Professional Documents
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VOLUME-II
SPECIFICATION - M6A
INDEX
APPENDIX – I DATASHEET 13
1.01.00 This specification covers the system description, basic design criteria and
minimum technical requirements of the Raw Water (RW) Chlorination system,
Circulating Water (CW) chlorination system along with all associated
equipment and controls.
1.02.00 The capacity of the chlorination plants for RW and CW system is indicated
elsewhere in this specification.
ii. Three (each 50%) Chlorination Streams common for two units, each
of capacity 150 kg/hr.
iii. One (1) common chlorine manifold with all necessary accessories
including straight lengths of pipe, fittings, isolation valves etc.
iv. Each chlorinator (total three streams for two units) shall be vacuum
feed type, complete with Vacuum Regulators and all accessories.
vi. Two (2) x 100% Chlorine gas filters for each chlorination streams,
with all accessories.
vii. Pressure reducing and pressure relief valves, motorized safety shut-
off valve for each chlorine gas line from outlet of each evaporator.
viii. Three (3) (each 50%) chlorination booster pumps with drive motors
and all accessories.
xii. All piping (for motive water, chlorine gas and chlorine solution),
fittings and valves (pneumatically and manually operated)
xiii. Diffuser assemblies for chlorine dosage into the cooling tower basin
/ forebay and pump sump.
i Three (3) Chlorine Ton Containers with isolation valves and roller
Trunnion brackets for each ton container.
iv Two (2) (each 100% capacity) chlorination booster pumps with drive
motors and all accessories.
vi Two (2) x 100% Chlorine gas filters, for each chlorination streams,
with all accessories.
viii Pressure reducing and pressure relief valves, motorized safety shut-
off valves for each chlorine gas line from outlet of each chlorinator.
3.03.00 All field instruments with cabling up to local junction box / System control
panel.
3.04.00 All Power and control cables with cabling and all accessories up to local
junction box / System control panel.
3.05.00 Anchor bolts with nuts, sleeves, shims, washers, embedment for equipment
and pipe supports, mating flanges.
3.07.00 Electric Hoists for handling chlorine ton containers for CW and RW
chlorinators including load indicator and ton container grabbing kit.
3.08.00 Platform type Weighing scale for weighing Chlorine ton containers.
i) CW Chlorination System
The chlorination Plant shall consist of three 3 x 50% vacuum solution feed
type chlorinators and 2x100% chlorine gas filters for each chlorinator. The
chlorinators shall be connected, independently to three (3) electrically heated
constant temperature water bath type chlorine evaporators of same capacity
as that of chlorinators.
The motive water shall be fed to the ejector through booster pumps and
chlorine solution shall be dosed into the CW forebay through diffusers. 3 x
50% booster pumps each capable of meeting the requirement of one
chlorinator shall be provided.
Chlorine solution shall be dosed in the stilling chamber of raw water Pre
Treatment plant.
The chlorination Plant shall consist of two (2) x 100% vacuum solution feed
type chlorinators and 2x100% chlorine gas filters for each chlorinator.
The motive water shall be fed to the ejector through booster pumps and
chlorine solution shall be dosed through diffusers. Three (3) booster pumps
each capable of meeting the requirement of one (1) unit shall be provided.
This system shall be supplied with all equipment and accessories, comprising
mainly the following:
c. Two (2) (one working and one standby) blowers for sucking and
delivering the chlorine gas upto the absorption tower for each system
(CW and RW system)
For absorption and neutralizing the leaked chlorine from the chlorination
system, a chlorine leak detection and absorption system shall be provided.
The system shall consist of absorption tower, one (1) no. Caustic solution
preparation cum re-circulation tank fitted with agitator, two (2) x 100% caustic
solution re-circulation pumps along with two (2) x 100% blower, FRP hoods
connected to the FRP duct leading to absorption tower inlet. Chlorine leak
detectors and monitors shall be provided for sensing any chlorine leakage,
and the absorption system shall start automatically by the signal from the leak
detector. The exhaust from the absorption system shall have residual chlorine
less than 0.1ppm.
4.02.00 Valves
4.02.01 The valves handling dry liquid or gaseous chlorine shall be the standard valves
used for such service. These valves shall conform to IS: 3224 with Body and
Stem material as “Forged Al Silicon bronze” and Monel respectively. Ball valves
shall be of forged steel body (ASTM-A-105), hastalloy-C ball and other internal
components suitable for handling chlorine. The pressure ratings shall be
suitable for the chlorine container pressure and as per the recommendations of
Chlorine Institute Standards, USA.
4.02.02 Valves handling chlorine under vacuum and chlorine solution shall be of
diaphragm type, the main body being made of PVC or rubber-lined cast iron.
The diaphragm material shall be of nylon reinforced Neoprene. The valves
handling ordinary water shall be outside screw and yoke, bolted bonnet type, of
cast iron body and bronze trim. The cast iron shall be of IS: 210 Gr. FG.260.
4.02.03 Non-return valves in ordinary water service shall be of cast iron to IS: 210 Gr.
FG 260 and swing check type. These shall have a permanent 'Arrow'
inscription on its body to indicate the direction of motion of water. The
non-return valve on chlorine line under vacuum to the injector shall be spring-
loaded diaphragm type, vacuum to open design.
4.02.04 Small size valves to be used for sampling and instrument isolation shall be of
Gun Metal as per IS: 778 Class I for non-corrosive service. For corrosive
Bhusawal TPS Expansion Project Volume – II
Page: 5
2 x 500 MW Balance of Plant Package M6A
MAHAGENCO
Maharashtra State Power Generation Co. Ltd.
service, these shall be of PVC or rubber lined C.I. body and ball/diaphragm
type.
4.02.05 The Bidder shall provide one automatic shut-off valve, to be located
downstream of the evaporator for C.W. System chlorinator. The valve shall
incorporate a pneumatically operated actuator. A three way solenoid valve shall
be included in the scope of supply, for on-off control of the Pneumatic actuated
valve. The valve shall have silver-plated bronze body, stainless steel spindle,
replaceable monel or teflon seat, teflon plug insert.
4.02.06 A Chlorine gas filter shall be included, upstream of the shut-off valve and
downstream of the evaporator, along with isolation valves. The filter shall have
removable filter element of glass wool and shall have an in-built arrangement to
trap any liquid chlorine droplets.
4.03.00 Piping
4.03.01 All piping and fittings coming in contact with chlorine shall be constructed from
materials of approved quality as per the recommendations of the Chlorine
Institute, USA. The liquid chlorine piping will be arranged so as to avoid the
necessity of expansion chambers. The layout, installation and the testing of all
piping systems shall follow the recommendations of the Chlorine Institute, USA.
4.03.02 The steel pipes used for liquid and gaseous chlorine shall be of seamless
carbon steel and Sch 80 thickness. Forged carbon steel fittings and flanges
with pressure ratings recommended by the Chlorine Institute, USA, shall be
used. PVC or similar materials shall not be used in liquid chlorine and
pressurized chlorine gas lines.
4.03.03 Flexible copper tubes of sufficient length and with expansion loop along with
necessary number of clamps shall be provided for connecting liquid chlorine
header with the ton containers.
4.03.04 Piping handling chlorine shall be as simple as possible, with minimum number
of screwed and flanged joints. Piping shall be well supported and adequately
sloped to allow drainage. Low spots shall be avoided.
4.03.05 The piping from chlorinators to the injectors and chlorine solution outlet upto
manifold shall be of mild steel to IS: 1239 heavy grade, lined inside with 3mm
thick rubber or equivalent non-corrodible lining. The lining shall be brought out
through all connections, bores and across flange faces.
4.03.06 Rigid PVC pipe as per IS: 4985 or HDPE pipe as per IS: 4984 of adequate size
shall be supplied complete with fittings and diffusing arrangement, from the
chlorine solution manifold to the points of application of chlorine solution.
The outdoor portion of chlorine solution piping upto the dosing points are to be
buried underground or as per the detailed layout duly approved by owner.
4.03.07 All piping handling ordinary water shall be as per IS: 1239 heavy grade ERW
and IS: 3589 or equivalent as applicable.
4.03.08 A water injector assembly outside the main chlorinator shall be provided for
each chlorinator. The injector shall be mounted vertically downward and shall
have flow-adjusting device. The main body shall be of rubber lined steel with
the nozzle and diffuser of hard rubber or plastic. The injector shall be provided
with a non-return valve to prevent flow of water to the chlorinator in case of
failure of power water. Strength of chlorine solution downstream of the injectors
shall not be more than 2500 ppm.
4.04.00 Insulation
All equipment and piping carrying hot fluid shall be suitably lagged. The design
of insulation shall be based on a maximum allowable temperature of 60 deg.C
on the exposed surfaces of insulation. The insulation shall be finished with an
aluminium sheet of 18 gauges.
For raw water chlorination, One (1) weighing machine with platform shall be
provided. The operating chlorine ton container will be mounted on the machine
platform.
For the CW system chlorination Two (2) weighing machine with platform
suitable for mounting one chlorine ton container shall be provided for keeping
track of chlorine content in the operating ton containers. Normally Two (2) ton
containers mounted on the weighing machine platforms will be connected to
chlorine supply manifold.
4.06.00 The guidelines mentioned above are not exhaustive. Salient design data /
design guidelines of different equipment / items are also given in the flow
diagrams, sub-sections and data sheets.
Chlorine ton containers and auxiliary ton container valves shall be of a design
approved by the Chief Controller of Explosives. Each item supplied shall be
stamped / approved by CCE.
ii) Evaporators
iii) Chlorinator
v) Layout
On/Off/Trip status of all the pumps, blowers, agitators and drive motors for
equipment shall be displayed.
A detailed quality assurance plan covering stage wise tests to be carried out
during the manufacturing of equipment/ vessels including performance testing
at site indicating involvement of bidder, sub vendor and owner categorically
shall be furnished along with the bid.
The tests at manufacturing unit of vendor / sub vendor shall include but not be
limited to following:
5.02.01 All butt welded joints used for fabrication of chlorine pressure chambers shall
be examined by 100% radiography as per UW-51 of ASME Section VIII Div.I.
5.02.02 All other welded joints shall be examined by liquid penetration test according to
the method outlined in ASME section VIII Div.I.
a. All piping and plate material for flanges shall be furnished with suitable
test certificates and proper correlation. These shall be identified before
proceeding with further fabrication.
c. The final pass of all welding shall be checked by dye penetrant method.
f. For the rubber lining of piping and ejectors testing of lining as per the
provisions of IS: 4682 - Part I.
5.03.01 Valves
c. For the rubber-lined valves, testing of lining as per the provisions of IS:
4682 - Part I.
5.03.02 Instruments
Pressure Gauges:
Pressure Switches:
Flow Gauges
a. Over pressure test at the same pressure as the test pressure of the
system.
Over pressure test at the same pressure as that of the associated tank
Level Switches
Solenoid Valves:
The control panel shall be subjected to tests to show that the panels have been
satisfactorily designed and manufactured in accordance with the relevant
standards. Following tests shall be carried out:
1. Each chlorinator system shall have a capacity not less than that specified.
The bidder shall quote separately for the following safety equipment/devices. In
addition he may quote separately with unit rates, his suggested safety device
other than those mentioned below:
APPENDIX – I
d) Material of Construction :
CW Chlorination RW Chlorination
System System
1.00.02 Chlorinators
CW Chlorination RW Chlorination
System System
f) Automatic pressure
--------Required--------
vacuum relief valve
d) Type : Centrifugal
j) Material of Construction
v) Gland and Stuffing Box : Cast iron IS: 210 Gr. FG 260
m) Accessories required for each pump : Coupling guard, drain and vent-
valves etc.
a) Chlorinated water supply point : Six (6) across the CW pump house
forebay for CW system for each
unit. One (1) each in the stilling
chambers for RW System. One (1)
before Overhead Water Storage
tank