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00 materials and of

INTENT OF SPECIFICATION This sub-chapter is intended to cover design, procurement,manufacture/fabrication,shop supply of various types of valves the testing C.W.system

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

engineering, Packing, Unloading, insurance, commissioning

testing, to


Transportation Storage, Erection, of


Preservation, of the

required number


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

covered valves




of supply of



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

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







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

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

ii) valve 5155/AWWA electric iv)

Nominal diameter


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

iii) Type of valve

actuator. Location Indoor in pump house.


Motor operated butterfly i) No.of valves Location -

valve 2 Nos. Makeup forebay. water pipe



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


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

Per BS with for make-


Outdoor valves


8 Nos. 4 nos. on tappings

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

Flanged Per B. water tower)


Type6 of valve



operated valve as


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

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

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

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

operated valve for T2.01.06 and

iii) Type of valve


Manually Flanged as Butterfly

Per BS- 5155/AWWA

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

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

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

Flange drilling of all valves shall be as per table 11

with matching ANSI/AWWA-C-504type and shall flanges . driven valves electric motor shall be : .01. and and simultasuit T2. The analysis of liquid to be handled given in Annexures-D All electric actuator a) Complete drive.1971.bolts.01. and c) All limit and torque switches shall be dust water proof. power b) Complete with Micro switch for disconnecting supply when the valve is operated manually. the Direction of flow shall be clearly indicated on valve by embossing an arrow on the valve body.08 gear switches Drilling of flanges shall be as per table-11 IS-6392.C with maximum temparature of humidity but both not occuring neously.necessary . The equipment shall be designed to this condition.01.07 All the Butterfly valves shall be of 6 Kg/cm2 and conform to B. T2.01.torque position limit switches and terminal board.nuts of is T2. be and T2. with & E.S -5155-1984 or The valves shall be double flanged supplied gaskets. rating 1987.of IS:6392-1971.09 d) The humid 100% climate prevailing at site is tropical 50 Deg.10 steel All the valves shall have a permanent stainless .

S.diameter. marked face of the wheel/lever shall with the words OPEN and CLOSE and an indicate the direction for opening/closing. IS-210 Grade FG260 C.13 All the valves shall be supplied with companion made of Carbon Steel plates conforming to Gr. 3. fan squirrel cage type.01. shut The valves shall be designed for 100% water tight off.S.01. either Shaft extension as per requirement.S. 5.12 All the valves shall be provided The with hand be arrow lever. T2. (304) S. bearings terminal boxes shall be IP-55.11 name plate and stainless steel tag fixed on the body indicating the tag number. 6.I. - Motor shall be totally enclosed.01.01.2A IS:2062- and drilled to I.S (304) S. flanges 1992 T2. 2. wheel/ clearly to T2.14 Body Disc Seat Shaft Seat retaining rings/and screws Shaft bearing : : : : : : C.pressure and manufacturing standard code of the valve. Materials of construction: 1.6392-1971 Table-11. IS-210 Grade FG260 Nitrite rubber/S. Terminal box liberally Terminal box of all motors shall be .I. and Degree of protection for motors.valve rating T2. 4. (304) Self lubricated TECHNICAL SPECIFICATION FOR MOTOR ACTUATORS FOR VALVES AC Motors cooled. Bearing suitable for running of motors in direction.

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

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

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

10. 6. 3. thickness of each coat shall Performance Guarantee and Warranty The valves supplied shall be as guaranteed per satisfactory performance Conditions Of Contract. Final be T2. 6. 2.paint. 8. 9. 5. LIST OF MANDATORY SPARES FOR VALVES the The following mandatory spares shall be included in contract for Butterfly valves of each size. Shaft Shaft key Bearings Allen screw 'O' rings Gland packing Seal clamping units and bolts Position indicator Actuators (as applicable) Torque/limit switches Handle 1 1 1 1 1 1 2 1 1 1 1 1 Set set set set set set sets set set set set set For DN 1600 gear operated butterfly valves. 2. Valve disc. 11. 12. 7. 10. 4. 7.04 for General phenolic suitably alkyd modified synthetic pigmented shall be enamel as given paint. II) Valve disc. 12. 9. 3. 4.Dry film 25 microns. 1. 1. 5. 8. I) For DN 1600 motor operated butterfly valves. 11. Shaft Shaft key Bearings Allen screw 'O' rings Gland packing Seal clamping units and bolts Position indicator Actuators (as applicable) Torque/limit switches Handle 1 Set 1 set 1 set 1 set 1 set 1 set 2 sets 1 set 1 set NA NA 1 set .

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

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

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

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

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

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

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

..........00 Guarantee Characteristic curves: for regulating valves submitted Note : This Guaranteed Performance Data is applicable for each size of the valve...00...... DESIGNATION ...00 2...... COMPANY SEAL: T3............ For 600mm dia 42 +5 sec....00 design..... DATE .....02.. SIGNATURE OF THE NAME ..00 3.00..00..for performance The contractor guarantees that meet each the Butterfly valve following cooling water system shall requirement : 1.. ......00 2............ ........00 2.00 Design working pressure of Butterfly Valve (Kg/cm2(g)) When valve fully closed Rate of leakage Maximum shut-off pressure..... INTENT OF SPECIFICATION This sub-chapter is intended to cover materials manufacture/fabrication......... from open to close and viceversa (only for electrically operated valves) : : : : : : : : 6 6 Nil 6 For 1600mm dia 75 +15 sec....................01........... (Kg/cm2(g)) Valve operating time in secs..... procurement... contractor ..... Not Applicable 4....... NAME AND ADDRESS OF COMPANY .......00........

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

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

sockets.D X Thickness in mm 219.1 273. flanges. crosses. generally tees..6 x x x x 6. plugs.various work air is - the specification and described in pipe paragraphs of the specification.35 7. covers pipes.01 specified The The term 'pipework' referred (such herein as bends. unions.14 7.0 323. fittings reducers.9 355. service air and instrument piping etc.14 .14 7. nipples. etc) valves.I. throttling stubs for primary sensing instruments etc. pipes shall be manufactured/supplied as below: pipes ISPart-I With ii) 200 mm to 350 mm size i) Upto 150 mm nominal size M. G. T3. Pipes ISthickspecified Nominal Dia DN DN DN DN 200 250 300 350 mm mm mm mm : : : : M.S.S ERW Black conforming 1239-1984 (Medium Duty) to Plain ends. for drinking water. ERW to conforming 3589-1973 but ness as below : O. pipe work for service water air also included in the scope of the contractor. pieces.

S.25 seamless (Hot dip galvanised) c) d) Drinking water Service water : : IS:1239 . plates Grade -A by submerged arc IS-2O62-1992 process as per IS-10234 or equivalent having indicated against the pipe dia: ------------------------------------------------------Nominal dia Outside dia Plate of pipe mm of pipe mm thickness mm .90 9.1984 (Part-I) Heavy G.02.01 Fabricated Steel Pipe lines All fabricated pipelines specified below shall conforming welding thickness fabricated to from tested quality M.S.02 a) For Service Air : IS:1239 .I.02 be T3.S. Pipes( Steel commercial iii) 400 mm to 600 mm size Manufactured - Spirally Welded at Rourkela Plant) of quality.M.D X Thickness in mm 406.14 7. IS:1239 .50 Fabricated from plates as in para T3. specified 1984 1984 T3.14 7.25 seamless b) For Instrument Air : IS:1239 .4 457.1984 (Part-I) Heavy duty/IS:1978 St. Nominal Dia DN DN DN DN iv) 400 450 500 600 mm mm mm mm : : : : O.1984 (Part-I) Heavy duty/IS:1978 St.1984 (Part-I) Heavy / IS:3589.0 508. 1600 mm and above M.0 610 x x x x 7.

02.03 a any T3.Straps shall be provided at field joints.) pipe circumferential weld shall be done in such way that the longitudinal welds become staggered in two consecutive sections.02. ii) iii) Out of straightness : T3. Pipe sections in straight lengths delivered at site joints done at shall be of suitable length to minimise shall as far as possible.02.05 drawings fabrication The 1 mm per metre length (Max.02.04 erection field be site T3.02 cold plates so plate. the fabrication End preparation yard to facilitate welding.------------------------------------------------------16OO mm 24OO mm 1632 2432 16 16 ------------------------------------------------------- T3.The plate All fabricated using pipes shall be a plate bending manufactured machine. The by bending shall that be gradually bent to true cylindrical no undue stress develops in the shape tolerances on dimensions of pipe fabricated from shall be as follows: i) On outer diameter as calculated from circumference Out of roundness : : + 1/4 of plate + 3 mm & -1. The of contractor shall submit detailed working pipelines and fittings including .5 mm thickness.

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

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

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

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

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

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

necessary.00 mm 2.1.00 mm 2.00 mm 5.00 mm 2.00 mm .00 mm 5.00 mm + 1. for this purpose.00 mm Manual arc Tolerance ------------------------Automatic ii) Stepping of one plate over the other Manual arc 1.00 mm b) Single Vee-groove Joints i) ii) Bevol angle Gap between two + 5 deg.00 mm iii) Stepping of one plate over other c) Lap Joint i) ii) d) Overlap Gap between the surface 2.00 mm .00 mm Tee-filler joints i) Gap between the 2.1. + 2. + 1.00 mm .00 mm 2.00 mm 1.00 mm + 5 deg. Tolerance be Deviations for assembly of welded joints may permitted to the following extent : Tolerance ------------------------Automatic a) Source butt-joints i) Gap between the ends of plates + 2.

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

and of Control rod assembly shall allow transverse rotational movements under limiting axial conditions the expansion joints. hypalon coatings may be applied at Control Rod Assembly Each expansion joint shall be supplied with control assembly to prevent excessive elongation or of long the bellow. T3. the flange shall have no eccentricity in relation to .05. spherical consist connecting plates (gusset plate) for fixing the with mating flanges.04 shall carcass Cover The exterior and interior surfaces of the bellow be coated with suitable material to protect the from outside damage and fluid corrosion. nuts Control rod assembly will & lock nuts.06 fabric on the End Flanges The expansion joint shall have integral The bolt hole reinforced full face rubber flanges. bolt.05 rod contraction of washers. the T3.T3.05. of on the Design of the control rod assembly shall take care the maximum axial thrust across the bellow calculated the basis of maximum fluid internal pressure and internal diameter of the arch. assembly Protective exterior.05.

05. washers 7. if any. Counter Flanges Counter flanges shall be as per AWWA C-207. The test shall be conducted . suitably match The companion flanges shall identification marked for easy erection by others. Hydrostatic Pressure Test and Vacuum Test a) internal half the All Pressure Test expansion bellows shall be subjected to hydrostatic (1. suitably During the test.05. and rubber gaskets shall be furnished. bolts. the be during T3.07 corresponding bolt hole of the flange on the other The end rubber flange shall be drilled to suit companion pipe flanges.5) times pressure test at a value of one and a the maximum working pressure under following conditions for thirty (30) minutes: i) ii) lateral Free position of the bellow With permitted (design) elongation and deflections iii) With design contraction and lateral deflection Inspection for leakage from the bellow shall be out during pressure test. b) test in Vacuum Test All expansion joint shall be subjected to a vacuum at 700 mm of Hg vacuum. check Before the hydro test and after the hydro test is the bellow shall be dimensionally inspected to deformation.08 Required numbers of carbon steel nuts.face. the control assembly shall be adjusted to obtain the test conditions of the bellow. carried over.

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

T3.5 497 xvi) Lateral deflection (mm) xvii)Angular deflection (deg.) - vii) Maximum flow (M3/hr) viii)Location ix) x) xi) Test pressure (kg/cm2g) Vacuum design Vacuum test - 16500 Indoor 7.10 Design Requirement i) ii) Qty.05. 6 Kg/cm2 Circulating water (for analysis see Annexure-D & E). Nominal diameter 5 Nos. 1600 mm.5 750mm of Hg vacuum 700mm of Hg vacuum Manufacturers std.) xviii) Torsional movement (deg./Min. Single arch type.5 0. 1-50 lb slip on type xii) Freelength (mm) xiii)Counter flange class xiv) Axial elongation(mm)xv) Axial contraction (mm) - 15 15 15 0. 44/30 iii) Type iv) v) Design pressure Liquid to be handled- vi) Working temperature (oC) (Max. AWWA-C 207.) xix) Pump speed (rpm) - .

06.W.00 1.5 Nos.01.00 1.00.00 1.00 1.00 1. bolts and washers - Carbon Steel IS:2062 3 mm thick reinforced rubber Carbon Steel . Continuous Spool type 750 1750 kgs (appx) .11 Materials of Construction Bellow Carcass Stiffening ring External cover Internal cover Control assembly Retaining ring Synthetic Rubber Synthetic fibre Manufacturers standard Hypalon or approved equivalent Manufacturer's standard Manufacturer's standard Galvanised Steel Flanges/Counter flanges Gasket Nuts. GENERAL Service Nominal size (NB)/Qty.05.03.00 1.T3.System 1600mm .ASTM A Grade A 307 Pipe thickness - 16 mm DATA SHEET FOR RUBBER EXPANSION JOINT 1. Duty Type Overall dimensions (mm) Gross weight of the complete assembly (kg) : : : : : : C.

1.07.00 4.01 3./Per Joint Twice the design pressure Synthetic Rubber Synthetic fibre Neoprene Rubber .00 2.00t 2. of limit / control rods Bursting pressure of bellow (kg/cm2g) MATERIAL OF CONSTRUCTION Bellow Carcass Bellow exterior : : : : : : : Single BS 4504 PN-10 6Nos.07.01.00 2. of arch / corrugation Flange pressure rating and drilling standard No. 2. Axial elongation / contraction (mm) : Lateral deflection (mm) Angular movement Torsional movement (degrees) Axial spring rate (N/mm) Torsional spring rate (kg/mm/deg) Frequency of vibration (Hz) : : : : : : 15/15 15 0.00 3.00 2.00 Model No.00 As per spec.00 2.00 Kg/cm2g : DESIGN AND CONSTRUCTION Design standard Design pressure (kg/cm2g) : : < 0.03.04. PERFORMANCE CAPABILITY : During Detail engg.00 3. 6 750 60 Design vacuum in mm of mercury: Design Temperature (oC) : 3.00 2.08.5 1925 (Appx) 180 During detail Engg.05.01. Maximum pressure drop through the expansion joint at design flow rate.00 2.01.00 3.00 3.07.5o 0.00 3.00 3.05.00 No.06.06.00 4.00 2.03.00 3.00 4.

00 5.00 Ring 4.0 Not recommended as Internal Rubber flange shall act as self gasket 5.05.00 6.04.00 5. A Sq.00 ACCESSORIES INCLUDED Control rod assembly with gusset plate.6/4.00 7.00 Bellow interior : Neoprene Rubber IS 2062 Gr. stretcher plate IS-2062 Gr. 5.00 4.4.00 4.00 7. : Yes Counter flanges with nuts.03.8/6.0.00 7.01.00 INSPECTION AND TESTING INCLUDED Materials Test Certificates Certificates for bought out items Dimensional tolerance as per specification Hydrotest as per specification : Yes : Yes : Yes : Yes 5.00 4.08. nuts spherical washers etc. Annular IS1367 Gr.A. Metal reinforcement : Control rod assembly: Retaining ring segments: IS:2062 Gr.A Fasteners Gaskets : : IS:2062 Gr.00.00 7.00 4.01.A Galvanised Flanges/counter flanges: IS:2062 Gr.02.02.00 4.00 .00 6.01. : Yes LIST OF TECHNICAL DOCUMENTS ENCLOSED WITH THE CONTRACT Dimensional General Arrangement drawing as specified A cross-sectional drawing of the expansion bellow Manufacturers standard catalogues and Literature A write-up on the manufacturing inspection and testing facilities available at the manufacturer's works Any other information : Yes : Yes : No : : 7.00 bolts etc.05.09.02.

. : 2 sets particular GUARANTEED DATA FOR R. Joints Control rod assembly complete with nuts etc.. Joint. nuts and gaskets Reinforced Rubber Gasket for above R.. 1. 2.00..5 BS 4504 PN-10 contractor guarantees that each rubber expansion minimum CW system shall meet the following Minimum bursting pressure of bellow (kg/cm2 g) : Axial elongation/contraction (mm) : Lateral deflection (mm) Angular movement (degrees) : : Torsional movement (degrees) : Flange standard : SIGNATURE .00.00 4.00 6. : 1 set : 1 set : N. 3.00 2.LIST OF MANDATORY SPARES FOR R.....00.00 7..00.. One set corresponds to the quantity of part used in one R.A.... Note: Rubber Expansion Joint Complete assembly of 1600 mm dia.00 5.00...00 Design working pressure of bellow (kg/cm2 g) : 6 Kg/cm2 12 kg/Cm2 15/15 15 0.E......00 3.E. JOINTS 1... 4. The joint performance for data. .JOINTS.E.00. Slip-on type matching flange with bolts.5 0...E.00.

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