T. Fuse Fail
Annunciation System Solid-state alarm annunciator shall be audio-visual integral back lighted name-plate type with flasher and horn, with inbuilt power pack and sequence logic. The alarm system shall have one set of accept, reset and test push-key unit. Annunciator shall generally be actuated by closing of alarm contact (normally open contact). In some case, the reverse configuration may be required.
3.04.03 3.04.04 3.04.05
Units shall be fully operable to all ambient conditions through (-) 6.4 Deg.C to 50 Deg.C and relative humidity of 100 percent. The system operating voltage of the annunciation system shall be 24V D.C., interrogation voltage shall be 48V D.C (to be created by bidder) Specific Design Requirements a) The annunciation system shall be designed with adequate safeguard against malfunctioning due to random noise and transient pick-ups. An input filter for draining the high frequency noise, with a built-in adjustable time delay (variable from 0-1 second) shall be provided for elimination of transit pick-ups and noise. Annunciation circuitry shall be silicon solid-state plug in module of state-of-art technology. All the components associated with the circuits shall be proven & guaranteed quality produced by reputed manufacturers. Plug-in-type glass epoxy printed circuit boards with nickel-plated tracks and gold plated contacts shall be used. The printed circuit boards shall have suitable facility for adapting NO and NC type initiating contacts. Printed circuit board shall be channel wise modular type and shall be of polarized construction. The boards shall be properly lacquered. Annunciation fascia lamps shall be mounted on the top of the panel front. The lamps shall be serviceable from panel front side.
b) c) d)
e) f)
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g)
The annunciation system shall incorporate suitable voltage stabilizers and the circuit should be immune to step variations in the supply voltage. The output going to the lamps shall be inherently designed with a current limiting feature, which restricts the surge current when the lamp comes on. The lamp drivers shall also be short-circuit protected. The annunciator shall be provided with two lamps per channel. The wattage rating of individual lamps shall be within 3.5 watts and the enclosure temperature rise with all the lamps glowing shall be guaranteed within 10 degrees centigrade without air conditioning. The lamps shall be off under normal conditions and shall flash or remain steadyon brightly under abnormal conditions. Expected life of the lamps with respect to cycles of operation shall be clearly mentioned in the offer. The annunciation windows shall be made of high impact polystyrene with a display area within 56 mm x 44 mm to 70 mm x 55 mm. The inscription shall be made on suitable photo film with black letters on white translucent background. The lettering shall be of 5 mm high, there shall be maximum 18 characters per line. The inscribed film shall be mounted behind the translucent polystyrene windows of white or red colour. The input circuit shall be protected from high voltage, up to 415V A.C. optical isolation of the input shall be a desirable feature.
h)
i)
j)
k) 3.05.00 3.05.01
Synchronizing Bidder shall quote synchronizing features into the AMF panel. The synchronizing would involve supply of selector switch, synchroscope, sync check relay, dead bus relays and necessary auxiliary relays facilating the synchronizing of DG set to the station supply. A synchronizing schematic shall be furnished in the offer. MCB/MCCB, Lamps, Meters, Control Panel All electrical components on the panel namely push buttons, MCB/MCCB, lamps, meters, control panels etc. shall meet the requirements of sub-section E-0 enclosed with the specification along with the following specification.
3.06.00
3.06.01
Indicating Lamp a) b) c) d) e) f) g) h) Voltage rating Wattage Lens Bulb replacement Wire connection Colour of lamps Legend plate Standard legends : : : : : : : : 24V DC/240V AC/220V DC. Low, LED cluster type Screw-on glass. From front. Rear Green, amber, red, white. Black anodized aluminium Close, running, open, ready.
3.06.02
Push Button Technical Particulars
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a) b) c) d) e) f) g) h) i) j) k) l)
Type Construction Enclosure Contact configuration Contact addition Contact element Continuous current Making current Gasket Cable Connection Legend plate Standard legends
: : : : : : : : : : : :
Shrouded (mushroom head for important trips). Modular NEMA-12. 4 stacks (2 NO + 2 NC in general). Add-on-stacks. Nickel-silver alloy 10 amps (approx.) 80 amps (approx.) Rubber gasket between actuator and panel. Rear Black anodized aluminium. Start-stop, forward, reverse, fast, slow, on, off, raise, lower, accept, reset, test, enable. Red, green, blue, yellow, black, gray.
m) 4.00.00 4.01.00
Colors
TESTING AND INSPECTION Tests at Manufacturers Works Tests shall be carried out during and after completion of manufacture of different component parts and the assembly as applicable in accordance with the requirement of relevant codes and standards. Following tests among others shall be conducted.
4.01.01
The alternator shall be type tested for the following tests as per IS:4723. a) b) c) d) e) f) g) h) i) j) k) Measurement of resistance and air gap Phase sequence tests Regulation test Measurement of open circuit and short circuit characteristics Efficiency test Temperature rise test Momentary overload test Over speed test High voltage test Insulation resistance test (before and after HV test) Noise level and vibration as per IS:12065 and IS:12075
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l) 4.01.02 4.01.03 4.01.04 4.01.05
Determination of deviation of voltage wave-form from sinusoidal
Static and dynamic balance test of rotating parts at applicable over speeds and to determine the vibration level. Radiography and magna flux examination of materials and welds. Ultrasonic test of castings and forgings. In addition to the above and routine test, the alternator and the starting motor shall be tested for the following routine tests: Rotor and Stator H.V. test. Full load and load rejection test. Terminal voltage measurement for starting condition as stated elsewhere. Generator open circuit and short circuit test. Measurement of winding Resistance and air gap Insulation Resistance test (before and after HV test) Phase sequence test Regulation test. Vibration measurement.
4.01.06
Tests on all electric motors, panels and other electrical equipment as per relevant IS or equivalent standards.
a)
Contractor shall carry out successfully no load test for one hour on all completely assembled diesel generator sets in his works prior to dispatch in presence of Owners representative. During testing, DG sets shall be assembled and fitted with all corresponding materials/accessories under Contractors scope. The assembly test shall include the following: i) ii) iii) iv) No load running of assembly and reading of voltage, current and speed. Functional tests on control panel. Functional tests on starting provision on the engine Functional tests on all field devices.
4.02.00
Commissioning checks. In addition to the checks and tests recommended by the manufacturer, the Contractor shall supervise following commissioning checks on each set at site. a) b) Load test for 6 hrs. with hourly records of ambient temperature, exhaust temperature, cooling water temperature, etc. Insulation resistance test for alternator
c) d) e) f) g) 5.00.00
Check of fuel consumption Insulation resistance of wiring Function tests Measurement of vibration Noise level check.
PERFORMANCE GUARATNEE The items of performance already indicated elsewhere shall be guaranteed by the Bidder in respect of the Diesel Generating unit and auxiliaries when operating under the specified conditions.
6.00.00 6.01.00 6.03.00
PAINTING Before dispatch of the equipment, shop coats of rust inhibiting paints, lacquers etc. shall be applied to various parts. After erection is complete, all the equipment shall be given final coats of painting of approved colour and quality as per manufacturers standard. Details of painting shall be approved by Owner.
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SUB - SECTION E4 TECHNICAL SPECIFCATION OF BATTERY & BATTERY CHARGER
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CONTENTS
CLAUSE NO. 1.00.00 2.00.00
DESCRIPTION INTENT OF SPECIFICATION EQUIPMENT & SERVICE TO BE SUPPLIED UNDER THIS SPECIFICATION DESIGN REQUIREMENT LAYOUT OF BATTERY AND BATTERY CHARGER FITTINGS AND ACCESSORIES TESTS DRAWINGS, DATA & MANUALS
PAGES NO. E4 : 1
E4 : 1 E4 :1
3.00.00 4.00.00
E4 : 3 E4 : 3 E4 : 3 E4 : 4
5.00.00 6.00.00 7.00.00
Technical SPECIFICATION FOR BATTERY & BATTERY CHARGER 1.00.00 1.00.00 1.01.00 SCOPE OF WORK INTENT OF SPECIFICATION This specification is intender to cover the design, manufacturer, assembly, testing and inspection at manufacturers works, properly packed and delivery at site of the following, complete with accessories for efficient and trouble free operation of the DG system. a) One (1) set (one working and other standby with 100% capacity) of 24 volt battery and battery charger unit for each Diesel Engine starting system, annunciation system etc.
2.00.00 2.01.00 2.02.00 2.03.00 2.04.00 2.05.00 2.06.00 3.00.00 3.01.00 3.01.01
EQUIPMENT AND SERVICE TO BE PROVIDED Battery and Battery Charger as per Sl. No. 1.00.00 above. First filling of electrolyte with 10% extra and all necessary accessories for above battery. One (1) set of special tools and tackle. Spare parts. All relevant drawings, data and instructions manuals. Complete erection & commissioning of Battery Charger unit and associated battery. DESIGN REQUIREMENTS Battery Besides the suitability of starting requirement of Diesel Engine all control, annunciation, indication etc. shall have power supply from 24 volt (2 x 12 volt) battery and battery charger unit. Bidder shall compute the ampere-hour capacity at suitable discharge rate based on above duty and furnish the calculation along with the Bid, which shall consider the duty cycle and 25% & 15% compensation for aging and unforeseen future growth respectively of each battery unit. The maximum and minimum ambient shall be 50 Deg. C and (-) 0.6 Deg. C respectively. The minimum voltage at the end of the load cycle shall not be less than 1.8 volts per cell. The ampere hour capacity of the battery shall be such that the engine can be started at least for three (6) starts at an interval of 5 sec. Further battery shall have capacity to meet the total load of DG system for a period of minimum 10 hours. The battery shall be lead acid plante or nickel-cadmium battery. The plates shall be designed for maximum durability during all service conditions including high rate of discharge and rapid fluctuation of load.
3.01.02
3.01.03 3.01.04
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3.01.05 3.01.06 3.01.07
Sufficient sediment space shall be provided so that the cells will not have to be cleaned out during normal life. All cells shall be sealed or closed type. Anti-splash type vent plug shall be provided for each cell. The battery shall be shipped uncharged with the electrolyte furnished in a separate non-returnable container. 10% extra electrolyte shall be furnished to cover spillage in transit or during erection in non-returnable container. The rack or equivalent arrangement for supporting battery shall be painted with at least three (3) coats of anti-acid paint of approved shade for lead acid battery. Racks with alkali-resistant paint shall be provided for nickel-cadmium battery. Battery Charger The battery charger shall be natural air cooled, solid state type bridge configurations and complete with all switches, fuses, contractors and instruments. The battery charger shall be suitable for 415 volts + 10%, 3 phase, 50 Hz, 4 wire AC supply. The battery charger shall be with dual provision of float charging and boost charging. The battery charger shall be capable to float/boost charge the battery set apart form supplying DG set DC load, if any. Suitable drooping devices shall be arranged to limit the output DC volts across the load at the time of boost charging the battery. The battery charger shall recharge the completely discharge battery to full capacity in eight (8) hours. The charger unit shall have 15% excess capacity. i. ii. iii. iv. Transformer shall be dry type, double wound, with copper conductor and ClassB insulation with temperature rise limited to Class-A insulation. Isolating switch shall be heavy duty, load break type, operated by an external handle. Fuses shall be HRC type and arranged for easy replacement. Semiconducting devices fuses shall be fast-acting type. Indicating meters (voltmeter and ammeter) shall be 96mm x 96mm, flush type 90 degree scale with antiglare glass, + 1% accuracy with zero adjuster on the front of the meter. The following indications/alarm annunciation shall be provided: a) b) c) d) e) f) g) Failure of input AC supply to the charger Low battery voltage DC output fuse blown Charger fail Over voltage Earth fault Battery on boost charge
3.01.08
3.02.00 3.02.01 3.02.02 3.02.03
v.
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4.00.00 4.01.00
LAYOUT OF BATTERY & BATTERY CHARGER The battery will be located by the side of the engine and the battery charger will be located nearby. Leads for DC connection with engine shall be supplied by the Bidder and same shall be of stranded copper conductor cable. FITTINGS & ACCESSORIES Each battery shall be furnished complete with following: a) b) First charge of electrolyte plus 10% extra. steel stand with 3 coats of anti-acid paints for lead-acid battery or steel rack with 3 coats of alkali-resistant paints for nickel-cadmium battery.
5.00.00 5.01.00
5.02.00 5.02.01
Battery Charger Auxiliary equipment Each battery charger shall be furnished with the following equipment and material mounted and wired on the front panel of charger enclosure. S. No. 1 2 3 4 5 6 7 Description Input voltmeter, scale 0-500 volts, (1% accuracy) with voltmeter selector switch Output voltmeter, scale 0-40 Volts (1% accuracy) Output Ammeter, scale 0-full Load with 25% margin (to be decided by Bidder)-1% accuracy Selector switch charge/OFF for selecting float charge/Boost Quantity 1 no. 1 no. 1 no. 1 no. 1 no. 1 no. 3 nos.
Isolating switch for incomer Indicating lamps as indicated under Sl. No. 3.03.08 Accessories as required for the Type of charger offered
6.00.00 6.01.00
TESTS Shop Tests All equipment and components thereof shall be subject to shop tests as per relevant IS standard. Acceptance and routine tests on battery shall be carried out as per relevant standards. The battery charger shall be tested for conformity to ripple free output, voltage regulation and load limiting characteristics.
6.02.00
Test Certificates i. Certified reports of all the tests carried out at the works shall be furnished in copies as required for approval of the Owner.
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ii. The equipment shall be dispatched from works only after receipt of Owners written approval of the test reports. iii. Type test certificates on any equipment, if so desired by the Owner, shall be furnished. Otherwise the equipment shall have to be type tests, free of charge, to prove the design. 7.00.00 7.01.00 DRAWINGS, DATA & MANUALS Drawings, Data and Manuals shall be submitted in triplicate with the bid and in quantities and procedures as specified as specified in General condition of contract and / or elsewhere in this specification for approval and subsequent distribution after the issue of Letter of Intent. Documents to be submitted with the Bid i. ii. iii. iv. v. vi. General Arrangement drawing of battery and battery charger unit. Bill of Material Typical schematic drawing of 24V DC system. Battery cell voltage characteristics and data for different discharge rates. Calculation for sizing (ampere hour) of battery and battery chargers for each category of service. Technical leaflets on a) b) 7.03.00 Battery Battery charger
7.02.00
Documents to be submitted for Approval and Distribution i. Dimensional general arrangement drawings of battery charger unit clearly showing device dispositions, cable entry, space requirements for operation and maintenance facility. 24V DC system schematic and wiring diagrams. Detailed bill of materials. Any other relevant drawing or data necessary for satisfactory installation, operation and maintenance.
ii. iii. iv. 7.04.00
Instruction manuals i. The manual shall clearly indicate method of installation, check-ups and tests to be carried out before commissioning of the equipment. ii. The Bidder may note that the drawings, data and manuals listed are minimum requirement only. The Bidder shall ensure that all other necessary write-ups, curves and information required to fully describe the equipment offered are submitted with his bid. The contractor shall also submit the reproducible of all the approved drawings for reference and record.
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SUB- SECTION-E5 TECHNICAL SPECIFICATION FOR ERECTION, TESTING & COMMISSIONING OF ELECTRICAL EQUIPMENT, CABLING & GROUNDING SYSTEM
CONTENT
CLAUSE NO. 1.00.00 2.00.00 3.00.00
DESCRIPTION SCOPE OF WORK MATERIAL & SERVICES TO BE FURNISHED SPECIFIC REQUIREMENT SUPPLY ITEMS
PAGE NO. 1 1 1
4.00.00
SPECIFIC REQUIREMENT ERECTION
5.00.00 6.00.00
PRE-COMMISSIONING TESTS DRAWINGS, DATA AND MANUALS
9 10
TECHNICAL SPECIFCATION FOR ERECTION, TESTING & COMMISSIONING OF ELECTRICAL EQUIPMENT, CABLING AND GROUNDING SYSTEM
1.00.00 1.01.00
SCOPE OF WORK This scope of work shall cover complete and efficient erection, testing and commissioning and putting into successful operation of all outdoor and indoor electrical equipment pertaining to DG system including cabling and grounding system. MATERIAL & SERVICES TO BE FURNISHED Bidder shall provide all labor (skilled and unskilled), supervisory and administrative personnel, transport vehicles, erection tools and tackle, mobile cranes, equipment and implements required for erection, testing and commissioning for timely and efficient execution of the contract. Installation work shall include supply of erection and other material, cabling (Supply of cable by the Owner), grounding, hardware, consumable and sundry items as required to complete the installation in all respect. Items of work to be performed by Bidder for equipment and material under the scope of this package shall include but not limited to a. b. c. d. e. f. g. h. i. Taking delivery from Owners store and safe transportation to site of erection. Opening and inspecting the material and equipment and reporting damages. Storing at Bidders plant site with suitable weather protection. Repairing minor damages, cleaning before erection and application of anti-corrosive paints after cleaning. Complete assembly, erection and connection. Testing and calibration of equipment /meters. Pre-commissioning check-up to ensure correctness of erection of equipment. Testing, trial run and commissioning including performance test in presence of Owner/Consultant and trial run. Obtaining Owners approval and written acceptance for satisfactory operation. Any item of work or erection material which have not been specifically mentioned but are necessary to complete the work involved shall be deemed to be included in the scope of this specification and shall be furnished by the Bidder without any extra cost to Owner. SPECIFIC REQUIREMENT SUPPLY ITEMS Accessory and Material Accessories and material shall comply with description, rating, type and size as detailed in this specification.
2.00.00 2.01.00
2.02.00
2.03.00
2.04.00
3.00.00 3.01.00 3.01.01
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3.01.02
All accessories, fittings, supports, hangers, anchor bolts etc. which are necessary for safe and satisfactory installation and operation of the equipment shall be furnished. They shall be complete and operative in all respect. All parts shall be made accurately to standard gauges so as to facilitate replacement and repair. All corresponding parts of similar accessories shall be interchangeable. Specific requirement for the major supply equipment are given below. Pre-fabricated Cable Trays Cable trays shall be pre-fabricated ladder type, sheet steel, hot dip galvanized furnished in standard length of 2.5 m. Cable tray straight run shall be of standard width such as 300mm, 450mm & 600mm. GI cable tray straight runs shall be supplied complete with hot dip galvanized sheet steel accessories such as coupler plates, ground continuity connections, nuts, bolts, washers, hangers, clamps etc. Horizontal/vertical bends, horizontal/vertical tee, elbow, reducers, horizontal crosspieces and protective covers. Cable trays, fittings & accessories shall be fabricated out of 14 gauge (2 mm thick) hot rolled mild steel sheets. Cable trays, fittings and accessories including all bolts, nuts, screws, washers etc. shall be hot dip galvanized after fabrication as per IS:2629. Galvanizing shall be uniform, clear, smooth and free from acid spots. The amount of zinc deposited shall not be less than 610 gms per square meter of surface area and in addition the thickness of the zinc deposit at any spot whatsoever, shall not be less than 75 microns.
3.01.03 3.01.04 3.02.00 3.02.01 3.02.02 3.02.03
3.02.04
3.02.05
Each 2.5M long section of all types of cable trays & each fittings like elbow, tees, crosses etc. shall be provided with two nos. hot dip galvanised side coupler plates & associated bolts, nuts and washers on each side. Bidder shall perform all tests necessary to ensure that the material and workmanship conform to the relevant standards and that such test are adequate to demonstrate that the equipment shall comply with the requirement of this specification. A 1.5 meter straight section of each type of cable trays shall be simply supported at the two ends. A uniformly distributed load of 100 Kg per metre shall be applied along the length of the tray. The maximum deflection at mid span shall not exceed 7 mm. Conduits and Accessories Generally cables shall be laid in cable trays or through conduits. The Bidder shall install terminate and connect conduits as approved by the Owner. Conduits shall be of rigid steel, hot-dip galvanized, furnished in standard length of 3 meters, threaded at both ends. Conduit diameter upto and including 25mm size shall be of 16 SWG and conduits above 25 mm diameter shall be of 14 SWG. Each piece of conduit shall be straight, free from blister and other defects, internal surface shall be smooth finish and covered with capped bushings at both ends.
3.02.06
3.02.07
3.03.00 3.03.01 3.03.02 3.03.03 3.03.04 3.03.05
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3.03.06 3.03.07
Flexible conduits shall be made with bright, cold rolled, annealed and electro-galvanized mild steel strips coated internally with epoxy and the sizes shall be 19, 32,51,63 & 76m. In some areas where cable trays do not exist and where the runs are generally straight, rigid PVC conduits conforming to IS: 4985 shall generally be used for control & instrumentation cables. PVC pipes with special Bell mouthing shall be of 110 mm, 160 mm & 200 mm outside diameter and shall be suitable for working pressure of 6kg/sq. cm. The length of each pipe shall be 5 to 6 meters. Necessary fittings & accessories as required for the installation shall also be provided. Junction Boxes Junction boxes shall be of 16 SWG hot-dip galvanized sheet steel, dust proof construction, conforming to IP-55 degree of protection. Outdoor junction boxes shall be of weatherproof construction. Junction boxes located in hazardous areas shall be flame-proof type. Junction boxes shall be complete with gasketed inspection cover conduit knock out/threaded hub and terminal blocks. Junction boxes shall be of two types viz one suitable for control wiring and the other with terminals for power cable terminations. Junction boxes for power cable terminations shall have minimum nine (9) nos. of terminals. Motor junction boxes for actuator drives shall have 20 way control terminals for terminations of 2.5 mm2.control cables. Separate terminals as required for termination of screen of shielded cables shall be provided. Junction boxes shall have the following indelible markings: Circuit nos. on top by while stenciled paint at site. Circuit nos. with ferrules (inside) as per approved drawing. Danger sign in case of 415V and above circuit.
3.04.00 3.04.01
3.04.02 3.04.03
3.04.04
3.04.05 3.04.06 3.05.00 3.05.01 3.05.02
Junction box should have a removal gland plate. Junction boxes shall be provided with two nos (2) earthing terminals complete with nuts and washers suitable for connection to 8 SWG G.I. wire. Terminals Multi-way terminal block of approved type, complete with screws, nuts, washers, and marking strips shall be furnished for connection of incoming/outgoing wires. Each control cable terminal shall be suitable for connection of 2 nos. 2.5 sq. mm stranded copper conductors without an damage to the conductor or looseness of conductors. Cable Termination & jointing kits The Bidder shall supply cable termination and jointing kits for LV Power and Control Cables along with all accessories. For cable termination and straight through joints for both LV Power and control cables, supply of various items of jointing kit such as necessary boxes, sealing compounds, ferrules, tapes, lugs, glands to be supplied shall be of reputed make. Cable End Markers
3.06.00 3.06.01 3.06.02
3.07.00
3.07.01
Each cable and conduit run shall be tagged with numbers that shall correspond to the cable and conduit schedules. Cables and conduits shall be tagged at their entrance and/or exit from any equipment, junction or pull box. Tags shall be aluminum with the number punched on it and securely attached to the cable by not less than two turns of G.I. wire. Location of cable joints, if any, shall be clearly indicated with cable markers with an additional inspection Cable Joint. Cable Glands Cable glands to be supplied by the Bidder for termination of cables shall be tinned brass gland, double compression type complete with necessary armor clamp and tapered washer etc. Cable glands shall match with the sizes of different LV power and control cables as required.
3.07.02 3.07.03 3.08.00
3.09.00
Cable Lugs Cable lugs to be supplied by the Bidder for termination of cables shall be tinned copper lugs suitable for termination of different cross-sections of LV power / Control cables. Lugs for power cables shall be compression type whereas lugs for Control/ Instrumentation/ Signaling cables shall be crimping type.
3.10.00
Sundry Steel All supports (including those for installation of cable trays), hangers, brackets shall be fabricated from galvanized steel. These shall be supplied and fabricated by the Bidder as per requirement.
3.11.00
Nameplate Nameplates shall be furnished for identification of devices and circuits. All switches, controls and indications shall be permanently and legibly marked in English as to clearly indicate their functions.
3.12.00
Grounding All material for grounding with regard to above and below grade earthing of electrical equipment, structures / column including the below grade earth grid shall be supplied by the Bidder.
3.13.00 3.13.01 3.13.02 3.13.03 3.14.00 3.14.01 3.14.02
Consumables and Erection Material Consumables Welding rods, gas, oil and grease, cleaning fluids, paints, electrical tape, plumbing and soldering material etc. shall all be supplied by Bidder as required. Hardware Bolts, nuts, screws, washers, supports, cable, clamps, ferrules, fixtures, inserts, sills, packers, shims, etc. shall also be provided by the Bidder. Danger board shall be supplied and fixed on various items on electrical equipment. Samples Owner reserves the right to call for samples if considered necessary and the same shall be submitted by the Bidder free and without any obligation. Any item of works or erection materials which have not been specifically mentioned but are necessary to complete the installation shall be deemed to be included in the scope
of this specification and shall be supplied and installed by the Bidder without any extra charge to the Owner
4.00.00 4.01.00 4.02.00 4.03.00 4.04.00
SPECIFIC REQUIREMENT - ERECTION The Bidder shall mount the equipment on respective foundation/supports, level and align the same and arrange for necessary grouting/anchoring Equipment erection shall be carried out in strict compliance with manufacturer's instruction and shall include all adjustments, checks and measurements. The Bidder shall record result of all erection tests and measurement and furnish copies of the same to the Owner for his reference and record. Schedule of suggested pre commissioning tests to be carried out on the above equipment are listed else where in this specification. Schedule of tests proposed to be carried out by the Bidder shall be submitted to the Owner in advance for approval in respect of each equipment. Excavation and Back Filling Bidder shall perform excavation and backfilling, as required. All excavation shall be back filled to the original level with good consolidation. Foundation and Civil works Equipment foundations, panel foundations and other civil work shall be provided by Owner. The Bidder shall check these foundations before commencement of erection to ensure their suitability. All final adjustment of foundation levels, chipping and dressing of foundation surfaces, setting and grouting of anchor bolts, sills, inserts and fastening devices shall be carried out by the Bidder including minor modification of civil work as may be required during erection. Any cutting of masonry / concrete work, which is necessary, shall be done by the Bidder at his own cost and shall be made good to match the original work. The Bidder shall obtain necessary approval of the engineer before proceeding with such work.
4.05.00 4.05.01 4.05.02 4.06.00 4.06.01
4.06.02
4.06.03
Concrete trenches and associated civil work shall be provided by the Owner as per trench route layout drawing furnished by Bidder. The Bidder can make use of those trenches etc. for cable / conduit installation, after getting approval from Owners engineer. Cabling and Grounding Cable installation work shall include erection of cable trays/racks, supports hangers, junction boxes, conduits, laying of conduits, dressing and clamping, jointing and termination (inclusive of supply of necessary jointing/ terminating kits, ferrules tapes and other accessories) and grounding of cable armor. In some cases buried cable may be acceptable, subject to approval of engineer, for which all excavation work, necessary back filling, supply of bricks and protection concrete slabs, removal of excess earth shall be considered part of the installation work. Bidder shall prepare in the specified format of the Owner, cable, conduit and tray schedule and interconnection diagram and submit for approval/record of the Owner.
4.07.00 4.07.01
4.07.02
Cable laying shall be started with approved cable schedule and interconnection diagram. Each core of the cables shall be provided with marking ferrules at all terminating ends as per the approved schematic and interconnection diagram. Cable trays and racks shall be numbered systematically. 4.07.03 Separate cable trays shall be used for the following group of cables. a. b. c. 4.07.04 415 V power cables Measuring, metering and control cables D.C Cables
Separate cables shall be used for following functions a. b. c. d. e. f. Power Control, interlock and indication Metering and measuring Alarm and annunciation CT Cables PT Cables
4.07.05
Embedded steel inserts, based on Bidders insert location and details, shall be kept on wall/floor/ceiling surfaces by the Owner for welding of cable tray brackets. The Bidder shall carefully examine those inserts & if necessary shall provide extra anchoring to make the cable tray system withstand horizontal / vertical accelerations due to seismic forces for indoor trays and wind load for outdoor trays, in addition to normal tray cable loadings. Bidder shall refer Cabling Notes and Details (dwg. No. K8B15-DWG-E-0400) for further details on cabling. Grounding installation work shall mean erection, welding, connection and painting, testing of above ground conductor and connection with Owners riser at nearest available locations including supply of galvanized flats. A continuous 50 x 6 mm G.S. Flat earthing conductor shall run along the supporting structure of overhead cable trays/cable shafts. This earthing conductor shall be attached to each section of cable tray/trays forming solidly grounded tray system through 50 x 6 mm G.S. Flats. For further details on grounding, Bidder shall refer Grounding notes and details (dwg. no. K8B15-DWG-E-0600) attached with this specification. Cables : Storage and Handling Cable drums shall be stored on hard and well drained surfaces so that they may not sink. In no case shall the drum be stored on the flat, i.e. with flange horizontal. Rolling of drums shall be avoided as far as practicable. For short distances, the drums may be rolled provided that they are rolled slowly and the direction marked on the drum. In the absence of any indication, the drums may be rolled in the same direction as it was rolled during taking up the cable.
4.07.06 4.07.07
4.07.08
4.07.09 4.08.00 4.08.01 4.08.02 4.08.03
4.08.04 4.08.05 4.08.06
For unreeling the cable, the drum shall be mounted on jacks or on a cable wheel. The spindle shall be strong enough to carry the weight of the drum without bending. While laying cable, cable rollers shall be used at an interval of 2000 mm max. The cables shall be strong enough to carry the weight of the drum without bending. Cable shall not be pulled from the end without having intermediate pushing arrangement. Bending radius of the cable during installation shall not be less than what is specified by the manufacturer. Cable Termination and Connection The work shall include all clamping, fitting, fixing, plumbing, soldering, taping, compound filling, cable jointing, crimping, connecting, shorting and grounding as required for the complete job. All equipment/material required for all such work shall be arranged by the Bidder and included in the price. When the equipment are provided with blank plates for cable conduit entry and cableend-box for power cables, the Bidder shall perform all drilling, cutting on the blank plate and any minor modification work required to complete the job. Control cable cores entering control panel/switchgear/MCC etc. shall be neatly bunched and served with nylon chord or PVC perforated tape to keep it in position at the terminal block. The Bidder shall tag all control cable cores in all junction box and at all terminations. The tags shall carry terminal numbers as per drawings The tags shall be of interlocked plastic type ferrules or approved equal. Spare core shall be similarly tagged, crimped with lug and taped on the ends. Spare cores shall be tagged with individual cable number. Termination and connection shall be carried out in such a manner as to avoid strain on the terminal. All cable entry points shall be sealed and made vermin and dust proof. Unused opening, if any, shall be effectively sealed. Testing Equipment The following minimum testing equipment shall be brought at site by Bidder: a. i) ii) b. c. d. e. f. g. Insulation tester Motor operated megger Hand operated megger 2000V grade 1000 V grade
4.09.00 4.09.01
4.09.02
4.09.03
4.09.04 4.09.05 4.09.06 4.09.07 4.09.08 4.10.00
Hand driven earth resistance megger, range 0-1/3-3 Ohms. Tong tester of suitable range. Contact resistance measuring set for micro ohms. Torque wrench. Multi-meter, test lamps, field telephone buzzer sets, different gauges. Digital voltmeter, ammeter and other measuring instruments.
h. 4.11.00 4.11.01 4.11.02 4.11.03 4.11.04 4.12.00 4.12.01 4.12.02
Secondary current injection set.
Checking and Cleaning of Parts All equipment parts and materials shall be carefully inspected and checked against the packing list and identified with erection drawings. Any discrepancy shall be reported forthwith in writing to the Owner and any rectification shall be with the full knowledge and approval of the Owner. All parts shall be thoroughly cleaned, all rust removed and surface polished, as required. Cleaned and polished parts shall be coated with anti-corrosive paints where necessary and stored with care and kept for erection. Opening of Packing Cases Packing cases and packages shall be opened in presence of the Employer or his authorized representative unless otherwise approved. Packing materials, timbers, nails and strips shall become property of Owner and shall be delivered or disposed off as directed by Owner. After opening the cases, packing material shall be removed immediately from storage areas of equipment to avoid fire hazards and damage. Methods and Workmanship Work shall be carried out in a first class, neat and workmanlike manner by technicians skilled in the appropriate trade. Details of installation shall be electrically and mechanically correct. Installation shall be carried out in such a manner as to provide easy access to other equipment installed. Inspection of Work In addition to Bidders supervision, Owner shall have the right to inspect at any time during erection, testing and commissioning of the equipment.
4.13.00 4.13.01 4.13.02 4.13.03 4.14.00
4.15.00 4.15.01 4.15.02 4.15.03
Protection of Work Bidder shall effectively protect his work, equipment and material from theft, fire, damage of tampering at his own expenses till the work is finally taken over by Owner. Finished work where required shall be suitably covered to keep it clean and free from defacement or damage. For the protection of his work, Bidder shall provide fencing and lighting arrangements, connect up space heaters and provide heating arrangements as necessary or directed by Owner. Bidder shall be held responsible for any loss or damage to equipment and material until the same is taken over by Owner in accordance with the Contract. Bidder shall be required to work in the same area as other contractors. Bidder shall protect and take care of the equipment and services, stores installed in the area by the other contractors such that no damage is caused by his works. For any damage caused
4.15.04 4.15.05
done by him to the equipment, services and works of the other contractors, he shall be liable to make good such damages at no cost to Owner. 4.16.00 4.16.01 Responsibility of Erection Bidder shall be fully and finally responsible for proper erection and safe and satisfactory operation of plant and equipment under his scope of work to the entire satisfaction of Owner. Work shall be executed in accordance with the directions, instructions and specifications which may be communicated to the Bidder by Owner from time to time. Equipment and materials which are wrongly installed shall be recovered and reinstalled promptly to comply with the design requirement, at the Bidders expense, to the satisfaction of Owner. Site Cleaning Bidder shall remove all scaffolding, ladders and temporary structures, erected by Bidder during erection in order to leave the work site clean and tidy to the satisfaction of Owner failing which the work shall not be considered as complete. 4.18.00 4.18.01 Erection tools and tackles The Bidder shall provide all tools, tackle, implements, mobile equipment such as crane, trailers, scaffoldings, ladders, welding machines, gas cutting, bending machine, hand crat, chain pulley blocks wire clues, hydraulic jack/motorized jack, wooden slipper, drill machine, hand/hydraulic compression tools for cable termination, vacuum cleaners box spanner of various size etc. which are required for transportation, handling and erection of the plant and equipment. Special erection tools, if any, furnished by the manufacturer along with the equipment may be provided by the Owner. Such tools shall be returned in good conditions to the Owner on completion of work. Owners tools and equipment may be made available on payment of charges if and when available. PRECOMMISSIONING TESTS Site tests to be carried out by the Bidder on completion of installation/erection of equipment are broadly listed below for ready reference and guideline only. The Bidder shall submit a detailed list of site tests of various equipment/system for Owners approval. Additional tests may have to be carried out without any extra charge, if desired by the Owner. Motors Motors shall be subjected to the following site tests as minimum. a. b. c. d. e. Physical checking of various parts/connections Insulation resistance test of winding, PI value and drying out, if required. Direction of rotation Starting current No load & load current measurement.
4.16.02 4.16.03
4.17.00
4.18.02
4.18.03 5.00.00 5.01.00
5.02.00
f. 5.03.00
No load run for 6 hours
AMF Control cum annunciation panel The AMF Control cum annunciation panel and LPBS shall be erected as per good engineering practice and assembled equipment shall be subjected to following site tests as minimum a. b. c. d. e. f. g. h. i. j. k. Physical checking of various parts/connections I.R. test Checking of control circuit Checking of overload relay & other protective devices Measurements of contact resistance (in micro- ohms) for all the three phase of circuit breaker. Measurement of resistance of the closing and tripping coils Checking the close trip operation at 70% and 100% of the rated auxiliary DC Voltage. Checking the auxiliary power circuits Checking of interlock provided and tripping of breaker through relay Testing of protective relays. Space heater operation check
5.04.00
Cables Cables shall be subjected to the following site tests as minimum. a. b. c. Physical checking of laying & termination Checking continuity of connections I.R. Test
6.00.00 6.01.00
DRAWINGS, DATA AND MANUALS To be submitted with the Bid Necessary drawings and technical leaflets of the following shall be furnished along with the bid: a. b. c. A network showing the proposed construction schedule indicating the milestone event. List of tools and tackles available with the Bidder for erection, testing and commissioning along with their capacity and rating Make, type and catalogue no. of different electrical items along with their leaflets, data sheets etc.
6.02.00
To be submitted for Approval and Distribution
E5: 10
After award of contract the Bidder shall furnish the drawing as indicated hereinafter for approval and after which for final distribution in quantities and procedures as set up in the applicable clause of the GCC. a. b. Make type and catalogue no. of cable termination kits, joints, and accessories. Dimensional GA drawing and data sheets for different electrical equipment such as AMF control cum annunciation panel etc. supplied under this specification. Bill of material for pre fabricated cable tray, conduits and accessories. Electrical layout showing equipment location, cable tray routing, etc. Cable tray/shaft details. Cable schedule and interconnection diagram with cable tray loading. Grounding layout and connection details.
c. d. e. f. g.
E5: 11
JINDAL POWER LTD.
ANNEXURE-I DATA SPECIFICATION SHEET FOR SITE METEOROLOGICAL CONDITIONS
DOCUMENT NO.: K8B15-SPC-M-0023, Rev. 1
JINDAL POWER LTD.
ANNEXURE-I
DATA SPECIFICATION SHEET FOR SITE METEOROLOGICAL CONDITIONS
1.
GENERAL Jindal Power Limited desires to set up 4 x 600 MW O.P Jindal Super Thermal Power Project near village Tamnar in Raigarh District in the State of Chhattisgarh, of which the Fuel Oil System under this specification constitute a part. In the event of any conflict between requirements of the clauses of this specification/documents and those of different codes/standards specified elsewhere in this specification, the most stringent requirement of all the clauses shall apply. Various equipment and items to be procured by the Contractor from his Sub-vendors shall be of proven design and good quality. However, the overall guarantee and responsibility shall wholly be confined to the Contractor of the package against this specification.
2.
Site / Working Conditions For the purpose of equipment design, the following data shall be taken into consideration: a) b) c) d) e) Site elevation above MSL Ambient Air Temperature : : < 261 M 500C Max. & 6.4 oC Min. 90% III per IS 1893-2005. 39 M/sec
Maximum Relative Humidity : Seismic Zone basic wind speed : :
3.
Climatic Conditions Meteorological data of site (Raigarh Station) is given below: a) b) c) d) e) Mean of daily max. temp. Mean of daily min. temp. Highest temp. recorded Lowest temp. recorded Relative humidity : : : : : 33.5 oC 21.5 oC 47.2 oC (19th June, 1960) 6.4 oC (24th December, 1959) Varies from 19% to 88%
SS-ANNEX-I: 1
JINDAL POWER LTD.
f) g)
Annual average rainfall Wind load
: :
Between 1000 2000 mm 39 m/sec. in accordance with IS : 875, Part-3 Zone III in accordance with IS: 1893, Part-3.
h)
Seismic Zone
SS-ANNEX-I: 2
ANNEXURE-II DATA SPECIFICATION SHEET FOR EMERGENCY DG SET
ANNEXURE II DATA SPECIFICATION SHEET FOR EMERGENCY DG SET
A.
DIESEL ENGINE
GENERAL INFORMATION Service Designation No. of engines required No. of engines working Duty Location Type of engine ACCESSORIES TO BE PROVIDED Base plate Sole plate Foundation bolts, nuts, sleeves etc. Governing system as specified Lubricating oil system as specified Turbo-charger and intercooler as specified Radiator water cooling system as specified Engine starting system as specified : Yes : Yes : Yes : Yes : Yes : Yes : Yes : Yes : Emergency Diesel Generator Plant : Internal combustion (Diesel Engine) : Five (5) : Four (4) : Intermittent : Outdoor, inside a shade : Vee type - Two (2) stroke/ Four (4) stroke.
1.00.00 1.01.00 1.02.00 1.03.00 1.04.00 1.05.00 1.06.00 1.07.00 2.00.00
2.01.00 2.02.00 2.03.00
2.04.00 2.05.00
2.06.00
2.07.00
2.08.00
SS-ANNEX-II: 1
3.00.00 3.01.00
ENGINE PARAMETERS Nominal output of engine at site referred to the alternator terminals and with machine operating under ambient conditions : Bidder to indicate KVA in accordance with the guidelines specified in this section at 0.8 power factor at 415 V, 50 Hz. 3 phase, 3-wire with neutral in ungrounded condition. Capacity of DG set shall not be less than 2000 KVA standard rating. Bidder to justify with calculation. : One hour in every twelve hours.
3.01.01
Period during which the engine will provide 10% greater output in every twelve hours Speed of the engine De-rating of the engine
3.02.00 3.03.00
: Not more than 1500 rpm. : Shall be done in accordance with BS ISO3046 pt I to VI for the difference in site condition from standard condition. : 2.5%
3.04.00
The tolerance for compression pressure, peak pressure and mean effective pressure LIQUID DATA Fuel of the engine
4.00.00 4.01.00
: High Speed diesel oil. The engine shall be capable of running with Light Diesel oil.
4.02.00
Analysis of fuel Specification : HSD IS-1460 : Clarified water As per Annexure-IV
4.03.00 4.04.00 5.00.00 5.01.00
Cooling water Analysis of clarified water SPECIAL FEATURE Starting feature
: The engine shall be capable of starting from cold condition on loss of normal A.C. supply and coming up to rated speed and rated voltage within 30 Sec.
SS-ANNEX-II: 2
Minimum margin on rating of engine
: The continuous engine break horse power rating at site condition shall be at least 15% greater than the maximum shaft horse power requirement of the generator at the rated KVA output and power factor. : 85 dB (A) at a distance of 1 M
5.03.00
Noise level
6.00.00
MATERIAL OF CONSTRUCTION Engine block including crank case Cylinder head Cylinder liner Crank case : Alloy cast iron. : Alloy cast iron. : Alloy cast iron. : Nitrided alloy- steel forging with integral balance weight. : Drop forged H.T. strength steel. : Forged aluminium alloy. : High tensile strength steel forging chrome plated: : Alloy cast iron (ductile) / alloy high strength grey iron. : Special heat resisting steel with chrome flashing and valve heads stellite faced. : Alloy steel. : Cast iron, IS: 210, Gr. FG-200. : : As per manufacturers standard. : As per manufacturers standard.
6.01.00
6.02.00 6.03.00 6.04.00
6.05.00 6.06.00 6.07.00
Connecting rod Piston Cam and cam shaft
6.08.00
Piston ring
6.09.00
Inlet & exhaust valves
6.10.00 6.11.00 6.12.00 6.12.01 6.12.02
Valve gear Fly wheel Radiator Shell Tubes
SS-ANNEX-II: 3
JIINDAL POWER J NDAL POWER LTD.. LTD B.
PIPES, VALVES, FITTINGS, ETC.
Sl.
Item
SERVICE High Speed Diesel Oil Cooling Water Pipe Seamless carbon steel As per IS-1239 (heavy as per ASTM-A 53 Gr.B. grade) for sizes upto 150 mm NB. For sizes 150mm NB. Pipe shall be as per IS-3589.
1.
Pipes
2.
Fittings a) 50 NB & below Forged to ASTM-A 105 Socket welded as per ANSI B 16.11 Wrought to ASTM A 234 Gr. WPB, Butt Welded as per ANSI B 16.9 As per ANSI B 16.5 Forged to ASTM-A-105 Socket welded as per ANSI B 16.11 Wrought to ASTM A-234 Gr. WPB Butt welded as per ANSI B 16.9 As per ANSI B 16.5
b)
Above 50 NB
3. 4.
Flanges Valves i) 65 NB & above
Butt welded ends ASTM Same as oil line valve A-216 Gr. WCB body & Pressure seal bonnet, Stainless Steel, trim, Renewable body seat Ring, outside screw And yoke, rising stem Socket welded end, ASTM-A 105/A216 Gr. WCB body & Bonnet, stainless Steel trim integral Seat, outside screw And yoke, rising Stem. ASTM A-193 Gr. 87 ASTM A-194, Gr. 2H Spiral wound compreSS-ANNEX-II: 4 ssed metallic asbestos SERVICE Same as oil line valve
ii)
50 NB & below
5. 6. 7.
Bolts Nut Gasket
ASTM-A-193 Gr. 87 ASTM-A-194 Gr. 2H Compressed CONSULTANTS DEVELOPMENTasbestos fibre with PVT. LTD. rubber binder.
C.
HORIZONTAL CENTRIFUGAL PUMP

GENERAL INFORMATION Service Designation Duty Location Type of pump : Emergency Diesel Generator Plant : Clarified cooling water pump : Intermittent : Outdoor : Horizontally Split Casing / End suction type : One (1) per DG Set : 1500 : Bidder to indicate : 30% to 125% of rated capacity : As per IS 5120 at Rated Capacity
1.00.00 1.01.00 1.02.00 1.05.00 1.06.00 1.07.00
1.08.00 1.09.00 1.10.00 1.11.00 1.12.00 2.00.00 2.01.00 2.02.00 2.03.00 2.04.00 2.05.00 2.06.00 2.09.00 2.10.00 2.00.00
Number of Pumps required Rated speed (r.p.m.) Rated Capacity (Cu.M/hr) Range of Operations Total Dynamic Head (MLC) MATERIAL OF CONSTRUCTION Casing Diffuser Impeller Wearing Rings Shaft Shaft Seal Mechanical Seal Base Plate Wetted Fastner
: ASTM A 743 Gr. CF8M : ASTM A 743 Gr. CF8M : ASTM A 743 Gr. CF8M : ASTM A 743 Gr. C440 : Stainless Steel SS-316 : ASTM-A276 Type 316 : Manufacturers Standard : IS-2062 : Stainless Steel AISI-304
SS-ANNEX-II: 5 DEVELOPMENT CONSULTANTS PVT. LTD.
ACCESSORIES TO BE PROVIDED Base plate Foundation bolts, nuts, sleeves etc. : Yes : Yes
3.01.00 3.02.00 3.03.00
Suction and Discharge Companion : Yes Flanges with Bolts, Nuts and Gaskets Gland Sealing Arrangement and Cooling : Yes
3.04.00
3.05.00
Bearing Lubrication and Cooling : Yes Arrangement Suction and discharge pressure Indicator Priming Connection with 3-way SS Isolating Valve Pump-motor Coupling Guard Vent with 3-way SS Isolating Valve Drain Connection with Valve Eye-bolts, Lifting Tackle etc. : Yes : Yes : Yes : Yes : Yes : Yes
3.06.00
3.07.00
3.08.00 3.09.00 3.10.00 3.11.00
SS-ANNEX-II: 6
ANNEXURE-III LIST OF MANDATORY SPARES
ANNEXURE-III LIST OF MANDATORY SPARES

1.00.00 DIESEL GENERATORS 1) 2) 3) 4) 5) 2.00.00 Four(4) Nos. Rotating Rectifiers (Diode) Two (2) Nos. Reference Voltage Adjuster Four(4) Nos. Varistor Two (2) Nos. Exciter PCB One (1) No. AC Module
DIESEL ENGINE 1) 2) 3) 4) 5) 6) 7) 8) 9) 10) 11) 12) 13) 14) 15) 16) Four (4) sets of fuel injection nozzles One (1) crank shaft with standard size journals One (1) set main bearings One (1) set big-end bearings Eight (8), V-belt for radiator fan Four (4), fuel injector One (1), set of fuel injection piping One (1), ring gear for fly wheel Eight (8) nos. of Element Corrosion Resistor. Eight (8) nos. of Element lub oil Filter. Eight (8) nos. of Element lub oil Bypass Filter. Sixteen (16) nos. of Element Fuel Filter. Sixteen (16) nos. of Plate corrosion Resistor. Four (4) nos. of Element Air cleaner outer. Four (4) nos. of Element Air cleaner inner. One (1) no. of Fuel Oil Pump.
SS-ANNEX-III: 1
17) 18) 19) 20) 21)
Four (4) nos. of Turbo-chargers. One (1) no. of Engine - starter Motor. One (1) no. of Lub Oil Pump. Sixteen (16) nos. of Piston rings & liner set. Bidder shall furnish suitable nozzle tester, barring bar, slings, eyebolts and other special equipment necessary for servicing the engine. Instruments- One (1) no. of each type and range Any other spare part recommended by the Bidder.
22) 23) 3.00.00
AMF PANEL 1) 2) 3) 4) Two (2) Nos. Annunciation window Two (2) Nos. Electronic Timer Sixteen (16) Nos. Indicating Lamps Four (4) Nos. Push Button
4.00.00
CONTROL PANEL 1) i) ii) 2) 3) Push Button Complete assembly - 5Nos for each colour Contact Element (1NO + 1NC) Block- 20Nos. Selector Switch-10Nos. for each type and rating Meter (Analog or Digital) i) ii) iii) iv) v) vi) vii) 4) 5) Ammeter-1No. for each type and range Voltmeter-1No. for each type and range Frequency-1No. for each type and range MW-1No. for each type and range MVAR-1No. for each type and range Power Factor-1No. for each type and range Synchroscope-1No. for each type and range
Indicating Lamps complete assembly-10Nos. for each Colour and type Mimic Lamps-10Nos. for each Colour and type
SS-ANNEX-III: 2
6) 7) 8)
MCB-2Nos. for each type and rating Door Limit Switch-2Nos Annunciation system i) Lamp Box with Facia & Lamps (LED type)- 25Nos. ii) Hooter-1No. iii) Each type of PCB (for non-PLC driven system)- 1(one) no.
SS-ANNEX-III: 3
ANNEXURE-IV CLARIFIED WATER ANALYSIS
ANNEXURE IV CLARIFIED WATER ANALYSIS CONSTITUENTS Calcium Hardness Magnesium Hardness Sodium Potassium Iron TOTAL CATIONS M - Alkalinity P Sulphate Chloride Nitrate TOTAL ANIONS Reactive Silica (Dissolved) Colloidal Silica pH value at 320 C Turbidity Alkalinity As CaCO3 CaCO3 CaCO3 CaCO3 CaCO3 CaCO3 CaCO3 CaCO3 CaCO3 CaCO3 CaCO3 CaCO3 SiO2 SiO2 CONTENT 148.5 65 35 < 0.2 ppm ppm ppm ppm ppm
248.7 ppm 114.5 ppm - ppm 70 ppm 34.2 ppm 30 ppm 248.7 ppm 10 ppm 3.0 ppm 7.15- 7.2 10 (Maximum) NTU
SS-ANNEX-IV: 1
O. P. Jindal Super Thermal Power Plant (4 X 600 Mw), Tamnar, Chhattisgarh
SECTION-III PROPOSAL EXHIBIT SHEETS
Rev-1
CONTENTS
SCHEDULES SCHEDULE-I SCHEDULE-II/1 SCHEDULE-II/2 SCHEDULE-III SCHEDULE-IV SCHEDULE-V SCHEDULE-VI SCHEDULE-VII SCHEDULE-VIII SCHEDULE-IX SCHEDULE-X
DESCRIPTION PROPOSAL PARTICULARS TECHNICAL PARTICULARS (MECHANICAL) TECHNICAL PARTICULARS (ELECTRICAL) WORK SCHEDULE DRAWING SUBMISSION SCHEDULE DEVIATION SHEET-PART-A DEVIATION SHEET-PART-B QUALIFYING REQUIREMENT SCHEDULE DECLARATION SHEET PRICE BREAKDOWN SHEET MAINTENANCE TOOLS & TACKLES
Rev-1
SCHEDULE-I PROPOSAL PARTICULARS 1. 2. 3. 4. 5. Bidders Complete Company Name Bidders Proposal Number Bidders Proposal Date Bidders Proposal Validity Name and Designation of the Officer of the Bidder to whom all references shall be Made for co-ordination a) Whether registered with D.G.S. & D? b) If so, give : i) Registration Number ii) Photostat copy of D.G.S.& D reference letter. 7. Photostat copy of Income Tax Clearance Certificate furnished Terms of Payment a) Terms of payment as per Owners Specification is acceptable? If not, specify terms of payment : Yes/ No : : : : : : :
6.
Yes/ No
8.
b) 9.
Delivery Period a) Delivery period in months for complete equipment from the date of issue of LOA (allowing time for approval of drawings and test certificates) :
b) Is the delivery period guaranteed under penalty? 10. Conformance a) Is the equipment offered strictly in conformance with the Owners Specification? b) If not, have the Deviation Sheets been duly filled up ?
Document No. : K8B15-SPC-M-0023 Rev-1 SCH-I: 1
Yes/ No
Yes/ No
Yes/ No
11.
Performance guarantee period for the equipment offered : a) b) From the date of commissioning at site From the date of despatch : : : Yes/ No
12.
Particular of past experience of similar work furnished ?
Rev-1
SCH-I: 2
SCHEDULE-II/1
TECHNICAL PARTICULARS (MECHANICAL)

1.00.00 1.01.00 1.01.01 1.01.02 1.01.03 DIESEL ENGINE AND ACCESSORIES General Information Make Type and Model No. Total weight of unit, Tonnes : : :
1.01.04
Basic type and rating at standard condition,
HP/KW
1.01.05 1.01.06 1.01.07 1.01`.08 1.01.09 1.01.10 1.01.11 1.01.12 1.01.13 1.01.14 1.01.15 1.01.16 1.01.17 1.01.18 1.01.19 Rotation direction (viewed from Power take-off end) Derating factors for altitude, % Derating factor for ambient temperature, % Net engine H.P. at site condition, HP Operating speed, rpm Number of strokes per cycle Arrangement of cylinders Number of cylinders Bore, mm Stroke, mm Swept volume, cc Compression ratio Maximum firing pressure, kg/sq.cm (g) Mean piston speed, rpm Brake mean effective pressure at rated load, kg/sq.cm (g) Mean indicated pressure at rated load, kg/sq.cm : : : : : : : : : : : : : : :
1.01.20
Rev-1
SCH-II/1: 1
O. P. Jindal Super Thermal Power Plant (4 X 600 Mw), Tamnar, Chhattisgarh :
1.01.21
Firing order (viewed from power take off end), kg/sq.cm Maximum time required to start the engine from cold condition and to bring up to full speed, seconds Rate of loading per second after attaining full speed, KW/Sec.
1.01.22
1.01.23
1.01.24
BSFC at : a) b) c) d) 1/4 load, gram/kwhr 1/2 load, gram/kwhr 3/4 load, gram/kwhr Full load, gram/kwhr : : : : : : : : : :
1.01.25 1.01.26 1.01.27 1.01.28 1.01.29 1.01.30 1.01.31
Lub oil temperature, Deg.C Lub oil pressure, kg/sq.cm (g) Fuel oil pressure, kg/sq.cm (g) Water inlet/outlet temperature, Deg.C Cyclic irregularity Recommended specification of fuel oil Governing : a) b) Temporary Permanent (Indicate) specific
: :
1.01.32
Material of construction codes/standards) : a) b) c) d) e) Cylinder Cylinder head Cylinder liners Crank shaft Connecting rod
Rev-1
: : : : :
SCH-II/1: 2 DEVELOPMENT CONSULTANTS PVT. LTD.
f) g) h) I) j) k)
Piston Piston rings Gudgeon pin Inlet/exhaust valves Valve springs Heat exchanger : i) ii) Shell Tubes
: : : : :
: :
1.01.33
Protection Devices a) b) c) High water temperature Deg.C Low lube oil pressure, kg/sq.cm(g) Overspeed, rpm : :
1.02.00 1.02.01
Lubricating Oil System General Information a) b) Type Minimum acceptable lub oil temperature at start up, Deg.C Lub oil consumption at rated load, L/hr. Recommended specification of lubricating oil : :
c) d) 1.02.02
: :
Engine Driven Lubricating Oil Pump a) b) c) d) e) f) Type Number/engine Location Capacity, L/min. Drive rating, KW Discharge pressure, Kg/sq.cm. : : : : : :
Rev-1
SCH-II/1: 3
1.02.03
Motor Driven Lubricating Oil Pump (For priming/ pre-lubrication of lub oil circuit, if required) a) b) c) d) e) f) g) Type Number/engine Location Capacity, L/min. Drive rating, KW Delivery pressure, Kg/sq.cm. Materials of construction (Indicate applicable codes/ standards) i) Casing : : : : : : :
: :
ii) Shaft 1.03.00 1.03.01 Turbo-Charger General Information a) b) c) d) e) f) Make Type Number/engine Speed, r.p.m. Charger air pressure at rated load, kg/sq.cm Material of construction (Indicate specific codes/ standards) I) ii) 1.03.02 Turbine blade material : Blower blade material :
: : : : :
After-Cooler a) b) c) d) Type Water flow, L/min. Water inlet temperature, Deg.C Water outlet temperature, Deg.C
Rev-1 SCH-II/1: 4
: : : :
e) f) g) h) I) 1.04.00
Free air flow, Cu.m./hr Inlet air pressure, Kg/sq.cm Inlet air temperature, Deg.C Air temperature drop, Deg.C Material of construction
: : : : :
Governing System a) b) c) d) e) f) g) Type Make Steady state speed Steady state incremental speed regulation Prescribed speed band All other details of speed control arrangement Class of governing : : : : : :
1.05.00 1.05.01
Cooling System Engine Jacket Water Cooling a) b) c) Type Engine jacket capacity Expansion tank/Head rank on radiator i) ii) iii) iv) d) Capacity of each tank, Litre Number Dimension, mm x mm Location : : : : : :
Water pump i) ii) iii) Type Number Capacity of each pump, L/min.
Rev-1 SCH-II/1: 5
: : :
O. P. Jindal Super Thermal Power Plant (4 X 600 Mw), Tamnar, Chhattisgarh : : :
iv) v) vi) e)
Type of drive Drive rating, KW Location
Cooler i) ii) iii) iv) v) vi) Type and make Number/engine Jacket water flow, L/min Inlet jacket water temperature, Deg.C Outlet jacket water temperature, Deg.C Cooling Water flow, L/min for shell/tubes, : : : : : : :
vii) Design pressure Kg/sq.cm viii) Hydro-test Kg/sq.cm ix) x) pressure
for
shell/tubes,
Effective heat transfer area, Sq.M Number of plates per heat exchanger (including extra) Gasket type & material
: :
xi)
: :
xii) Cleaning frequency of heat exchanger, hours xiii) Whether Cooler by-pass line with control valve, provided ? 1.05.02 Lub Oil Cooling a) b) c) Type Engine lub-oil capacity, Litres Lub-oil cooling circulating pump i) ii) iii) Type Number/engine Location
Rev-1 SCH-II/1: 6
Yes/No
: :
: : :
O. P. Jindal Super Thermal Power Plant (4 X 600 Mw), Tamnar, Chhattisgarh : : : : : : : : : :
iv) v) vi)
Capacity, L/min. Delivery pressure, kg/sq.cm(g) Type of drive
vii) Drive rating, KW d) Lub-oil cooler i) ii) iii) iv) v) Type Number/engine Lub-oil flow, L/min. Lub-oil inlet temperature, Deg.C Lub-oil outlet temperature from cooler, Deg.C Water inlet temperature to cooler, Deg.C
vi)
: :
vii) Water outlet temperature from cooler, Deg.C viii) Water flow, L/min ix) x) xi) Design pressure, kg/sq.cm(g) Test pressure, kg/sq.cm(g) Effective heat transfer area, sq.m
: : : : :
xii) Number of plates per heat exchanger (including extra) xiii) Cleaning frequency, Hours e) Whether provided i) Lub-oil by-pass to cooler with control valve
Yes/No
1.05.03
Engine air intake filter a) b) c) Type Manufactured by Pressure Drop across filter
Rev-1 SCH-II/1: 7
: : :
O. P. Jindal Super Thermal Power Plant (4 X 600 Mw), Tamnar, Chhattisgarh : :
d) e)
Free area Particle removing efficiency
1.05.04
Fan cooled Radiator a) b) c) d) e) f) g) h) Type Make Location Water inlet temperature, Deg.C Water outlet temperature, Deg.C Cooling air flow, Cu.M./Hr Total cooling surface area, Sq.M. Material of construction (Indicate specific codes /standard) i) ii) iii) Tubes Fins Header : : : : : : : : : :
1.05.05
Cooling Fan a) b) c) d) e) f) Type Number Location Capacity of each fan, N.Cu.M/Hr Power installed for each fan, KW Maximum power consumption of cooling air fan at MCR of generator at rated operating condition, KW Fan speed, r.p.m. Total cooling surface area, Sq.m. Material of construction (Indicate applicable codes/standards)
Rev-1 SCH-II/1: 8 DEVELOPMENT CONSULTANTS PVT. LTD.
: : : : : :
g) h) i)
: :
1.05.06 1.05.07
Total cooling water required per engine, Cu.M/Hr Cooling water make up required per engine, Cu.M/Hr (To be provided by the owner) Engine Starting System Electric Starting System General a) b) Type No. of electric starter motor provided & total KW rating Minimum no. of consecutive starting possible Is the system complete with auto starter, indicating lamps, cable etc.
: :
1.06.00 1.06.01
: :
c) d)
: :
1.07.00 1.07.01
Exhaust System General Information a) b) c) d) Type Exhaust manifold pressure, kg/sq.cm. Exhaust manifold temperature, Deg.C Maximum allowable temperature difference from two cylinders, Deg.C : : : :
1.07.02
Silencer a) b) c) d) e) Type Maximum noise attenuation, db Material of construction Diameter, mm Spark arrester, Yes/No : : : : :
1.07.03
Stack a) b) Diameter, mm Height, m

Rev-1 SCH-II/1: 9
: :
O. P. Jindal Super Thermal Power Plant (4 X 600 Mw), Tamnar, Chhattisgarh : : : Yes/No Yes/No
c) d) e) 1.08.00 1.08.01
Material of construction Whether rain protection cowl provided Whether lightening arrester provided
Fuel Oil System General Information a) b) Type Specific fuel oil consumption per engine at 1/2, 3/4, full load at site condition, gm/kw/hr Maximum F.O. viscosity at engine inlet : :
c) 1.08.02
Fuel Oil Day Storage Tank a) b) c) d) e) f) g) Type of construction Number Dimensions, mm Effective volume, Cu.m. Capacity, Tonnes Design and Testing Standard Accessories provided with each : : : : : : :
1.08.03
Strainer a) b) c) d) e) f) Type & Size Number Location Size of screen mesh, mesh Capacity, cu.m./hr Accessories and connections provided : : : : : :
1.09.00 1.09.01
Piping, Fittings and Valves General a) Furnish piping and valve schedule with size, type of ends, wall thickness, material of
Rev-1 SCH-II/1: 10
construction, rating, codes etc. for oil system b) Furnish all interconnecting piping and fittings, hangers support etc. as required :
Rev-1
SCH-II/1: 11
SCHEDULE-II/2
TECHNICAL PARTICULARS (ELECTRICAL)

A. AC MOTOR
1.0 1.1 1.2 1.3 1.4 1.5 2.0 2.1 2.2 2.3 2.4
GENERAL Application Quantity Make Frame Size Applicable Standard TYPE AND RATING Type of Motor Service Duty Cycle/Designation Rated Continuous Output At 40 Deg.C ambient At 50 Deg.C ambient KW KW : : : : : : : : : :
2.5 2.6 2.7 2.8 2.9 2.10 2.11
Rated Speed Rated Voltage & % variation Rated Frequency & % variation Full load current No load current Rated Power Factor
r.p.m. : : : Amps : Amps : : : : :
Efficiency at rated voltage and frequency : a) Full load % b) c) 3/4 load 1/2 load % %
3.0 3.1
PERFORMANCE Method of Starting

Rev-1 SCH-II/2: 1
:
3.2 3.3 3.4
Starting Current at rated voltage Starting Torque at rated voltage Starting time at : a) b) With load Without load (driven equipment coupled)
% flc. : kg.m : 80% 100% 110% Voltage Voltage Voltage sec. sec : : 80% 100% 110% Voltage Voltage Voltage sec. sec. : :
3.5
Safe stall time at a) b) Hot condition Cold condition
4.0 4.1 4.2 4.3 4.4 4.5 4.6 4.7
CONSTRUCTION Degree of Protection of Enclosure Method of Cooling Insulation Class Temperature Rise Over 50 Deg.C ambient (by resistance) Tropicalised Winding Connection Bearings a) b) c) Make Type Recommended lubricant : : : : : : :
Yes/No : : D.E. N.D.E.
4.8
Motor Terminal Box a) b) c) d) Type Fault withstand Current KA Fault Current Withstand Time Sec. : : :
Cable lugs & glands furnished Yes/No :
5.0
ACCESSORIES
Rev-1
SCH-II/2: 2
5.1
Space Heaters a) b) No. x Watt Volt, phase, frequency : :
5.2
Winding temperature detector a) b) Type Nos. furnished : :
5.3
Bearing temperature detector a) b) Type Nos. furnished : :
5.4
Temperature Indicators a) b) c) Type Nos. provided Locations : : :
5.5
Temperature Alarm Contact a) b) Nos. provided Locations : : : : : : :
5.6
c) Contact rating Flow Switch a) b) c) d) Type Nos. provided Locations Contact Rating
5.7
Current Transformer for differential protection a) b) c) Nos. provided Current Ratio Class : : :
5.8
Accessory Terminal Box a) No. provided :
Rev-1
SCH-II/2: 3
b) 6.0 6.1
Cable glands furnished
Yes/No:
GROUNDING No. of grounding pads provided a) b) On motor body On terminal box : :
7.0 7.1 7.2 7.3
MISCELLANEOUS Type of mounting :
Overall dimension (LxBxH) mm x mm x mm : Moment of Inertia (Sq.GD) a) b) c) Stator Rotor Total Kg.Sq.m Kg.Sq.m Kg.Sq.m : : :
7.4
Weight a) b) c) Stator Rotor Total Kg Kg Kg : : :
Rev-1
SCH-II/2: 4
DG LOAD PCC & AMF Panel (Separate sheet shall be used as applicable) 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 ASSEMBLY Make : Type Reference Standard Location (Outdoor / Indoor) Mounting Voltage (Nom./Max.), Volt Rated Nominal Current (In-panel) Phase, No. of wires, Frequency No. Hz 1.9 Short Circuit Rating a) b) 1.10 Interrupting Symmetrical, KA rms Short time for1 sec., KA rms : : : : : : : : : :
Insulation Level 1-min., 50 Hz Voltage withstand, KV rms :
1.11
Construction a) Metal clad, free standing floor mounting Yes/No
1.12
Enclosure a) b) Degree of Protection Thickness of sheet metal, mm i. ii. iii. iv. v. vi. Load Bearing member Frame Door (no equipment) Door (equipment mounted) Partition Integral Base frame
Rev-1
: : : : : :
1.13
PCC & AMF Panel fully assembled, wired and tested at factory Yes/No Termination of Incomer (Bus-duct / Cable) CONSTRUCTION Design a) b) Completely compartmentalized Working height limits from top of base frame Termination of Incomer (Bus-duct/Cable) Clearance in Air (Phase-Phase) Clearance in Air (Phase- Netral) Minimum cable termination Height Max. size / no. of cable that can be terminated in the cable chamber with out using extension Provision of earthing switch / Truck Gland plate thickness (multi-core / single core) Maximum height of panel Cable alley width Integral Base frame size Safety auto-shutter provided at drawout Panel extendable at both end Removable FRP shrouds bus bar joints/tap Any Dummy panel considered Whether Bus coupler panel needs adaptor pane Maximum shipping length
: :
1.14 2.0 2.1
: :
c)
d) e) f) g)
: : : :
h) i)
: :
j) k) l) m)
: : : :
n) o)
: :
p) q)
: :
r) 2.2
Draw out features provided for

a) Circuit breaker with SERVICE, TEST and ISOLATED position Yes/No b) c) d) Voltage Transformers Protective Relays Yes/No Yes/No
: : :
MCC module provided with service test & isolated position Yes/No
2.3
Breaker Cubicle a) Breaker cubicles restricted to bottom 2-tiers only Yes/No Working height limits from floor level
b)
mm
c)
Cubicle door can be closed with Breaker in isolated position Yes/No
2.4
Control Compartment provided with individual front access door? PCC section provided with a) b) c) Removable back cover Full height cable chamber Cable alley width
2.5
: : : :
2.6 2.7
Horizontal wire way for inter panel wiring All meter, switch and relays flush mounted type Yes/No Minimum clear space required at a) b) c) d) Front for breaker withdrawal, mm Front of other panels Rear Clearance from ceiling mm
2.8
2.9
Vertical Section for a) Overall Dimension (L x B x H), mm i) ii) Incomer Outgoing Feeder
Rev-1
: : :
SCH-II/2: 7
b) 3.0 3.1 3.2 3.3 3.4
Approximate Weight ,
Kg
BUSBAR Make : : :
Material & Grade Reference, Standard Cross Sectional area, sq.mm a) b) Main Bus bar Vertical Bus bar (specify min size) Control supply Bus Auxiliary Bus Ph / N Ph / N
: :
c) d) 3.5
: :
Continuous current (at site condition, 50 C ambient & within cubicle) a) b) Main bus bar Vertical bus bar Amp Amp
: : : : :
3.6 3.7 3.8
Maximum temperature rise over 50 C Short-time current for 1 sec. KA rms. Separate enclosure/phase barriers sleeving/shrouding provided for : a) b) c) Main busbar Vertical droppers Circuit Breaker connections
: : :
3.9
Bus Connections : a. b. c. Silver plated Provided with anti- oxide grease Bimetallic connectors between dissimilar metals : :
3.10
Minimum clearance of bare busbar and connection : a) Phase to phase mm

Rev-1
:
b) 3.11 3.12
Phase to ground
mm mm Yes/No
: : : : :
Busbar support spacing Busbars colour coded HR PVC Sleeving Heat Shrinkable Type
3.13
Bus Support Insulator a) b) c) d) e) f) g) Make : Type Reference Standard Voltage class KV mm : : : : : :
Min. Creepage Distance Cantilever Strength Net Weight
Kg/sq.cm Kg
4.0 4.1 4.2 4.3 4.4 4.5 4.6 4.7
CIRCUIT BREAKER Make Type : : : KV : : :
Reference Standard Rated Voltage (Highest volt) Rated Frequency No. of Poles Rated Currents : a) Continuous (at site condition, 50 C amb. & within cubicle), Amp. Short-time Current for1 sec. KA rms. Hz No.
: :
b) 4.8
Maximum temperature rise over 50 C ambient C. Rated Operating Duty Interrupting Capacity at rated Voltage and Operating duty a) Symmetrical KA rms.
Rev-1
: :
4.9 4.10
: :
b) 4.11 4.12
Asymmetrical
KA rms. KA.peak
: :
Rated Making Current Transient Recovery Voltage a) b) Rate of Rise Peak Voltage
KV/ms KV
: :
4.13
Insulation Level 1-min. 50 Hz voltage withstand KV rms. :
4.14
At 100% interrupting capacity a) b) c) Opening time Arcing time Total tripping time ms. ms. ms. ms. : : : : : : :
4.15 4.16 4.17 4.18 4.19
Total closing time Number of breaks per pole
Total length of breaks per pole mm Total length of contact travel mm Rate of Contact Travel a) b) At tripping At closing m/s m/s
: :
4.20
No. of breaker operations permissible, without requiring inspection, replacement of contacts and other main parts a) At 100% rated current b) At 100% rated interrupting current
: : :
4.21
Type of Contacts a) b) Main Arcing : :
4.22
Material of Contacts a) b) c) Main Arcing Whether contacts are silver plated

Rev-1
: : :
SCH-II/2: 10
d) 4.23 4.24
Thickness of silver plating Kg
: :
Contact Pressure at no load Minimum clearance in air a) b) Between poles
mm
: : :
Between live parts & ground mm
4.25 4.26
Type of arc control device ? Operating Mechanism a) b) c) d) Type No. of breaker operations stored Trip free or fixed trip ? Anti-pumping features provided?
: : : :
4.27
Spring Charging Motor a) b) c) Rating Voltage KW V : : :
Permissible Voltage variation % Time of charging
4.28
Closing Coil a) b) c) Voltage V Permissible Voltage variation % Closing current at rated voltage A : : :
4.29
Tripping Coil a) b) c) Voltage V % A : : :
Permissible Voltage variation Trip current at rated voltage
4.30
For trip circuit supervision can the tripping coil be connected in series with a) b) Green lamps when breaker is open Red lamps when breaker is closed
: : :
4.31
Breaker/Cubicle Accessories
Accessories such as control switch, indication lamps, relays furnished as specified Breaker/Breaker Cubicle provided with following : a) b) c) d) e) f) g) h) I) j) Mechanical safety interlock Automatic safety shutter Emergency manual trip Mechanical ON-OFF indicator Manual spring charging device Manual operating handle Operation counter Charge/Discharge indication Cell switch with 4 NO + 4 NC contacts :: Spare auxiliary switch with 6 NO + 6 NC contacts for interlock mounted on stationary parts as specified Test/ Service position Limit switches
: : : : : : : :
k) 4.32
Cell/Auxiliary Switch a) b) Are switch contacts convertible type? Contact rating 220V DC i) ii) Make & Continuous Break (Inductive) Amp Amp Kg : : : :
4.33 4.34
Net weight of the breaker
Impact load for foundation design (to include deadload plus impact values on opening at maximum interrupting rating) Kg Overall Dimension (LxBxH) mm
: : :
4.35 4.36
Type test report on identical breaker furnished CONTROL MODULE Control Modules:
5.0 5.1
Rev-1
SCH-II/2: 12
Fully draw out 5.2
Yes/No
Power / Control disconnects silver plated for good contacts Draw out Modules of same type & rating are physically & electrically interchangeable Module sizes (L x D x H) a) Incomer Breaker 3200 A 2500 A 2000 A 1600 A 1250 A b) Outgoing feeder Breaker 3200 A 2500 A 2000 A 1600 A 1250 A 1000 A 800 A mm mm mm mm mm mm mm mm mm mm mm mm
5.3
5.4
: : : : :
: : : : : : :
6.0 6.1
CONTROL & INDICATIONS Push Buttons a) b) c) Make Type & Cat. No. Contact rating i) Make & Continuous o 240 V AC
Rev-1
: : : Amp Amp : :
SCH-II/2: 13
o ii)
220/48/24 V DC
Amp Amp Amp Amp
: : : : :
Break (Inductive) o o 240 V AC 220/48/24 V DC
d) 6.2
Number of Contacts (NO & NC)
Lamps a) b) c) d) Make Type & Cat. No. Voltage Burden : : :
6.3
Selector Switch a) b) c) d) Make Type & Cat. No. 3-position stay put type Contact rating i) Make & Continuous o o ii) 240 V AC Amp : : : : : : : : Amp : :
220/48/24 V DC Amp
Break (indicative) o o 240 V AC
220/48/24 V DC Amp
e) 7.0 7.1 7.2 7.3 7.4
Key interlock furnished?
ANNUNCIATOR Make & model Type Reference Standard Sequence designation : : : :
Rev-1
SCH-II/2: 14
7.5 7.6 7.7 8.0 8.1 8.2 8.3 8.4 8.5 8.6
No. of windows per group Overall dimension of a group (mm) Detailed write-up furnished ? CURRENT TRANSFORMER Make Type Reference Standard C.T. Ratios as per drawings ? Rated frequency Class/ALF or ISF/VA burden furnished for a) b) Relaying C.T. Metering C.T. :
: : :
: : : : : : :
8.7
Short-Circuit Withstand a) b) Short-time current for 1 sec. KA rms. Dynamic current KA peak : : : : :
8.8 8.9 8.10 9.0
Class of Insulation Temperature rise over 50 Deg.C ambient Basic Insulation level KV rms
CONTROL & AUXILIARY TRANSFORMER (As applicable) a) b) c) d) e) f) g) h) i) Make Ratio VA rating Taps available Connection Fuse protected Auto changeover scheme included Local & Remote alarm for control supply Class of Insulation
Rev-1
: : : :
:
j) 10.0 10.1 10.2 10.3 10.4 10.5 10.6 10.7 10.8
Module size
VOLTAGE TRANSFORMER Make Type Reference Standard Voltage ratio Rated frequency Accuracy class VA burden : Over Voltage factor a) b) Continuous 30 seconds : : : : : : : : : : :
10.9 10.10 10.11 10.12
Class of Insulation Temperature rise over 50 C ambient Basic Impulse Level Winding Connection a) b) Primary Secondary Kvp
: :
10.13
Fuse a) b) Continuous rating Amp. KA rms. : :
Symmetrical fault rating
11.0 11.1
RELAYS Microprocessor based / Numerical type with built in test facilities Type of mounting ? Reference Standard All relays furnished as per the drawings & Annexures All relevant relay leaflets and catalogue furnished ?
Rev-1 SCH-II/2: 16
: : :
11.2 11.3 11.4
: :
11.5

Make Type Cat. No.
11.6
Relay Details
11.6.1 Incomer a) b) c) d) e) f) Voltage controlled IDMTL over current (51V) Reverse power (32) Line over voltage (59) Line under voltage with time delay (27) Under frequency (81U) VT fuse failure : : : : : :
11.6.2 Miscellaneous relay a) b) c) Anti-pumping relay Trip supervision relay Time delay relay Delay on drop out Delay on pick up e) Lock out relay with 220 V DC Hand reset 86 4 pairs of contacts 8 pairs of contacts f) Latch auxiliary relay 220V DC with one operating coil and one rest coil 52X 4 pairs of contacts 8 pairs of contacts g) Aux. Relay 220V DC with self reset 4 pairs of contacts 8 pairs of contacts h) i) 12.0 12.1 DC supply supervision relay Synchro Check relay 25 X : : 62 2 : : 94 74 : :
: : : : : : : :
METERS Make :
Rev-1
SCH-II/2: 17
12.2 12.3 12.4 12.5 12.6
Type Reference Standard Size Scale Accuracy class Instrument safety factor Range/Rating Burden :
: : :
12.7
Meter Switch a) b) b) Make Type Cat. No. : : :
13.0 13.1 13.2 13.3 13.4
SECONDARY WIRING Type of Insulation Voltage grade Conductor material Conductor Size (Minimum) a) b) Potential Circuit Control & Current Circuit : : : : : :
13.5 14.0 14.1 14.2 14.3 14.4 14.5
Wires identified at both ends with markers? TERMINAL BLOCK Make Type Cat. No. Voltage grade 20% spare terminals furnished Suitable for cable cross section
: : : : :
15.0
CABLE TERMINATION
15.1
Cable termination/connection furnished as specified Cable entry provision from bottom Removable Gland Plate a) b) c) Material for multi-core cable Material for I/C cable Thickness of the plate
: Yes/No :
15.2 17.3
: : :
15.4 Minimum Height from gland plate 15.5 Gland plate cutout dimension Type of terminal (Power / control / CT) 16.0 16.1 16.2 GROUND BUS Ground bus furnished Material 19.3 Size 17.0 17.1 17.2 17.3 NAME PLATE Material Thickness Size for : a) b) Panel Equipment / Device (flush) Internal components 18.0 18.1 SPACE HEATER / PLUG SOCKET Cubicle Heater a) b) c) 18.2 Thermostat controlled Wattage Voltage : : : : : : : : : :
Plug Socket a) Type

Rev-1 SCH-II/2: 19
:
b) 18.3
Rating
Motor Heater a) b) c) Provision made for motor heater supply Separate contactor furnished If so, contactor rating : : :
18.4
Cubicle heater, motor heater & plug socket circuit provided with individual switch fuse unit ? : AC / DC SUPPLY Isolating switch fuse / MCB unit for incoming supply : a) b) A.C. - type & rating D.C. - type & rating : :
19.0 19.1
19.2
Isolating switch fuse / MCB unit at each cubicle a) b) A.C. - type & rating D.C. - type & rating
: : :
19.3 20.0 20.1
Local & Remote monitoring of supply available? : PAINTING Finish a) b) Inside Outside : :
21.0 21.1 21.2 22.0 22.1
NO.OF ACCESSORIES FURNISHED Breaker lifting / handling truck Racking in/out handle DRAWINGS / DATA Typical drawings furnished for a) b) c) General Arrangement Foundation Plan Breaker Control Schematic : : : :
: :
Rev-1
SCH-II/2: 20
d) 22.2 22.3
Single line diagram (showing power components, protn & metering) : Yes/No :
Bill of Material G.A. Drawing of each board furnished Catalogues or relays Catalogues of ACBs Catalogues of other switchgear components Type test certificates
23.0 23.1
TESTS Routine test to be performed on PCC/DB a) b) c) d) e) f) : : : : : :
23.2
Type test quoted a) b) : :
24.
DIMENSIONS & WEIGHTS OF ALL PCC
Overall Dimension mm
Approx weight Kg
a. b. c. d. e. f.
: : : : : :
1.00.00 .01.00
BATTERY AND BATTERY CHARGER BATTERY

1.01.01
General a) Make b) Cat No. c) Type d) Reference Standard : : : :
1.01.02
Rating a) Rated Voltage Volt : :
b) 10-hour rating at 27 Deg.C to 1.85 Volt per cell AH c) 1-hour discharge rate to 1.85 Volt per cell d) 1-minute discharge rate to 1.85 Volt per cell e) Does the battery meet the required duty cycle curve ? f) 1.01.03 Cell voltage characteristics during duty cycle furnished? Performance
a) Does the battery meet the required duty cycle curve ? Yes/No b) Cell voltage characteristics during duty cycle furnished? Yes/No c) Minimum cell voltage during duty cycle
: :
d) AH efficiency at 10-hour e) Expected life of Battery f) 15% margin considered g) 25% ageing compensation factor considered Yes/No : 1.01.04 Battery Characteristics a) Recommended charging rate for Volt/Cell Amp i) Float charging
Document No. : K8B15-SPC-M-0023 Rev-1 SCH-II/2: 22
Hr. Yes/No
: : :
:
O. P. Jindal Super Thermal Power Plant (4 X 600 Mw), Tamnar, Chhattisgarh : : : :
ii) Equalising Charge iii) Boost charging in 10 hrs. a) Start b) Finish b) Recommend specific gravity at 27 Deg.C i) For first filling ii) At full charge iii) At end of 10-hour discharge c) Short-circuit current for a dead-short across battery terminals, when i) Float charge at 2.23 Volt/Cell ii) Boost charge at 2.75 Volt/Cell Ohm
: :
KA KA
: : : :
d) Battery internal resistance e) Cell voltage characteristics during charging furnished ? 1.01.05 Cells
a) Number of cells per battery b) Type of the cell c) Cell designation as per I.S. d) Material of the container e) Overall dimension of each cell mm f) Weight of complete cell i) Without acid ii) With acid g) Internal resistance of cell 1.01.06 Intercell Connector a) Intercell connector furnished? b) Type of intercell connector bolted/burned c) Material of intercell connector 1.01.07 Plates a) Number of positive plates per cell b) Type of positive plate c) Type of negative plate 1.01.08 Separator a) Type b) Material
: : : : : :
Kg Kg Ohm
: : : : : : :
: : :
: :
c) Thickness 1.01.09 Electrolyte a) Amount of electrolyte for first filling i) Per cell litre ii) Per set b) First filling with10% extra furnished? c) Electrolyte conform to 1.01.10 Racks a) b) c) d) e) Number of racks per battery Number of cells per rack Type of racks Rows/tiers Material of rack Racks provided with i) Numbering tags for cells ii) Teakwood clamps for cables f) Insulator with 5% extra furnished for i) Cell Yes/No : ii) Stand Yes/No :
: : : :
: : : : : : : : : :
g) Inter-row, Inter-tier connectors and end take-off furnished ? h) Connection hardware with 5% extra furnished 1.01.11 Dimension & Weights a) Overall dimension (L x B x H) mm b) Approx. Weight Kg c) Battery layout drawing furnished? 1.01.12 Ventilation requirements a) b) c) d) e) 1.01.13 Accessories furnished with each battery a) b) c) d) e) f) g) h) i)
: : :
: : : : :
: : : : : : : : :
O. P. Jindal Super Thermal Power Plant (4 X 600 Mw), Tamnar, Chhattisgarh : : :
j) k) l)
Float Charger 1.02.00 1.02.01 BATTERY CHARGER General a) b) c) d) 1.02.02 Make Cat. No Type Reference Standard : : : :
Float cum Boost Charger
Rating a) A.C. Input i) ii) iii) iv) Voltage + % variation Volt _ Phase No. Frequency + % variation _ Hz Input amps at rated load including supply of battery charging current : : : :
b) D.C. Output i) ii) Voltage Current Volt/Cell Amp. : : :
c) Type of Cooling d) Maximum Temperature within cubicle above 50`C ambient i) ii) 1.02.03 Performance a) Regulation for 0-100% rated load with + 10% _ input voltage and + 5% input frequency _ variation % b) Ripple content in D.C. output: a) With battery % b) Without battery % c) Guaranteed efficiency at rated load d) Power Factor at rated laod
Rectifier transformer SCR
Deg. C Deg. C
: :
: : : :
% %
Float Charger 1.02.04 Miscellaneous a) Charger provided with following features i) Automatic voltage regulation ii) Current limiting circuitry iii) Smoothing filter circuit iv) Soft-start feature v) Is manual operation permissible ? b) SCR elements provided with i) Surge protection ii) Fast acting HRC fuse 1.02.05 A.C. Switch a) b) c) d) 1.02.06 Make Type/Cat. No Reference Standard Rated Current : : : :
: : : : :
: :
Amp
A.C. Fuse a) b) c) d) Make Type/Cat. No. Reference Standard Current rating i) Continuous ii) Interrupting : : : Amp KA : :
1.02.07
A.C. Contactor a) b) c) d) e) f) Make Type/Cat. No. Reference Standard Rated Current Amp Utilization category Thermal overload with in-built single-phase preventor provided ? : : : : : :
1.02.08
Rectifier Transformer a) Make b) Type/Cat. No. : : Float Charger c) Reference Standard d) Ratings :
O. P. Jindal Super Thermal Power Plant (4 X 600 Mw), Tamnar, Chhattisgarh : : : : : :
i) KVA ii) Voltage ratio iii) Vector group iv) % impedance at 75 Deg.C e) Class of insulation f) Method of cooling 1.02.09 Controlled Rectifier (SCR) a) b) c) d) e) Make Type/Cat. No Reference Standard Rms Current rating Surge Current i) One-cycle ii) Repetitive cycle f) Peak inverse voltage i) Continuous ii) Surge
: : : : Amp Amp Volt Volt : : : :
1.02.10
Filter Choke a) b) c) d) Make Value Quantity Class of Insulation : : : :
mH
1.02.11
Filter Capacitor a) b) c) d) Make and Type Voltage Class Current Rating Quantity : : : :
Volt Amps
1.02.12
D.C. Fuse a) b) c) d) Make Type/Cat. No. Reference Standard Current rating : : :
Float Charger i) Continuous ii) Interrupting 1.02.13 D.C. Contactor a) Type/Cat. No. b) Reference Standard c) Current rating
Document No. : K8B15-SPC-M-0023 Rev-1
Amp KA
: :
Amp
SCH-II/2: 27
: : :
d) Utilization category e) Economy resistor provided 1.02.14 Blocking Diodes a) b) c) d) Make Type/Cat. No Reference Standard Current rating i) One-minute ii) One-hour e) Peak inverse voltage 1.02.15 Indication Lights a) b) c) d) e) 1.02.16 Make Type/Cat. No. Reference Standard Wattage Series resistor Ohm
Yes/No
Amp Amp Volt
: : : : : :
Watt
: : : : :
Meters a) b) c) d) e) Make Type/Cat. No. Reference Standard Size Accuracy : : : : :
1.02.17
Alarm-Facia a) b) c) d) Make Type/Cat. No. Reference Standard No. of window per facia : : : : Float Charger Float cum Boost Charger
1.02.18
Change-over Switch a) b) c) d) e) Type/Cat. No. Reference Standard Rating No. of poles Key interlock furnished ? : : : : :
Amp
1.02.19
D.C. Switch a) b) c) d) Make Type/Cat. No. Reference Standard Rating

Rev-1
Amp
SCH-II/2: 28
: : : :
e) No. of poles f) Key interlock furnished ? 1.02.20 Charger Panel a) b) c) d) Make Type Reference Standard Enclosure i) Degree of protection ii) Sheet steel thickness mm Panel provided with i) Internal lamp with door-switch ii) Space heater with thermostat iii) 5A 3-pin receptacle Internal Wiring i) Insulation ii) Voltage grade iii) Minimum conductor size Power Terminals i) Make ii) Size/Cat. No. Control Terminals i) Make ii) Size/Cat. No iii) 20% spare terminal furnished ? Ground Terminal furnished ? Overall dimension (LxBxH) mm Approx. Weight Kg
e)
: : : : : : : : : : : : : : : : : : : : : Float Charger Float cum Boost Charger
f)
g)
h)
i) j) k)
l) General Arrangement drawings furnished ? m) Accessories as specified furnished with battery charger ?
: :
Rev-1
SCH-II/2: 29
1.00.00 1.01.00 1.01.01 1.01.02 1.01.03 1.01.04 1.01.05
GENERATOR General Make Type Cooling medium for winding and core Method of cooling Maximum continuous rating under site condition and at 0.8 p.f, KW Electrical power consumption of the running auxiliaries of DG set, KW Net maximum continuous output under site conditions at 0.8 p.f (excluding auxiliaries), KW Full load current, Amps Excitation at MCR a) b) Voltage, Volts Current, Amps : : : : : : :
1.01.06
1.01.07
1.01.08 1.01.09
1.01.10
Rise of voltage and frequency when rated load is thrown off a) b) With AVR, Volts, Hz Without AVR, Volts, Hz : : : : : : : :
1.01.11 1.01.12 1.01.13 1.01.14 1.01.15 1.01.16 1.02.00 1.02.01
Terminal voltage at rated load, KV Frequency, Hz Variation of terminal voltage, % Variation of frequency, % Speed . r.p.m. Direction of rotation Generator Reactive Capability Maximum line charging (zero lead), KVAR
Rev-1 SCH-II/2: 30
:
1.02.02 1.03.00
Maximum inductive (zero lag), KVAR Temperature rise over ambient at rated operating condition Temperature rise of armature windings above cooling medium temperature (measured by embedded detectors), Deg.C Temperature rise of field winding above cooling medium temperature (resistance) , Deg.C Temperature of exit cooling air from the windings (detected by thermocouple), Deg.C Generator bearing temperature rise, Deg.C Losses Copper loss Iron loss Windage & friction loss Stray loss Efficiencies At MCR and rated p.f, % At 75% MCR and rated p.f, % At 50% MCR and rated p.f, % At 40% MCR and rated p.f, % At 20% MCR and rated p.f, % Regulation under conditions of rated speed, voltage and output a) b) c) At 0.80 p.f. lag At 1.0 p.f. At 0.9 p.f. lead
1.03.01
1.03.02
1.03.03
1.03.04 1.04.00 1.04.01 1.04.02 1.04.03 1.04.04 1.05.00 1.05.01 1.05.02 1.05.03 1.05.04 1.05.05 1.05.06
: : :
: : : : :
: : : :
1.05.07
Maximum continuous and momentary unbalanced load capability Short circuit ratio
Rev-1 SCH-II/2: 31
1.05.08
:
1.05.09
Symmetrical short circuit capacity and duration of short circuit Asymetrical short circuit capacity and duration of short circuit Saturation constant Electrical characteristics (calculated on maximum capacity)at 100% cooling for direct axis and quadrature axis Unsaturated synchronous reactance, % Unsaturated transient reactance, % Unsaturated sub-transient reactance, % Saturated transient reactance, % Saturated synchronous reactance, % Saturated sub-transient reactance, % Negative sequence reactance, % Zero sequence reactance, % D.C. resistance at ... Deg.C a) b) Stator winding, Ohms Rotor winding, Ohms
1.05.10
1.05.11 1.06.00
1.06.01 1.06.02 1.06.03 1.06.04 1.06.05 1.06.06 1.06.07 1.06.08 1.06.09
: : : : : : : :
: :
1.07.00
When a motor with the starting KVA equal to generator rating is started Maximum transient dip in voltage at main switchgear as percentage of rated voltage, % Time taken to restore the voltage, Secs. Permanent dip in voltage Maximum transient dip in frequency, % Machine time constant Field time constant with open circuited stator winding (Td0), Secs Field time constant with 3 phase short circuit of
Rev-1 SCH-II/2: 32
1.07.01
1.07.02 1.07.03 1.07.04 1.08.00 1.08.01
1.08.02
stator winding (Td'3) , Secs 1.08.03 Field time constant with 2 phase short circuit on stator winding (Td'2) , Secs Field time constant with single phase short circuit on stator winding (Td'1) , Secs Time constant of the aperiodic component for 2 phase and 3 phase short circuit (TA3) , Secs Time constant of aperiodic component during single phase short curcuit (TA1) , Secs Time constant of the periodic component of the subtransient current for 3 phase, 2 phase & single phase short circuit (Td"), Secs Type and degree of enclosure Type of mounting Type of bearing and its lubrication Space heater provided? if yes, Quantity Voltage Wattage Stator shell Thickness of shell Material of shell Overall dimension a) Diameter, mm b) Length, , mm 1.11.04 1.11.05 1.14.00 1.14.01 1.14.02 Dimension drawings attached? Number of terminals brought out? : Insulation (for both stator & rotor) Type and class of insulation Slot insulation
Rev-1 SCH-II/2: 33
1.08.04
1.08.05
1.08.06
1.08.07
1.09.00 1.10.00 1.11.00 1.12.00 1.12.01 1.12.02 1.12.03 1.11.00 1.11.01 1.11.02 1.11.03
: : :
: : :
: :
: : :
:
1.14.03 1.14.04 1.14.05
End coil insulation Insulation conforms to Insulation level a) Impulse withstand voltage of i) ii) iii) b) Stator winding, KV peak Terminal bushing, KV peak Field winding, KV peak
: : :
: : :
One minute power frequency withstand voltage of : i) ii) iii) Stator winding, KV rms Terminal bushing, KV rms Field winding, KV rms : : : :
1.14.06
Pull-out power at rated voltage and the field set for rated KVA at rated as well as unity p.f. , KW Fly wheel effect, WK2. for Generator with and without excitor Engine Overall Inertia constant (H), KWSec/KVA Vibration limits Generator air gap, mm
1.15.00 1.15.01 1.15.02 1.15.03 1.16.00 1.17.00 1.18.00
: : : : : :
1.19.00 1.19.01 1.19.02 1.20.00
Effective winding capacitance to ground Per phase, microfarad All phases connected together, microfarad, Effective surge impedence to neutral, per phase, ohms Saturated synchronous impedence
Rev-1 SCH-II/2: 34
: : :
1.21.00
:
1.22.00 1.21.00 1.21.01 1.21.02 1.21.03 1.21.04 1.24.00 1.25.00 1.25.01
Permissible percentage of winding unprotected Performance curves furnished ? Open circuit and short circuit characteristics curves Load excitation curve Reactive capability curves Negative Phase sequence characteristic curve Suitable for parallel operation with unit supply ? I2 t constant of the generator Continuous negative sequence capability of the generator Temperature detector furnished a) b) c) Quantity Type Resistance at 0 Deg.C
: : : : :
Yes/No Yes/No Yes/No Yes/No Yes/No
1.25.02
: : :
1.26.00 1.26.01 1.26.02 1.26.03 1.26.04 1.26.05 1.26.06 1.26.07 1.26.08 1.26.09 1.26.10 1.26.11
Excitor Make Type of excitation Range of stabilisation Capacity, KW Operating voltage, Volts Ceiling voltage, Volts Exciter response ratio Operating current, Amps Maximum current rating, Amps Class of insulation Temperature rise over ambient at MCR a) Winding (by thermometer), Deg.C
Rev-1 SCH-II/2: 35
: : : : : : : : :
:
b) 1.26.12 1.27.00 1.28.00 1.29.00 1.30.00 1.30.01 1.30.02 1.31.00 1.31.01 1.31.02 1.31.03 1.31.04 1.31.05 1.31.06 1.31.07 1.31.08 1.31.09 1.31.10 1.31.11 1.32.00 1.31.00 1.34.00 1.34.01 1.34.02 1.34.03
Winding (by RTD), Deg.C
: : : :
Characteristic curves included ? Armature winding type Field winding type Rectifier assembly details (for brushless system) Shunt field current corresponding to Rated voltage, Amps Ceiling voltage, Amps Atomatic voltage regulator Make Type Dead band Range of droop setting Response time, Secs. Voltage of operation, Volts Range of voltage adjustment Catalogues and characteristic curves attached ? CT/PT burden Provision made for parallel operation Information regarding field flushing, if applicable Sling for handling rotor Sling for handling stator Make, quantity and location of the following Current transformers Temperature detectors Space heaters
Rev-1 SCH-II/2: 36
: :
: : : : : : : : : : : Yes/No
: : :
1.35.00 1.35.01 1.35.02 1.35.03 1.35.04 1.35.05 1.35.06 1.35.07 1.35.08 1.35.09 1.35.10 1.35.11 1.35.12 1.35.13 1.35.14 1.35.15 1.35.16 1.35.17 1.35.18 1.35.19 1.35.20 1.35.21 1.35.22 1.35.23 1.35.24 1.35.25 1.35.26
Annunciation System Make Model No. Catalogue No. Type Architecture Type of printed card Type of contact (NO/NC selectable on card) System power supply Card power supply Type of hardware Indications on card Mounting of cards Distribution of P.S. module Distribution of flasher cards Input isolation Contact interrogation voltage Input delay Ambient temperature Relative humidity Surge withstand capability Lamps per fascia Lamp wattage Changing of lamps MTBF of lamps Flash rate Size of fascia, mm(h) x mm(w)
Rev-1 SCH-II/2: 37
: : : : : : : : : :
Yes/No
(a)
: : : : : : : : :
1.35.27 1.35.28 1.35.29 1.35.30 1.35.31 1.35.32 1.35.33 1.35.34 1.35.35 1.35.36
Inscription type Inscription letter height Fascia front cover material Maximum distance between contact logic cards Type of audible alarm Mounting of audible alarm Operating voltage Sound intensity/tone adjustability Annunciation sequence as per specification Power supply unit sized to cater for additional cards Minimum duration of impulse for initiating contact Detailed catalogue with circuit diagram furnished at Accept/Reset/Test P.B. provided Push Button Make Model No. Catalog No. Type Construction Enclosure Contact configuration Contact addition Contact assembly housing Contact element MTBF Voltage rating
Rev-1 SCH-II/2: 38
: : : : : : : : : : Yes/No Yes/No Yes/No
1.35.37 1.35.38 1.35.39 1.36.00 1.36.01 1.36.02 1.36.03 1.36.04 1.36.05 1.36.06 1.36.07 1.36.08 1.36.09 1.36.10 1.36.11 1.36.12
: : :
: : : : : : : : : : : :
1.36.13 1.36.14 1.36.15 1.36.16 1.36.17 1.36.18 1.36.19 1.36.20 1.36.21 1.36.22 1.37.00 1.37.01 1.37.02 1.37.03 1.37.04 1.37.05 1.37.06 1.37.07 1.37.08 1.37.09 1.37.10 1.37.11 1.37.12 1.37.13 1.38.00 1.38.01
Continuous current Making current Breaking capacity Overall size Gasket Cable connection Legend plate Standard legend Colours Any special features Indicating Lamp Make Model No. Catalogue No. Voltage rating Wattage Housing Lens Bulb replacement Wire connection MTBF of filament Overall size Colour of lamps Any special features AMF Panel Make
Rev-1 SCH-II/2: 39
: : :
: : : : : :
: :
: : : : :
: : : : :
1.38.02 1.38.03
Type Construction a) b) c) d) Material Sheetmetal thickness Degree of Protection Floor channel sills and kick plate furnished?
: : : :
1.38.04
Nameplate a) b) c) Material Thickness Size for i) ii) Equipment Panel : : : :
1.38.05
Internal Illumination a) b) Volt Watt : :
1.38.06
Space Heater a) b) c) Volt Watt Thermostat Controlled : : :
1.38.07
Plug Socket a) b) Type Rating : : :
1.38.08
Panel illumination, space heater and plug socket circuits provided with individual switch fuse unit ? AC/DC Supply Type and rating of isolating switch fuse units for
1.38.09
Rev-1
SCH-II/2: 40
a) b)
Incoming A.C. Supply Incoming D.C. Supply
1.38.10
Internal Wiring a) b) c) d) Wire type Voltage grade Conductor material Conductor Size for i) Current/Control Circuit ii) Voltage Circuit e) Wires identified at both ends with ferrules ? : : : : : :
1.38.11
Terminal Block a) b) c) Make Type/Catalogue No. 20% spare terminals furnished? : : :
1.38.12
Ground Bus a) b) Material Size, mm x mm :
1.38.13
Painting a) b) Type of finish Colour Shade - Inside/Outside : : A V W F PF
1.39.00 1.39.01 1.39.02 1.39.03 1.39.04
Indicating Instrument Make Type Reference Standard Type of Movement

Rev-1 SCH-II/2: 41
: : : :
1.39.05 1.39.06 1.39.07
Accuracy Class Scale in Degrees VA Burden a) b) Current Coil Voltage Coil
: :
: :
1.40.00 1.40.01 1.40.02 1.40.03 1.40.04 1.40.05 1.40.06 1.40.07
Integrating Meter Make Type Reference standard Furnished in Drawout Case ? Type of Register Accuracy Class VA Burden a) b) Relays Generator Differential Earth fault Over current Lockout Under Voltage Auxiliary Any other type Catalogues of all relay submitted with bid Other accessories essential for satisfactory operation, maintenance and erection provided
Rev-1 SCH-II/2: 42
: : : : : :
Current Coil Voltage Coil
: : Make Type Cat No.
1.41.00 1.41.01 1.41.02 1.41.03 1.41.04 1.41.05 1.41.06 1.41.07 1.41.08 1.42.00
: : : : : : : : : Yes/No
1.41.00 1.41.01 1.41.02 1.41.03
Weight schedule Weight of engine and accessories, Kg. Weight of generator and accessories, Kg. Heaviest weight to be erection/maintenance, Kg. handled for : : : .
1.44.00
Details of all deviations from this specification furnished
Yes/No
Rev-1
SCH-II/2: 43
ERECTION, TESTING, COMMISSIONING FOR ELECTRICAL EQUIPMENTS, CABLING & GROUNDING SYSTEM (Separate sheet shall be used as applicable) 1.0 1.1 1.2 1.3 CABLE TRAYS Make Type/Material Load Bearing Capacity between two supported points Load bearing capacity under cantilever condition Cable trays are furnished complete with all accessories ? Cable trays & accessories properly galvanised ? Standard width of cable trays furnished Reference Standard CONDUITS Make Type/Material Reference Standard Gauge - upto 25 mm dia. - above 25 mm dia. 2.5 3.0 3.1 3.2 Catalogue furnished? JUNCTION BOX Make Type/Material : : : : : : : : : :
kg
1.4
kg
1.5
1.6
1.7
mm
: :
1.8 2.0 2.1 2.2 2.3 2.4
3.3 3.4 3.5
Reference Standard Degree of Protection Outdoor/Indoor Catalogue furnished?

Rev-1 SCH-III: 1
: : :
4.0 4.1 4.2 4.3 4.4 4.5 4.6 5.0 5.1 5.2 5.3 5.4
TERMINAL BLOCK Make Type Reference Standard Current rating Catalogue furnished ? 20% spare terminals provided CABLE TERMINATION KIT Make Type Suitable for voltage grade Cable termination kit furnished for XLPE & PVC cables Complete with all accessories? CABLE STRAIGHT-THROUGH JOINTING KIT Make Type Suitable for Voltage Grade Cable Jointing Kit furnished for both XLPE and PVC cables ? : : : : : : : : : : : :
: :
5.5 6.0 6.1 6.2 6.3 6.4
6.5 7.0 7.1 7.2 7.3 7.4 7.5 8.0
Complete with all necessary accessories : CABLE GLAND Make Type/Material Double Compression Type Complete with armour clamp Catalogue furnished? CABLE LUG : : : : :
Rev-1
SCH-III: 2
8.1 8.2 8.3 8.4 9.0 9.1 9.2 9.3 9.4 9.5 10.0
Make Type/Material Sizes furnished as specified Reference Standard FERRULES Make Type/Material Colour Interlocked type? Reference GROUNDING Above ground grounding :
: : : :
: : : :
10.1 10.2
Size Material
Rev-1
SCH-III: 3
SCHEDULE III WORKS SCHEUDLE

We hereby guarantee that the submission of drawing and other data, delivery, erection, testing and commissioning of all the pipes shall be so arranged that they are delivered, erected and commissioned and are ready for final acceptance of the Owner as per periods given below : 1.0 Sl. No. 1.01 DRAWING SUBMISSION SCHEDULE Activity Period to be counted from the date of L.O.I.
PERT Network showing firm schedule of various stages of work Fabrication/layout drawings for all pipes along with design calculations etc. SUPPLY SCHEDULE Activity Period to be counted from the date of L.O.I.
1.02
2.0 Sl. No. 2.01 2.02
Completion of supply of all pipes as per specification Erecting, testing and commissioning of all pipes as per specification
We hereby agree to abide by the above works schedule and in case of delay on our part, we agree to pay liquidated damages to the Owner in terms of the contract.
Rev-1
SCH-III: 4
SCHEDULE - IV
DRAWING SUBMISSION SCHEDULE Bidder has to indicate below item wise, the date of submission of drawings/documents to be furnished by him as stipulated in the specification taking date of issue of Letter of Intent as datum. Sl no Description Approval Submission for Record Information Submission in weeks from the date of LOI
The Bidder shall also furnish the time in weeks for resubmission of reviewed/ commented drawings from Owner from the date of receipt.
Rev-1
SCH-IV: 1
SCHEDULE - V DEVIATION SHEET: PART - A

If the proposal has got any deviation from the Technical Specification, the Bidder shall tabulate those deviations clause by clause in this Schedule. Add more sheets, if required. Clause No. Deviations
Rev-1
SCH-V: 1
SCHEDULE - VI DEVIATION SHEET: PART - B

If the proposal has got any deviation from the tendering conditions and the Conditions of Contract, the Bidder shall tabulate those deviations clause by clause in this Schedule. Add more sheets, if required.
Clause No.
Deviations
Rev-1
SCH-VI: 1
SCHEDULE VII QUALIFYING REQUIREMENT SCHEDULE

Bidder shall indicate as per format given below the details of his experience in executing similar Contract with reference to the requirement specified in this specification. The Bidder shall also include documentary evidence from the customer to substantiate his statement. Sl. No. Work Details Name of Owner & Address Order Value Date of Commissioning
Rev-1
SCH-VII: 1
SCHEDULE - VIII DECLARATION SHEET

I, ........................................................... certify that all the above typed-in data and information pertaining to this specification are correct and are true representation of the equipment covered by our formal Proposal dated ................................
I, hereby certify that I am duly authorized representative of the supplier whose name appears above my signature.
Bidders Name
.....................................................................
Authorized Representatives Signature
.....................................................................
Authorized Representatives Name (Typed)
.....................................................................
Manufacturers Intent
The Manufacturer hereby agrees fully to comply with the requirements and intent of this specification for the price indicated.
Authorized Representatives Signature : .....................................................................
Rev-1
SCH-VIII: 1
SCHEDULE - X
MAINTENANCE TOOLS AND TACKLES
Bidder shall furnish below item wise list of proposed special maintenance tools and tackles for which prices shall be indicated in the price schedule AB:
Sl. No.
System/sub-system
Description
Quantity
Note : Additional sheets of similar size and format may be annexed as per bidder's requirement.
Signature of Bidder Name Designation Company seal Date:
: : : :
Rev-1
SCH-X: 1
JINDAL POWER LTD
Techanical Specification for Diesel Generator Set
O.P. Jindal super Thermal Power Plant(4x600 Mw),Tamnar, Chhattisgar SCHEDULE-IX/1
Schedule - IX/1 PRICE BREAK-DOWN SHEET FOR SUPPLY Freight & Any other Taxes & FOR Transit Duties / Levies (give Total Insurance detail) Price (*) (*)
SL NO.
DESCRIPTION
UNIT
QTY (approx.)
CIF/ExCIF/ExWorks Unit worksTotal Excise Duty Price (* ) Price (*)
Sales Tax
Custom Duties
Counter Velling Duties
NOTE
(1) To specify % of CIF / Ex-works unit price. (*) For the currency of the bid, Bidder is suggested to refer the relevant clauses of Conditions of Contract, Section-I of this Bid Documents Bidder's Stamp & Signature
Sch-IX/1 : 1

Ifb Tender DG Sets 19 May 10 TC SP

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Ifb Tender DG Sets 19 May 10 TC SP

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JINDAL POWER LIMITED

TECHNICAL SPECIFICATION FOR DIESEL GENERATOR SET

DEVELOPMENT CONSULTANTS PRIVATE LIMITED

JINDAL POWER JINDAL POWER LTD.. LTD

Technical Specification for Diesel Generator Set

O. P. Jindal Super Thermal Power Plant (4 X 600 MW), Tamnar, Chhattisgarh

SECTION-I SECTION-II SECTION-III

CONDITION OF CONTACT TECHNICAL SPECIFICATION PROPOSAL EXHIBIT SHEETS

DOCUMENT NO.: K8B15-DBR-M-0023 , REV -1

Development Consultants Pvt. Ltd.

JINDAL POWER JINDAL POWER LTD.. LTD

Technical Specification for Diesel Generator Set

O. P. Jindal Super Thermal Power Plant (4 X 600 MW), Tamnar, Chhattisgarh

SECTION-I CONDITIONS OF CONTRACT [TO BE ATTACHED BY JPL]

DOCUMENT NO.: K8B15-SPC-M-0023, REV -1

DEVELOPMENT CONSULTANTS PVT. LTD.

JINDAL POWER JINDAL POWER LTD.. LTD

Technical Specification for Diesel Generator Set

O. P. Jindal Super Thermal Power Plant (4 X 600 MW), Tamnar, Chhattisgarh

SECTION-II TECHNICAL SPECIFICATION

DOCUMENT NO.: K8B15-SPC-M-0023, REV -1

DEVELOPMENT CONSULTANTS PVT. LTD.

JINDAL POWER JINDAL POWER LTD.. LTD

Technical Specification for Diesel Generator Set

O. P. Jindal Super Thermal Power Plant (4 X 600 MW), Tamnar, Chhattisgarh

SECTION II: TECHNICAL SPECIFICATION

SUB-SECTION E3 SUB-SECTION E4 SUB-SECTION E5

DOCUMENT NO.: K8B15-SPC-M-0023, REV -1

DEVELOPMENT CONSULTANTS PVT. LTD.

JINDAL POWER JINDAL POWER LTD.. LTD

Technical Specification for Diesel Generator Set

O. P. Jindal Super Thermal Power Plant (4 X 600 MW), Tamnar, Chhattisgarh

SECTION III PROPOSAL EXHIBIT SHEETS [SCHEDULES]

DOCUMENT NO.: K8B15-SPC-M-0023, REV -1

DEVELOPMENT CONSULTANTS PVT. LTD.

JINDAL POWER JINDAL POWER LTD.. LTD

Technical Specification for Diesel Generator Set

O. P. Jindal Super Thermal Power Plant (4 X 600 MW), Tamnar, Chhattisgarh

SECTION III PROPOSAL EXHIBIT SHEETS [SCHEDULES] CONTENTS SCHEDULES DESCRIPTION

DOCUMENT NO.: K8B15-SPC-M-0023, REV -1

DEVELOPMENT CONSULTANTS PVT. LTD.

JINDAL POWER JINDAL POWER LTD.. LTD

Technical Specification for Diesel Generator Set

O. P. Jindal Super Thermal Power Plant (4 X 600 MW), Tamnar, Chhattisgarh

SECTION-IV SL. NO.

TENDER DRAWINGS DRAWING NUMBER DRAWING TITLE

DOCUMENT NO.: K8B15-SPC-M-0023, REV -1

DEVELOPMENT CONSULTANTS PVT. LTD.

JINDAL POWER JINDAL POWER LTD.. LTD

Technical Specification for Diesel Generator Set

O. P. Jindal Super Thermal Power Plant (4 X 600 MW), Tamnar, Chhattisgarh

SECTION-II SUB SECTION: M0 GENERAL SPECIFICATION

DOCUMENT NO.: K8B15-SPC-M-0023, REV -1

DEVELOPMENT CONSULTANTS PVT. LTD.

JINDAL POWER JINDAL POWER LTD.. LTD

Technical Specification for Diesel Generator Set

O. P. Jindal Super Thermal Power Plant (4 X 600 MW), Tamnar, Chhattisgarh

SUB- SECTION: M0 CONTENTS

DOCUMENT NO.: K8B15-SPC-M-0023, REV -0

DEVELOPMENT CONSULTANTS PVT. LTD.

JINDAL POWER JINDAL POWER LTD.. LTD

Technical Specification for Diesel Generator Set

O. P. Jindal Super Thermal Power Plant (4 X 600 MW), Tamnar, Chhattisgarh