DIPE PROJECT REPORT

On
Installation of Boiler (oil fired) with accessories for laundry Plant.

Submitted to
The Director, Directorate of Distance Education,
Annamalai University , Annamalai Nagar,
Tamil nadu 680002.
Submitted by
Gautam Rohella
[682]Diploma in Industrial Project Engineering
Enrl. No:- 6821100004
Year 2011-2012.

PART

II - TECHNIC AL

SPECIFICATIONS

CONTENTS

SECTION
PAGE NO

1.0

2.0

3.0

GENERAL DESCRIPTION
1.1

Scope

1.2

Building

1.3

Schedule of Requirement, Schedule of Equipment

1.4

Technical Data
4

1.5

Electric Supply
5

4
4

STEAM BOILERS
2.1

Scope
6

2.2

Materials and Construction

6

2.3

Burners
7

2.4

Feed Unit
8

2.5

Control
8

2.6

Installation

TANKS

4.0

3.1

Scope
10

3.2

Hot Water Mixing Tanks/Boiler Feed Tank

10

3.3

Installation

10

PLATE HEAT EXCHANGERS

4.1

Scope
11

4.2

Materials and Construction

11

4.3

Installation

4.4

Testing
11

11

CONTENTS (Cont)

SECTION
PAGE NO

5.0

WATER SOFTENNING PLANT

6.0

7.0

8.0

5.1

Scope
12

5.2

Capacity
12

5.3

Quality of Treated Water

5.4

Location
12

5.5

Standards
12

5.6

Equipment
13

5.7

Materials and Construction

13

12

PUMPS
6.1

Scope
14

6.2

Condensate Recovery/ Hot Water Pumps

14

6.3

Installation

6.4

Painting
14

CHIMNEY AND BREACHING

7.1

Scope
15

7.2

Materials and Construction

15

PIPING
8.1

Scope
17

8.2

L.P.G. Piping
18

8.3

Steam condensate / Hot water piping

18

14

9.0

8.4

Installation

8.5

Testing
23

8.6

Painting
24

19

INSULATION
9.1

Scope
25

9.2

Insulation of Piping
25

9.3

Insulation of Tanks
26

9.4

Insulation of Chimney
26

9.5

Painting
26

CONTENTS (Cont)

SECTION
PAGE NO

10.0

ELECTRICAL PANEL BOARD

27

11.0

SCHEDULE OF EQUIPMENT
36

12.0

SCHEDULE OF TECHNICAL DATA

38

13.0

MODE OF MEASUREMENT
40

14.0

LIST OF APPROVED MAKES OF EQUIPMENT /

MATERIALS
42

15.0

LIST OF DRAWINGS
44

1.0

GENERAL DESCRIPTION

1.1

Scope:

1.1.1

These specifications together with the commercial specifications, bill

of quantities and drawings cover the supply, installation, testing and
commissioning of Boilers and Ancillaries for the proposed Hometel,
Chandigarh.

1.2

Building:

1.2.1

Hometel, Chandigarh structure consists of the following:

a) Basement

Car Park, Laundry.

b) Ground Floor

Kitchen, Banquet etc.

c) First Floor

Banquet, Meeting Room,

Gymnasium.

d) Second Floor

Restaurant, Bar, Lobby.

e) Service Floor

Staff Cafeteria, Storage, etc.

f) Third to Eight Floor

Typical Guest Floors.

g) Terrace Floor

1.3

Schedule of Requirements, Schedule of Equipment:

1.3.1

Schedule of Requirements and Schedule of Equipment are shown on

the drawings.

1.4

Technical Data:

1.4.1

Technical Data of all equipment shall be furnished in the tenders by

the Tenderers as required under the Section: Schedule of Technical
Data'.

1.5

Electric Supply:

1.5.1

Three phase electric supply will be 415 V +5%,50 Hz,4 wire.

1.5.2

Single phase electric supply will be 240V, 50 Hz.

2.0

STEAM BOILERS

2.1

Scope :

2.1.1

Scope of this section comprises the supply, erection, testing and

commissioning of steam boilers comprising of furnace, water tubular
coils, burners, controls and accessories complete in all respects and
conforming to the following specifications.

2.2

Materials and Construction :

2.2.1

Steam boilers shall be of the IBR, Liquified Petroleum Gas (LPG)

burning, vertical, coil type, once through forced circulation, fully
automatic, high efficiency, water tube packaged unit capable of instant
generation of steam.

2.2.2

The boiler shall be of compact and light weight, robustly constructed

as per IBR standards suitable for 10.5 kg/cm 2 steam pressure.
However the working pressure shall be adjustable between 7 to 12
kg/cm2. The boiler shall be provided with integral forced draft burner
and burner controls.

2.2.3

The main heat exchanger of the boiler shall be made out of seamless
tubes of A 192-57 or equivalent size as per ISS to ensure resistance
towards heat, pressure and corrosive atmosphere which causes heavy
stress on the steam coil. The coil shall be enclosed in double jacketed
casing serving as two way arrangement. The heat exchanger coil shall
have sufficient heating surface area.

2.2.4

The boiler shall be provided with an atmospheric economiser and shall

have an efficiency of not less than 88% on NVC as per BS-845.

2.2.5

Air from blower for combustion shall be brought to pass through the
outer jacket to cool the boiler and simultaneously to heat the air
resulting in better combustion. The outer jacket through which cold air

passes shall be used as a good natural insulator keeping the

temperature around the boiler low and also to preheat the air.

2.2.6

2.2.7

Boiler shall consist of but not be limited to the following mountings and
controls completely fitted and piped :

a)

Horizontal reciprocating feed pump.

b)

Spring loaded safety valve.

c)

Steam pressure gauge with syphon and cock.

d)

Steam temperature indicator cum controller.

e)

Pressure switch for burner control.

f)

Blow down valve with blow down switch.

g)

Check and relief valves for boiler feed line.

h)

Low pressure switch.

i)

Main steam stop valve.

j)

Auxiliary steam stop valve.

k)

Float valve for water tank.

l)

Steam separator.

m)

Economiser.

n)

Flue gas temperature indicator cum controller.

The boiler will be inspected during construction by an authorised

representative of the Owner/ Consultant at their discretion. After
completion, the boiler shall be subjected to hydrostatic test of two

times the working pressure and shall be stamped as such including all
the identifying marks and symbols as required.

2.2.8

Boilers shall be insulated and cladded with 26 gauge aluminium

sheets in the factory itself, as per manufacturers standards, which
shall be got approved from the Owner/ Consultant before
manufacture.

2.3

Burners :

2.3.1

The fuel burning equipment shall be an integral part of the boiler unit,
factory mounted and factory fire tested. The complete boiler unit shall
have the approval of the boiler and explosive inspectors for safety, if
the statutory requirement call for it. The fuel burning equipment shall
include high limit control, operating control, wind box complete with
electric sparks ignition assembly, forced draft fan with adjustable air
inlet vanes, air flow safety switches, key lock switch, start interlock,
ignition transformer, photo cell scanner assembly, control cabinet
containing electronic combustion and programming control, manual
potentiometer, terminal strips, colour coded internal wiring, signal
lights indicating ignition, main fuel, flame failure and low water
conditions, individual fused circuits for controls, motors and heaters,
burner on/off switch and magnetic motor starters with thermal overload
protection. All indicating lights and switches shall be identified by
etched name plates.

2.3.2

Boiler burner equipment shall be of the horizontal pressure jet type

complete with direct drive fuel burner, magnetic solenoid valves,
pressure and vacuum gauges.

2.3.3

Oil burning equipment shall be suitable for continuous operation of the

fuel pump when the burner is not running.

2.3.4

The burner shall be suitable for Liquified Petroleum Gas (LPG) as fuel.

2.4

Feed Unit :

2.4.1

Boiler feed unit shall be assembled on a common frame, completely

piped with suction and discharge headers, gate valves, non-return

valves and pressure gauges with siphon and cock at the inlet and
outlet of pump.

2.4.2

Feed water pump supplied with the boiler shall be multistage

centrifugal pump with stainless steel body and stainless steel piston
and shaft suitable for handling the boiler feed water. The pump shall
be capable of operating on 3 phase, 415 volts, 50 cycles A.C. power
supply and will include DOL starter. The pump shall be suitable for
operation at high temperature.

2.4.3

Economiser shall be capable of heating the boiler feed water from 20

0
C to 85 0C. The economiser shall be of shell and water through the
tube. The economiser shall be of fabricated MS with provision for
periodical cleaning of the heat transfer surface. The economiser shall
have necessary control valves, temperature and pressure indicators.

2.5

Controls :

2.5.1

Automatic control panel board made from 14-16 SWG MS sheet totally
enclosed type with modular dust and vermin proof construction shall
be mounted on the boiler. All controls shall be accessible from front.
Necessary safety features for safe working of boiler shall be
incorporated. The board shall have indication lamps for 3 phase R.Y.B.
with main switch. A rotary switch with 1 to 2 position for start-ofoperation, suitable contactors with thermal relays for protection of
motors, ignition transformer at burner, electric timer for spark,
prevention of flame failure and selector switches for by-passing ignitor
or burner shall be provided if required. The panel shall have a
voltmeter and an ammeter.

2.5.2

Safety interlocks and audio-visual indications for any fault in the

system like no water, low level/ high level in water tank, overload of
boiler feed pump, overload of blower, high steam temperature, high
steam pressure, low fuel temperature and flame failure, steam/ water/
oil pressure indicators and steam temperature indicator-cum-controller
shall also be provided.

2.6

Installation :

2.6.1

The entire boiler installation shall be complete with necessary and

sufficient appurtenances such as nuts, bolts, grouting pieces,
brackets, supports, hangers, gauges, etc. so as to result in a complete
installation in full compliance with the Indian Boiler Act, if required as
per law and the relevant Local Codes and Practice.

3.0 TANKS

3.1

Scope:

3.1.1

Scope of this section comprises the supply, installation and

commissioning of fuel oil tanks, hot water mixing tanks, condensate
recovery tank and flash heat exchangers.

3.3

Hot Water Mixing Tanks /Boiler Feed Tank:

3.3.1

Hot Water Mixing Tanks/Boiler Feed Tank shall be fabricated from

heavy gauge M.S. plates of thickness indicated in the B.O.Q.
Necessary inlet, outlet and drain connections shall be provided along
with make up float valve, water level gauge tube, low level water
alarm, dial type thermometer, 75mm dia. vent connection and an
access manhole not less than 450mm dia.

3.3.2

Mixing tanks shall have cold water connection from the water supply
system and hot water connection from the PHEs. Domestic hot water
return shall also be connected to the mixing tanks. Hot water supply
from the mixing tanks to the user points shall be maintained at
continuous 60 C temperature by means of thermostats controlling the
hot water flow into the mixing tanks.

3.3.3

A separate gauge and control panel shall be provided near the tanks
to indicate the temperature and pressure of each function.

3.3.4

Tank shall be insulated and cladded as given in the section

INSULATION.

3.3.5

Tank can be either vertical or horizontal subject to the space

availability at site.

3.4

Installation :

3.4.1

Mixing tanks, boiler feed tank can be installed either on the floor or on
a raised platform made out of M.S. structural materials at the location
shown on the drawings. Blow down tank shall be installed at the floor
level.

4.0

PLATE HEAT EXCHANGERS

4.1

Scope :

4.1.1

Scope of this section comprises the supply, installation, testing and

commissioning of water to water, plate type heat exchanger
conforming to the specifications and of the sizes and capacities set
forth in the Schedule of Equipment.

4.1.2

Heat exchanger shall be provided between hot water generator and

mixing tanks.

4.2

Materials and Construction :

4.2.1

Heat exchangers shall be of plate type for heating water.

4.2.2

Plates shall be of stainless steel or suitable material to avoid

corrosion.

4.2.3

Plates shall be corrugated to impart rigidity, induce turbulence and

enhance heat transfer surface.

4.2.4

Gaskets shall be of voton or equivalent material to withstand

temperature of upto 180 Deg. C.

4.2.5

Heat exchangers shall be tested to a minimum of one and a half times

the working pressure.

4.3

Installation:

4.3.1

Heat exchanger shall

recommendations.

be

installed

as

per

manufacturers

4.4

Testing:

4.4.1

Heat exchangers shall be tested for the performance and the results
shall be furnished.

5.0

WATER SOFTENING PLANT

5.1

Scope :

5.1.1

Scope of this section comprises the design, manufacture, supply

erection, testing and commissioning of the water softening plant,
complete with necessary accessories, interconnecting pipe work etc.

5.1.2

The supply of equipment, accessories and their erection including

electrification and inter connecting pipe work shall be complete in all
respects and any equipment not covered in this specification but
considered essential by the Tenderer in order to guarantee the proper
operation of the plant shall be included in the tender. Necessary
equipment, their expected performance and disposition in the plant are
indicated in the specifications and drawing. However, if the Tenderer
desires, he may suggest alternative equipment and their layout
capable of meeting the requirements of final water quality as well as
the area and head room restrictions within the plant room.

5.2

Capacity :

5.2.1

The plant shall be capable of softening the quantity of water indicated

in the B.O.Q. of hard water of 600 ppm total hardness within 8 hours
regeneration time.

5.3

Quality of Treated Water :

5.3.1

The hardness of softened water shall be less than 5 ppm (Commercial

Zero).

5.4

Location :

5.4.1

The water softening plant shall be located in the Mechanical Plant

Room.

5.5

Standards:

5.5.1

The components shall conform to the latest relevant standards

published by the Bureau of Indian Standards.

5.6

Equipment :

5.6.1

All components of the plant shall be constructed to the satisfaction to

the Owner and Consultants. The equipment shall be shop assembled
as far as possible, except where the assembly is required to be done
at site.

5.6.2

The items listed below are for the general guidance of the Tenderer
and will be considered as part of the equipment and will not be paid
separately. Tenderer shall include all items essential for the complete
water softening plant and shall revise or modify the list and submit his
tender on the list which he considers suitable for guaranteeing the
performance of the plant.

a)

Resin Unit (Softner).

b)

Brine Measuring Tank.

c)

Chemical Dozer - The water softner shall have a chemical dozer

as an integral part of the softening plant. The capacity shall
match that of the water softner.

d)

A set of external control butterfly valves on all piping for raw

water inlet, softened water outlet, backwash inlet, backwash
outlet, brine, water inlet to brine, rinse drain, backwash drain,

brine tank drain, air vent, drain pressure piping with sampling
cocks and inter connecting piping and water meter.

e)

Monobloc centrifugal pumps with starter capable of pumping

water from raw water tank to softener to boiler feed tank.

f)

First charge of all consumables.

5.7

Materials and Construction :

5.7.1

All material shall conform to the relevant Indian Standard

specifications for such work and shall be tested for 1 1/2 times the
working pressure.

6.0

PUMPS

6.1

Scope:

6.1.1

Scope of this section comprises the supply, installation testing and

commissioning of pumps.

6.2

Condensate Recovery/ Hot Water Pumps :

6.2.1

Condensate Recovery/ Hot water pumps shall be monobloc type with

cast iron body and bronze impellers mounted on stainless steel shaft
running in sleeve/ ball/ roller bearings with suitable high temperature
lubrication. The discharge end of the pumps shall have seal trust
bearings while the inlet end shall have mechanical seals and flexible
coupling.

6.2.2

Net Positive Suction Head requirements of the pumps shall be

sufficiently within the maximum N.P.S.H. available so as to avoid
cavitation and vapour locking. Pumps shall be connected to 1500 rpm.
T.E.F.C. ball bearing motors, factory mounted and aligned on common
base.

6.2.3

Pumps shall be provided with coupling guards, test and/or air vent
cocks, suction and discharge shut off valves, discharge check valves,
suction Y-strainers with brass screen, suction and discharge pressure
gauges and all other standard accessories whether specified or not.

6.2.4

Pumps, fittings and accessories shall be insulated as specified in

section INSULATION.

6.3

Installation :

6.3.1

Pumps shall be installed as per manufacturers recommendations.

Pump set shall be mounted on M.S. foundation which in turn shall be
mounted on vibration isolation fittings.

6.3.2

Pumps shall preferably be factory aligned. Whenever necessary, site

alignment shall be done by competent persons. Bedplate levels and
alignment results shall be submitted to the Owner/ Consultants for
approval.

6.4

Painting :

6.4.1

After complete installation and testing, the pumps, accessories and

fittings shall be given two coats, three mils each, of approved finishing
paint.

7.0

CHIMNEY AND BREACHING

7.1

Scope:

7.1.1

Scope of this section comprises the supply, installation and

commissioning of breaching and chimney for steam boilers and hot
water generator.

7.1.2

Separate breaching and chimney shall be provided for each category

of equipment.

7.2

Materials and Construction:

7.2.1

Breaching and chimney shall be of circular cross section and

fabricated from M.S. plates complete with hot formed angle flanges
fully welded at ends. Thickness of plates shall be as specified in the
B.O.Q and as required for structural stability.

7.2.2

Length of each vertical section shall not exceed 3 meters and those of
the horizontal section 1.2 meters. the sections shall have 40 x 40 x 5
mm angle iron flanges and joined by means of appropriate number of
bolts, nuts and gaskets.

7.2.3

All elbows shall be welded from a minimum of seven sections. All

branch entry points shall be 30 Deg. Y type.

7.2.4

All joints shall be securely jointed and asbestos gasketed so as to

provide leak proof joints.

7.2.5

Breaching shall be supported by heavy angles iron brackets or

channel hangers and held down by 3 mm M.S. plates.

7.2.6

Vertical section of the chimney shall be adequately supported by

means of M.S. structurals.

7.2.7

Chimney shall be provided with lightning arrestor, if required.

7.2.8

Chimney shall be provided with suitable cowl on top.

7.2.9

Each equipment connection shall be provided with a positive closing

gas tight damper with suitable lever arrangement.

7.2.10

Equipment breaching and chimney shall be fully insulated and cladded

with 24 gauge aluminium sheets as given in section INSULATION.

7.2.11

Chimney shall be provided with suitable access door (without breaking

insulation) for removal of soot and cleaning at locations necessary and
required. Chimney shall also have water drain connection and gas
sampling 100mm nipple, as required.

8.0

PIPING

8.1

Scope:

8.1.1

Scope of this section comprises the supply, fabrication, installation,

testing and commissioning of piping for fuel oil, steam and hot water.

8.2

L.P.G. Piping :

8.2.1

The entire gas piping shall be carried out as per the Code of Practice
and Standards of Petroleum Regulations.

8.2.2

Materials

a)

Gas piping shall be of seamless black steel. Pipe material shall

conform to the following :

---------------------------------------------------------------------------------------------------Material
NB

Thickness

(mm dia)

(mm)

---------------------------------------------------------------------------------------------------6

2.65

10

2.90

15

3.25

20

3.25

Seamless black steel pipe

conforming to ASTM A.106, Gr.

B,
25

4.05

32

4.05

40

4.05

50

4.50

65

4.50

80

4.50

ANSI B.36.10, Schedule 40.

----------------------------------------------------------------------------------------------------

8.2.3

b)

All fittings such as bends, elbows, tees, caps, coupling etc. shall
be forged steel with ends suitable for socket welding. The fittings
shall be seamless conforming to IS 1239 (Part II).

c)

Flanges and flanged fittings shall be of steel conforming to IS

4864.

d)

Slip-on flanges or welded neck flanges or screwed flanges shall

be used for pipe sizes below 50mm. Bolts and nuts shall be of
carbon steel and to suit matching flanges. Gaskets shall be of
CAF. Bolting shall conform to IS 1367.

e)

Pig-tails shall be of copper tubes with brass nuts. Tubes shall be

seamless and of 21 kg/cm2 pressure rating. Nuts shall be
hexagonal headed swivel type and shall be provided at both
ends.

Valves :

a)

Shut off valves shall be fire safe ball valves.

b)

Valves upto 40mm size shall be lever operated, reduced bore,

short patter, three piece design with ends suitable for socket
welding. Body bonnet and cover shall be of forged steel. Seating
for the SS 304 ball shall be of PTFE ring. Valves shall conform to
IS 2789. Rating of the valves shall be 55 kg/ cm2.

c)

Valves of sizes above 40mm shall have carbon steel body,

bonnet and cover. The ball shall be of SS 316, with PTFE body
and seat ring. Valves shall be lever operated, full bore, two piece
design having serrated raised face with flanged ends. Valves
shall conform to BS 5351. Rating of the valve shall be 10.5
kg/cm2.

8.3

Steam/ Condensate Recovery/ Hot Water Piping :

8.3.1

All piping shall be seamless for 100mm dia. and above and heavy
class annealed black E.R.W. type for 80 mm and below. The pipes
used shall stand cold bending of 180 Deg. around a mandrel which
shall be eight times the nominal diameter of the pipe without
developing cracks or opening of the weld. The pipes shall be tested to
the pressure of 21 Kg/cm2 by hydrostatic means.

8.3.2

Bends shall be cold formed upto 62 mm NB and fire bent for higher
sizes. Specials such as bends shall be fabricated from the straight
pipe stock, as required.

8.3.3

All valves and fittings 50 mm dia. and above shall be rated for 10.5
Kg/cm2 working pressure and 21 Kg/cm2 test pressure. All valves
40mm dia. and below shall be tested to 35 Kg/cm2 for leak proof
closure.

8.3.4

Flanges shall be carbon steel slip-on type conforming to IS 6392.

Flanges upto 40mm dia. shall be rated at 42 Kg/cm2 and those of
50mm dia.and above shall be rated at 21 Kg/cm2. All flanges shall
have serrated faces suitable for asbestos composition gaskets.

8.3.5

All valves shall be flanged type. Check valves shall be of gun metal
with flanged ends.

8.4

Installation :

8.4.1

Consultants drawings indicate the proposed location of various

equipment. Pipe runs and sizes shall meet the site conditions.
Contractor on the award of the work, shall prepare detailed shop
drawings, showing the routing, cross-section, longitudinal sections,
details of fittings, locations of isolation, drain and air valves etc.
Specific openings in buildings and other structures through which the
pipes are designed to pass, shall be considered while preparing the
shop drawings.

8.4.2

All pipe joints shall be welded except where flange joints are specified.
Pipes upto 65mm NB shall use socket weld fittings with fillet welding.
Larger sizes shall use butt welding type single V 35 deg. Flange joints
shall be provided at the following positions :

8.4.3

a)

Pair of flanges for isolation of equipment

b)

Mating flange for equipment flange connections

c)

Mating flange for valves

d)

Pair of flanges at every 40M continuous run of piping.

All piping shall be laid and tack welded in position with flanges, valves
etc. After inspection and approval by the Owners site representative
as to the alignment and height, the piping shall be full welded. Slip-on
flanges shall be demounted for welding.

8.4.4

Pipes shall be thoroughly cleaned before being installed. Pipes shall

be sloping towards drain points.

8.4.5

Only Advani Orlicon overcord SS or superbond S welding electrodes

shall be used for welding of the pipelines and supports. Welding
currents shall be as per manufacturers standards. Contractor shall
ensure that electrodes do not absorb moisture.

8.4.6
be

All welded piping will be subject to the approval of the Owner and shall
carried out as follows:

a) The ends of pipe lengths to be welded shall be cut with a saw or

cutter and the edges bevelled to form a 'V' groove before welding.
Under no circumstances edges shall be formed by gas cutting. All
special instructions/ precautions given by the Owner/ Consultant in
this regard shall be followed.

b) Pipes to be welded shall be properly aligned and held together in

place with cleats.

c) Root weld shall be done with 2.5 mm dia welding rods. Filler weld
and cap weld shall be done with 3.15 mm or 4 mm welding rods.

Notes: 1) Welding of taps shall generally be done with the pipes at the
floor level. Fabricated pipes shall then be hoisted in position
and welded to upstream or downstream pipe. Branch
connections from all pipes of dia 50 mm NB and lower shall
be taken by means of ready-made Schedule 80 Tees.

2) Only certified and Owner approved Welders shall be

entrusted with the work of final welding.

8.4.7

About 10% of the total welded joints shall be subjected to dye

penetration tests by the Contractor and approved by the Owner/
Consultant. The rate for the same shall be included in the installation
contract value.

8.4.8

Piping shall be properly supported on or suspended from stands,

clamps, hangers etc. The Contractor shall adequately design all
brackets, saddles, clamps, hangers, etc. and be responsible for their
structural integrity.

8.4.9

Pipes passing through walls & floors shall be provided with sleeves as
follows :

----------------------------------------------------------------------------------------------Space

Sleeve

Sleeve pro

Sleeve

dia(mm)

jection(mm) material

Sleeve packing
& closure

-----------------------------------------------------------------------------------------------

Floor

Outside

50 Above

1.25mm

32 Kg/cum resin

Diameter

Finished

GSS

bonded fibre

+
Insulation

Floor

glass with 8mm

Level

thick polysul-

phide

50

i) Internal
Wall

-do-

Flush

-do-

32 Kg/cum resin

with

bonded fibre

finish

glass closed on
both sides with
1.0mm GSS split
flanges with
brass screws.

ii) External -do-

-do-

Wall

-do-

Caulked with
lead wool and
oakum & closed
on both sides
with 1.25mm
GSS split flanges
with brass
screws.

-----------------------------------------------------------------------------------------------

8.4.10

Pipe supports shall be of steel, adjustable for height upto 50mm and
with a prime coat of red oxide and two finish coats of matt black paint
after installation. Where pipe and clamp are of dissimilar material,
gasket shall be provided between them. Supports shall be spaced as
follows :

------------------------------------------------------------------------------------------------Size

Horizontal

Vertical

-----------------------------------------------------------------------------------------------Upto 15mm

1.22 m(4-0)

1.83 m (6-0)

20 to 25mm

1.83 m(6-0)

2.44 m (8-0)

32 to 125mm

2.44 m(8-0)

3.0 m (10-0)

150mm & over

3.00 m(10-0)

3.0 m (10-0)

----------------------------------------------------------------------------------------------

8.4.11

Additional supports shall be provided at the bends, at heavy fittings

like valves near equipment and as directed by the Owners site
representative. Pipe hangers shall be from structural steel, steel
inserts in concrete, wall brackets or floor supports as decided by the
Owners site representative depending upon the location of the
support. Hangers shall not be secured to light weight roof, wall, false
ceiling or any other member which is not structurally meant for such
loading. Hangers from structural steel shall be from suitably designed
clamps or attachments and in no case should drilling or punching of
such steel members be allowed.

8.4.12

Pipe clamps shall be specially fabricated fittings. All clamps shall be of

mild steel prime coated with red oxide and finish coated with matt
black paint.

8.4.13

Vertical pipe risers shall be supported at each floor.

8.4.14
undue

Insulated piping shall be supported in such a manner as not to put

pressure on the insulation, 20mm (3/4) metal sheet shall be provided
between insulation and the clamp, saddle or roller extending at least
(6) on both sides of the clamp, saddle or roller.

150mm

8.4.15 All pipes using screwed fittings shall be accurately cut to the required
sizes and threaded in accordance with I.S. 554/1955 and burrs
removed before laying. Open ends of the piping shall be blocked as
the pipe is installed to avoid entrance of foreign matter. Wherever
reducers are to be made in horizontal runs, eccentric reducers shall be
used if the piping is to drain freely. In other locations, concentric
reducers may be used.

8.4.16 Drains shall be provided at all low points in the piping system and shall be
of the following sizes:
---------------------------------------------------------------------------------------------------Mains

Drain

---------------------------------------------------------------------------------------------------Upto 300 mm

(12)

Over 300 mm (Over 12)

25 mm (1)
38 mm (1 1/2)

----------------------------------------------------------------------------------------------------

8.4.17 Drains shall be provided with gate valves of equal size with rising spindle.
Drains shall be piped through equal size G.I. pipe to the nearest drain
or floor waste or as shown on drawings. Piping shall be pitched
towards drain points.
8.4.18 After complete installation, the piping shall be flushed to remove debris,
de-rusted with suitable acidic medium and finally passivated and kept
full. The entire system shall be hydraulically balanced to achieve
design flow.
8.4.19 All suspensions shall be through anchor fasteners of HILTI or approved
equivalent make only (Test certificate shall be furnished).
8.5

Testing:

8.5.1

Pipe welds shall be subjected to dye penetration test as specified in

9.4.7 above.

8.5.2

All piping shall be tested to hydrostatic test pressure of at least one

and half times the maximum operating pressure, but not less than 10
kg/sqcm (150 PSI) for a period of not less than 24 hours. All leaks and
defects in joints revealed during the testing shall be rectified to the
satisfaction of the Owner/ Consultant.

8.5.3

Piping repaired subsequent to the above pressure test shall be retested in the same manner.

8.5.4

Systems shall be tested in sections and such section shall be securely

capped.

8.6

Painting:

8.6.1

All piping, accessories and fittings shall be painted with a coat of red
lead primer and three coats of enamel paint as per I.S.I.

9.0

INSULATION

9.1

Scope:

9.1.1

Scope of this section comprises the supply and installation of all

insulation work for equipment and piping operating at higher than
ambient temperature.

9.2

Insulation of Piping:

9.2.1

Insulation material shall be rigid performed section of fiberglass with a

K value of not more than 0.60 Kcal/cm/Sq.mt/Hr/Deg. C at 95C
mean temperature and having a density of not less than 80 Kg/m3.

9.2.2

No insulation shall be applied until the pipe is satisfactorily pressure

tested.

9.2.3

Thickness of insulation shall be 50 mm for steam/ hot water pipes.

9.2.4

Pipe insulation shall be applied as follows :

9.2.5

a)

Pipes shall be thoroughly cleaned with a wire brush and rendered

free from all rust and grease.

b)

Rigid sections of insulation material shall be tightly fixed to the

pipes, butting all joints and tie down with lacing wire.

c)

The insulation shall be finished with 28 gauge chicken wire mesh

and 26 gauge aluminium sheet cladding with cadmium coated
self-tapping screws.

All underground or in-trench or exposed to outside piping shall be

insulated as follows :

a)

Steps (a) and (b) described above in 9.2.4.

b)

Polythene sheet shall be wrapped around the insulation.

c)

28 gauge chicken wire-mesh shall be fixed and finished with two

layers of sand cement plaster each 7 mm thick.

d)

After the plaster, a layer of tarfelt shall be fixed.

e)

Over the tarfelt sufficiently thick coat of hot bitumen R/85/25 shall
be applied.

9.2.6

All valves, fittings, strainers etc. shall also be insulated in the same
manner as piping.

9.3

Insulation of Tanks :

9.3.1

Insulation of mixing tanks and condensate recovery tanks shall be with

80 mm thick board of fiberglass crown on phenotherm, bonded with
heat resistant binder of K value not more than 0.60 KCal / cm/ Sq.mt/
Hr/ Deg.C at 95C mean temperature and suitable for temperature
upto 540C and of density not less than 80 Kg/m3.

9.3.2

Insulation shall be applied in two layers. Insulation board shall be fixed

with the help of suitable heat resistant adhesive. First layer shall be
inserted in 80 mm x 80 mm x 3 mm thick M.S. frame of size 600 mm x
600 mm. The frame shall be welded to the tank sides, bottom and top.
The second layer shall be inserted and fixed to the first layer with
adhesive.

9.3.3

The insulation shall be covered with 26 gauge aluminium sheet

cladding screwed to the M.S. frame with cadmium coated self tapping
screws.

9.4

Insulation of Chimney :

9.4.1

Insulation shall be of 80 mm thick fibre glass crown white wool

matresses or phenotherm.

9.4.2

Insulation shall be fixed in M.S. frame of size 600 mm x 600 mm. The
frames shall be welded all around the chimney. Insulation shall be
covered with galvanised chicken wire mesh (0.5 mm x 15 mm).

9.4.3

The insulation shall be provided with 26` gauge G.I. sheet cladding
screwed to the M.S. frame with cadmium coated self tapping screws.

9.5

Painting :

9.5.1

All insulated piping etc. exposed to view shall be painted in one base
coat and two coats of approved colour, except where the finish is
aluminium or G.I. cladding.

SECTION 10.0

ELECTRICAL PANELS/BOARDS

10.1

Scope :

10.1.1

Scope of these specifications covers the design, material selection,

manufacture, testing at manufacturers works, insurance, packing,
transportation, loading/unloading, supply at site, installation, testing
and commissioning of the low voltage electrical panels/ boards
covered in the BOQ, for indoor installation.

10.2

Codes and Standards :

10.2.1

Some of the important applicable codes/ standards issued by the

Bureau of Indian Standards are listed below for the guidance of the
Tenderers. Latest issues of the standards/codes shall be
applicable:

IS 5

Colours for ready mixed paints and enamels

IS 2834

Shunt capacitors for Power Systems.

IS 5578

Guide for marking of insulated conductors.

IS 8623

Low voltage switchgear and controlgear.

IS 11353

Guide for uniform system of marking and

identification of conductors and apparatus
terminal.

IS 13703

Low voltage fuses for voltages not

exceeding 1000 V A.C. or 1200 D.C.

IS 13947

Specifications for low voltage switchgear

and controlgear.

10.3

Materials and Construction :

10.3.1

Main busbars of Panels shall withstand short circuit current of 25

kA for 1 sec. at 415 V, 3 PH, 4 Wire, unless specified otherwise.

10.3.2

Panels shall be of compartmentalised design comprising free

standing vertical sections, fully interlocked pattern, fabricated from
CRCA sheet steel. They shall be totally sheet steel enclosed, dust
and vermin proof and shall be extensible on both sides. The
Purchaser/ Owner may accept panels suitable for wall mounting in
exceptional cases.

10.3.3
Panel
of any
1800 mm
be provided

height shall not be more than 2100 mm. However, mounting

operating switch, circuit breaker, etc. shall not be more than
above the base level. Minimum clearance of 200 mm shall
between the floor of the panel and the lowest module.

10.3.4

Sheet steel, cold rolled/ hot rolled, used for the body of the panel
shall be atleast 2/2.5 mm thick and the base angle/sheet shall be
at least 3 mm thick. The design shall be based on modular
construction having a pleasing appearance. The degree of
protection shall be IP 52. Barriers of 1.6 mm sheet shall be
provided between modules as well as between modules and the
busbars and between modules and cable chamber. Each module
shall have independent hinged door with concealed hinges. All
module doors shall be earthed using minimum 2.5 sq. mm copper
conductor, green coloured PVC insulated wire. A base channel of
75 mm x 40 mm x 5 mm thick shall be provided at the bottom.

10.3.5

Doors/ bolted covers etc. shall have gaskets made of non-ageing

materials to make the module dust tight. Each door shall be
provided with lock.

10.3.6
Switches, breakers, etc. shall be mounted on the rear plate of the
module.
Only switch/ breaker handles, push buttons, indicating
lamps, meters etc shall be mounted on the module door.
10.3.7
Door interlock shall be provided for every module so that it shall
not be
possible to open the door with the switch/ breaker in the

closed position. It
person only.

shall be possible to defeat this interlock by authorised

10.3.8

Adequate space shall be provided for termination of cables. The

panel shall be fabricated only after obtaining Consultants approval
for the general arrangement and schematic drawings.

10.3.9

Painting for Steel Work :

All steel work shall undergo a rust removal process comprising
alkaline degreasing, descaling in dilute sulphuric acid, cold rinsing,
phosphating and passivating. The steel work shall then be powder
coated, powder coating thickness shall not be less than 50 micron.
The paint shade for panel inside/ outside shall be RAL 7032 as per
IS 5.

10.3.10

Wire Ways :
PVC trunking wireways of adequate capacity shall be provided for
clamping and accommodating inter panel/inter-feeder wiring, if any.
Horizontal wireways shall be provided at the bottom for the
interpanel wiring, if any. Clamping facility shall be provided in the
wireways and modules for clamping of wires.

10.3.11

Cable Entry :
Cable entry for the incoming and outgoing feeders shall be as
specified in the drawings/ to suit site conditions. Removable sheet
steel gland plates shall be provided for fixing the cable glands.
The space in cable alleys between gland plates and terminals for
connecting the lugs, must be adequate for the specified size of
cables. Manufacturer shall show these clearances on the general
arrangement drawings and the same shall be increased if so
instructed by the Consultants, without extra price. The Tenderers
may submit such drawings with their tenders, if approval is
required before finalising the order. Supports for clamping cable
cores and module identifying numbers shall be provided in cable
alleys.

10.4

Components & Accessories :

10.4.1

Switchgear :
Fuse switch units or circuit breakers as specified in the B.O.Q.
shall be incorporated.

Shrouds shall be provided for live terminals in each module. Each

terminal shall have spring washers. Cam operated rotary switches
with adequate terminal adaptors upto 25 AMP are acceptable but
higher ratings switch shall be heavy duty conforming to IS 13947.
Minimum phase to phase and phase to earth clearances of 25 mm
and 20 mm respectively shall be provided. Phase barriers shall be
provided, where appropriate clearances are not available.

10.4.2

Breakers:

(A)

Moulded Case Circuit Breaker (MCCB) :

MCCB shall be Current Limiting type and shall comprise Quick

Make-break switching mechanism preferably of Double Break
Contact system. Arc extinguishing device and the tripping unit shall
be contained in a compact, high strength, heat resistant, flame
retardant, insulating moulded case with high withstand capability
against thermal and mechanical stresses. All MCCBs rated 200
Amps and above shall have adjustable magnetic short circuit pickup. The MCCBs shall be 3 pole with link in the neutral, unless
specified otherwise.

The trip command shall override all other commands. MCCB shall
employ maintenance free double break contact system to minimise
the let thru energies and capable of achieving discrimination upto
full short circuit capacity of downstream MCCB. The manufacturer
shall provide both discrimination tables and let thru energy curves.

The breaking capacities specified will be ICU=ICS i.e type-2 Coordination as per IEC-947-2/ IS 13947.

The MCCBs shall be provided with rotary handle operating

mechanism. The handle position shall give positive indication of
ON OFF or Tripped position thus qualifying to disconnection as
per the IS/IEC indicating the true position of all the contacts. In
case of four pole MCCB the neutral shall be defined and capable of
offering protection.

All MCCBs shall be provided with thermal magnetic releases

unless otherwise asked for differently in the BOQ. MCCBs offered
shall be capable of performing the desired duties such as motor
control, capacitor control etc.

(B)

Miniature Circuit Breaker (MCB) :

Miniature Circuit Breaker shall comply with the relevant IS

standard. Miniature circuit breaker shall be quick make and break
type for 230/415 V AC 50 Hz application with magnetic thermal
release for over current and short circuit protection. The breaking
capacity shall not be less than 10 KA at 415 VAC. MCBs shall be of
DIN mounting type. The MCB shall be Current Limiting type.
MCBs shall be classified as per their Tripping Characteristic
curves defined by the manufacturer. The MCB shall have the
minimum power loss (Watts) per pole defined as per the IS/ IEC
and the manufacturer shall publish the values. The MCBs shall be
1 pole, 3 pole with link-in the neutral or 4 pole type as specified.
Housing shall be heat resistant and having a high impact strength.
The terminals shall be protected against finger contact to IP20
Degree of protection. All DP, TP and TPN miniature circuit breakers
shall have a common trip bar independent of the external operating
handle. MCBs offered shall be capable of performing the desired
duties.
(C)

Earth Leakage Circuit Breaker Current Operated Type (ELCB):

a)

System of Operation :

Earth Leakage Circuit Breaker (ELCB) shall work on the

principle of core balance transformer. The incoming shall

pass through the torrodial core transformer. As long as the

currents in the phase and neutral shall be the same, no
electro motive force shall be generated in the secondary
winding of the transformer. In the event of a leakage to
earth, an unbalance shall be created which shall cause a
current to be generated in the secondary winding. This
current shall be fed to a high sensitive miniature relay which
shall trip the circuit if the earth leakage current exceeds a
predetermined critical value. ELCB/ RCCB shall be current
operated independent of the line voltage. Current sensitivity
of a minimum of 30 mA and a maximum of 300 mA at
240/415 volts AC and shall have a minimum of 20000
electrical operations.

b)

Mechanical Operation :

Moving contacts of the phases shall be mounted on a

common bridge actuated by a rugged toggle mechanism.
Hence, the closing/ opening of all the three phases shall
occur simultaneously. This also shall ensure simultaneous
opening of all the contacts under automatic tripping
conditions.

c)

Neutral Advance Feature :

Neutral moving contact shall be so mounted on the common

bridge that at the time of closing the neutral shall make
contact First before the phases and at the time of opening
the neutral shall break last after allowing the phases to open
first. This is an important safety feature which is also
required by regulations.

d)

Testing Provision :

A test device shall be incorporated to check the integrity of

the earth leakage detection system and the tripping
mechanism. When the unit is connected to service, pressing
the test knob shall trip the ELCB and the operating handle
shall move to the OFF position.
10.4.3

Isolators :
Isolators shall conform to the applicable Indian Standard and shall
be suitable for operation on 415V, 3ph, 4wire, 50Hz supply. The
isolators shall be of AC23 category. The design shall employ quick
make and quick break mechanism. ON-OFF mechanical position
indications shall be marked. The isolators shall have padlocking
facility in OFF position. Unbreakable moulded plastic handles shall
be provided. Isolators shall be 4 pole/ 3 pole with brass neutral link
as specified.

10.4.4

Contactors :

Contactors shall conform to the applicable Indian Standards.

Contactors proposed shall be capable of performing the desired
duties such as motor starting, capacitor control etc. Minimum 2 NO
+ 2 NC auxiliary contacts shall be available. Contactor coils shall
be suitable for operation on the stipulated AC/Dc voltages.
Contactors shall be of AC3 duty, unless noted otherwise.
10.4.5

Instruments :
Instruments shall be digital flush mounting type. Digital Load
Managers shall be provided as indicated in the SLD and B.O.Q.
Energy meters shall be suitable for 3 phase 4 wire unbalanced
load. Energy meters shall be mounted flush and gaskets shall be
used for making the door cut-out dust tight.

10.4.6

Current Transformers :
Current transformers shall be bar primary type with accuracy class
and VA burden as specified.

10.4.7

Busbars :

Three phases and neutral horizontal electrolytic Copper busbars as

specified in the B.O.Q., uniformly rated having maximum current
density 1.0 Amps per sq.mm with temperature rise not exceeding
40oC., shall be provided for the entire length of the panels. The
rating of busbars shall be as specified in the B.O.Q. G.I. earth
busbar of 50x6mm size or as specified shall be provided for the
entire length of the switchboard. The busbars shall be housed in
separate busbar chambers, provided with removable bolted
covers. Covers shall have non-ageing gaskets. Busbar supports
shall be of non-hygroscopic anti-tracking material such as epoxy
cast resin. Busbar supports shall be sufficiently close and robust to
effectively withstand electro-mechanical stresses in the event of
short circuit. Bolted joints shall be provided with spring washers,
lock nuts etc. for anti-vibration. Vertical busbar chambers shall be
provided in addition to the horizontal busbars. Phase busbars and
busbar joints shall be covered with heat shrinkable sleeves in R-YB colours and neutral with black sleeves. Interconnection upto 63A
shall be carried out by copper PVC wires of 650/1100 V grade and
those above 63A shall be by busbar jumpers with proper sleeves.
The rating of internal wiring/ busbar jumpers on the downstream
side of switches/ breakers etc shall be in line with the specified
sizes of outgoing cables.

10.4.8

Wiring and Terminals :

Flexible copper wires of 650V/ 1100V grade shall be used for

wiring between components on the modules and components on
the doors. Solid copper wires shall be used for wiring between
components on the modules. The size of the copper control wires
shall not be less than 1.5 sq.mm for control circuits and 2.5 sq.mm
for power circuits. C.T. section to be with minimum 2.5 sq. mm
wires. Flexible copper wires shall be used for power wiring. Colour
coded wires shall be used for control and power wiring. For
termination of conductors of sizes higher than 25 sq.mm, terminals
in the form of copper busbar pieces shall be provided. Terminal
blocks shall be minimum 16A size and suitable for upto 4 sq.mm
core connection. Spring washers, zinc passivated or plated bolts,
lock nuts etc. shall be provided with such terminals. Lugs shall be
used for terminating flexible copper wires. Lugs shall be fitted by
crimping method only. Ferrules shall be provided for every control
terminal including the terminals of the components. The ferrule
number shall be the same as the control terminal number.
Automatic dropping type terminals or shorting facility shall be
provided where CT secondary leads are to be terminated.

10.4.9

Indicating Lamps :

These shall be of the cluster LED type of specified colours.

10.4.10

Control & Selector Switches :

These shall be of the rotory type with black handles.

10.4.11

Labels :

Engraved PVC/ Black anodised labels shall be provided on all

components and feeders. A common label shall also be provided
for the panel. Inscription on labels shall be finalised during detailed
engineering. All components shall have identification labels inside
the panels also.

10.4.12

Space Heaters :

Space heaters shall be provided with Caution-Live Terminals notice

near them inside the panel. Space heaters shall be controlled by
HRC fuses and thermostats. Space heaters shall be of 40 W or
60W and suitable for operation at 240 V single phase A.C supply.
Power supply for the space heater shall be derived from the
upstream side of the incomer. Space heaters shall be provided in
each cable alley, as applicable.
10.4.13

Interlocks :

Suitable mechanical interlock castle key type shall be provided, if

specified. For automatic operation, only electrical interlocks shall
be provided. Interlocking scheme shall be designed for automatic
operation.

10.5

Drawings/ Data For Panels/ Boards :

10.5.1

Before fabrication of the panels/ boards, Contractor shall submit

detailed general arrangement drawings, single line diagrams and

schematic diagrams for all circuits/ modules for approval. G.A.

drawings shall show foundation/ fixing details also.
10.5.2 G.A. drawings shall indicate the list of components with manufacturers
reference scheme/wiring diagram and detailed bill of materials.
10.5.3 Changes suggested by the Consultants during approvals shall be without
any price variation.
10.6

Testing at Manufacturer s Works :

The panels/ boards in fully wired and assembled condition shall be

offered for inspection by the Owner at manufacturers works.
During inspection, following tests/ measurements/ checks shall be
carried-out :
a)

Dimensional checks and verification of BOQ.

b)

Mechanical and Electrical operation tests.

c)

High voltage test at 2.5 kV for 1 min.

d)

Insulation resistance measurement before and after HV test.

For bought-out items, manufacturers test certificates shall be

furnished.

11.0

SCHEDULE OF EQUIPMENT

11.1

Steam Boilers :

a) Service

Centralized steam supply to

laundry and kitchen.

b) Number and capacity

2 Nos x 600 kg/hr

c) Working pressure

12 kg/cm2

d) Fuel

Liquified Petroleum Gas (LPG).

e) Type

Vertical water tube coil type

f) Location

Mechanical Plant Room

on Lower Terrace.

11.2

Hot Water Mixing Tank :

a) Service

Hot water mixing

b) Number and capacity

2 Nos x 4000 litres

c) Type

Horizontal cylindrical

d) Location
Basement

Mechanical

plant

room

in

on raised platform.

11.3

Boiler Feed Tanks :

a) Service

Cold water fed to boilers.

b) Number and capacity

1 No. x 2000 litres

c) Type

Horizontal cylindrical.

d) Location
Lower

Mechanical

plant

Terrace on raised
Platform.
11.4

Water Softener :

Room

on

11.5

a) Service

Softening of boiler feed water

b) Number and capacity

1 No x 9600 liters per 8 hours

c) Type

Vertical cylindrical

d) Location
Basement.

Mechanical

a) Service

Hot water circulation.

b) Number and capacity

10 Nos (6+4 standby) in 4

plant

room

in

Hot Water Pumps :

circuits.
c) Type

Monobloc suitable for high

temperature application.

d) Location
Basement.

11.6

Mechanical

Plant

a) Service

Condensate recovery

b) Quantity

2 Nos (1+1 standby)

c) Location
Basement.

Mechanical

Room

in

room

in

Condensate Pumps :

plant

12.0

SCHEDULE OF TECHNICAL DATA

Tenderer shall furnish all the under mentioned technical data along with their
tenders. :

12.1

Steam Boilers :

a) Manufacturer (Boiler & Burner)

b) Steam from 20 Deg.C water

(kg/hr)

c) Heat output

(Kcal/Hr)

d) Output pressure

(Kg/cm2g)

e) Fuel (LPG)

(Kg/Hr)

f) Start-up time

(Min)

g) Burner control
h) Voltmetric capacity of coil

(Lit)

i) Feed water pump motor

(HP/KW)

j) Blower motor

(HP/HW)

k) Total electric load

(KW)

l) Feed water inlet to unit

(mm)

m) Fuel inlet size

(mm)

n) Thermal efficiency

(%)

o) Flue outlet size

(mm)

p) Draft required at flue-outlet

(mm Wg)

q) CO,SO,NO x contents in flue gas

(Grms/Hr)

r) Soot contents in flue gas

(%)

s) Temperature of flue gas

( C)

t) Overall dimensions

(mm)

u) Operating weight

(kg)

12.2

Pumps:

a) Manufacturer
b) Overall dimensions

(mm)

c) Weight

(Kg)

d) Size of foundation

(mm)

e) Speed

(rpm)

f) Discharge

(L.P.M.)

g) Head

(m)

h) Efficiency

(%)

i) Performance curves

12.3

Insulation:

a) Manufacturer
b) Material
c) `K' Value at 95 Deg C mean temp.

12.4

Water Softener:

a) Manufacturer
b) Material of construction
c) Overall dimension

(mm)

d) Weight

(kg)

e) Capacity

(LPH)

f) Regeneration time

(Hr)

g) Brine required for re-generation

(kg)

SECTION 13.0

MODE OF MEASUREMENT

Following mode of measurement will be applicable for piping, insulation

and sheet metal work.
13.1

Piping:

13.1.1

Uninsulated Piping:

13.1.2

a)

Measurement of uninsulated piping will be on the basis of

linear measurement including all materials and labour for
installed pipes.

b)

The linear rate per meter for each nominal diameter shall
include all pipe fittings, flanges, unions, gaskets for joints,
bolts and nuts, pipes supports and hangers, vibration isolation
devices or suspenders, flexible connections and any other
item required to complete the pipe installation except valves or
any kind of strainers.

c)

The cost of excavations, back filling and finishing the surface

for underground piping will be paid separately as given in the
B.O.Q.

d)

The length of the pipe section will be from flange face to flange
face.

e)

For fittings like bends, elbows, branches, tees, etc. the same
principle of linear measurement as for pipe sections will be
adopted except for bends, the length of which will be the
average of the lengths of inner and outer periphery along the
curvature.

Insulation of Piping:

Measurement of pipe insulation will be on the same basis as for

uninsulated pipe and the linear rate per meter shall include all the
items as in uninsulated piping plus the cost of pipe insulation (with
plaster, water proofing wherever provided). The linear
measurement will be taken on bare pipe before the application of
insulation.

13.1.3

Valves/Strainers:

Measurement will be on unit basis. For underground piping

wherever applicable, the cost shall include the cost of making a
masonry valve pit with steel cover. Where they are insulated, cost
shall include cost of insulation. Cost of excavation will be paid
separately as given in the B.O.Q.

13.2

Chimney and Breaching

Measurement of chimney and breaching will be on the basis of

linear measurement including all material and labour for installed
chimney and breaching.

Linear rate per meter for each nominal diameter shall include all
fittings, flanges, gaskets, nuts, bolts, supports, hangers,
accessories etc. complete in all respects.

13.3

Equipment

Equipment and electric panel will be counted in numbers when all

components, accessories and fittings are supplied and installed as
a whole.

SECTION 14.0

LIST OF APPROVED MAKES OF EQUIPMENT/

MATERIAL :

Only one of the under mentioned makes of equipment and materials will be
acceptable. Although the acceptable makes are given, the Contractor shall
submit samples of all materials other than heavy equipment and obtain prior
approval of the Owner/Consultants (whose decisions shall be binding) for the
make of each item before ordering the same. This condition is also applicable to
all items of equipment and material for which makes are not given in this
specifications:
Note :

Tender prices shall be based on the make of equipment/ materials underlined or

Tenderers own manufactured product. However, while procuring the equipment/
materials, the selected Contractor may choose any other make in this list subject
to any rebate available being passed on to the Owner. Selection of equipment/
material before procurement shall be got approved from the Owner/ Consultant.

1.

Steam Boiler

Tenderers own. If bought out, it shall be similar in construction to

`Thermax but conforming to the specifications and subject to approval
of the Owner / Consultant.

2.

Pumps

i) Jyoti
ii) Mather & Platt
iii) Kirloskar

3.

Steel Pipes

i) Indian Seamless
ii) Jindal
iii) Maharashtra Seamless
iv) SAIL
v) TATA

4.

Butterfly

i) Audco
ii) Inter valve

5.

Balancing Valves

i) Advance

6.

Check Valves

i) Kirloskar
ii) Leader

7.

Ball Valves

i) Audco
ii) BDK
iii) Rapidcool
iv) Shalimar

8.

Insulation for pipes/ chimney

i) AFFICCO
ii) FGP
iii) KIMMCO
iv) Phenotherm
v) U.P. Twiga

9.

Starter

i) L & T
ii) Siemens
iii) Cutler Hammer

10.

L.T. switchgear

i) L&T
ii) Siemens
iii) English Electric

15.0

LIST OF DRAWINGS

----------------------------------------------------------------------------------------------------------------Drawing No.

TITLE

-----------------------------------------------------------------------------------------------------------------

165-B-01

SCHEMATIC STEAM AND CONDENSATE DIAGRAM.

165-B-02

SCHEMATIC HOT WATER GENERATION DIAGRAM

165-B-03

BOILER ROOM (TERRACE) LAYOUT

165-B-04

HOT WATER GENERATOR ROOM AND LAUDRY LAYOUT.

Project Start Date :

Project Finished:
Summary :
Location:
Project Director:

December 5th 2005

December 19th 2005
Solar Central Water Heating System for TEKFEN factory
Adana Turkey
brahim Sudas isudas@auraset.com

SUMMARY
The project included the design, manufacture and installment of central solar water
heating system of the TEKFEN factory in Adana, Turkey.
The project consisted of 3 phases:
the design : project was first designed in the beginning of July. After revisions
th
the final project was approved by November 14 .
manufacturing: The manufacturing (panels, tanks, stand) and the
procurement (automation, pump, plumbing, etc) was done between November
st
th
21 -December 5 .
on site installation : Project installation was carried out between December
th
th
5-19 and was delivered in working condition on December 19 .
The factory produces bags for fertilizers and works 24-hours in 3 shifts. The project
was designed and the installation was carried out exclusively by Auraset engineers
and installation teams. Solar panels stand and the vertical boilers were
manufactured by Auraset.

Factory is owned by a conglomerate that owns the largest contracting group in

Turkey known with construction of dams, bridges, industrial facilities all over Turkey,
Russia and Asia. (Company is famous with its strictness with regards to technical
standards. Detailed technical documents and drawings were presented at each stage
in the project.
Related web links:
Tekfen Group
http://www.tekfen.com.tr/english/index.asp)
Bag factory
http://www.toros.com.tr/English/tst_torba.asp
ASSIGNMENTS carried out during the course of the Project:
1. The system was designed according to the insolation values of month of May
in Adana region. The system is designed to produce 5 tones of hot water daily to
provide hot water for the 100 employees of the factory. The challenge was to
divide the hot water into three parts so that for each of the three shifts there is
enough water to take shower.
Facts for the design of the project ( average values for May):
Ambient temperature: 21,3
Water temperature: 20,7
Required water temperature: 50
Collectors used: AA 950 BC (1,6 m2)
All rights of the project reserved. It is legally prohibited to use all or a part of this project for any purpose without the written
approval of the designer.

TEKFEN FACTORY CENTRAL SOLAR WATER HEATING PROJECT- December 2005

Daily calorie requirement: 5000* (50 -20,7) = 146500kcal / day

Solar Panel requirement: 36 units
Application:
All collectors store the heat produced throughout the day in the 4 solar boilers. The
nd
rd
first shift uses solar boiler no 1 and 2, the 2 and 3 shifts utilize solar boilers no 3
and 4 respectively.
Principle:
Water heated in the panels are circulated between the panels and the tank
serpentines by the help of 2 automatically controlled pumps. Water stored in the
tanks reach the collecting and distributor line in three separate lines and will be
distributed to the showers individually for each shift by manual valves.
Usage:
During winter months when boiler is in operation, hot water produced by the solar
collectors is connected to the cold water inlet of the boiler. In sunny days solar
heating line will be given directly to the showers through the boiler outlet.

2. The project required the design of a

special platform for the placement of
the solar panels. The tilt angle was
designed to 36. One challenge was
the line of pine trees located to the
south of the location where solar
panels were decided to be located.
The shadow of the trees were
preventing the panel garden from
almost 1,5 hour of direct sunshine in
the afternoon. The platform was
leveled up 2 meters to overcome this
problem. Walkways of 50 cm width
were also included in the platform.
3. The platform was pre-manufactured at
the factory, to decrease the amount of
installation hours on-site as well as to
avoid any potential problems that may
delay the delivery date.

Manufacturing and Pre-assembly of

platform at the factory site.

4. The project also included the lay out of

concrete foundations for the platform,
also carried out by Auraset. The
mountage of the platform after
concrete foundation was completed,
took 4 workers 2 days without the
need for special equipment, i.e. crane.
All rights of the project reserved. It is legally prohibited to use all or a part of this project for any purpose without the written
approval of the designer.

TEKFEN FACTORY CENTRAL SOLAR WATER HEATING PROJECT- December 2005

5. 4 units of vertical solar boilers each 1250 lt. capacity was designed and
manufactured for the project. The tanks were
Technical Specs
Body
Shell thickness
Serpentines
Insulation
Casing

Hot deep galvanized

6 mm.
42 , 7 m
10 mm glasswool
Galvanized steel

Manufacturing and Loading of solar tanks at the factory

6. Installation was realized by, in average 5 workers in 11 working days. This

included:
a)
b)
c)
d)
e)
f)
g)

Assembly of the platform

Placement of vertical tanks
Piping between the collectors and collectors and the vertical boilers
Piping between the vertical boilers and the factory heating centre
Installation of pumps and automation
Insulation of entire piping.
Concrete foundation was laid out before the installation was started, during
the manufacturing of product at the factory.

7. Following documents are presented in the attachment that demonstrates the

technical aspect of the project:
a)
b)
c)
d)
e)

Platform 1
Platform 2
Platform 3
Project Principle
Plumbing Model

All rights of the project reserved. It is legally prohibited to use all or a part of this project for any purpose without the written
approval of the designer.

TEKFEN FACTORY CENTRAL SOLAR WATER HEATING PROJECT- December 2005

f)
g)
h)
i)

Panel- exchanger connection

Placement of Platform and Tanks
Panel-Piping connections
Tank hot and cold water connections

The platform and its concrete foundation

Test Run

Piping Installation

All rights of the project reserved. It is legally prohibited to use all or a part of this project for any purpose without the written
approval of the designer.