DOC.

NO:- BE-LAL-EMV-113-S-0001

LALITPUR SUPER THERMAL POWER PROJECT 3X660 MW

LALITPUR, UTTARPRADESH

TECHNICAL SPECIFICATIONS
FOR
COMPRESSED AIR SYSTEM

BAJAJ INFRASTRUCTURE DEVELOPMENT

COMPANY LTD.

CARBERY INFRASTRUCTURE PTE LTD



Lalitpur Super Thermal Power Project

SECTION: INDEX
SHEET 1 OF 1

3 x 660 MW, Lalitpur, Uttar Pradesh

COMPRESSED AIR SYSTEM

INDEX SHEET

INDEX SHEET FOR SPECIFICATION VOLUMES

Volume I

Instructions to bidders, Bid Qualification

requirements, Important Commercial Terms and
Conditions

Volume II

Technical specifications
Drawings




Lalitpur Super Thermal Power Project - 3 x 660 MW

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VOLUME - II

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

SECTION:
CONTENTS
SHEET 1 OF 4

SPECIFICATION FOR COMPRESSED AIR SYSTEM

SECTION
NO.

TITLE

NO. OF SHEETS

SCOPE OF ENQUIRY

PROJECT INFORMATION

C1

CODES, STANDARDS AND SYSTEM DESCRIPTION

C2

EQUIPMENT TO BE SUPPLIED, ERECTED / INSTALLED,

TESTED AND COMMISSIONED BY BIDDER

11

C3

MISCELLANEOUS SERVICES FROM THE CONTRACTOR

C4

EQUIPMENT AND SERVICES TO BE PROVIDED BY OTHERS

C5

TERMINAL POINTS

C6

DESIGN, LAYOUT, MAINTENANCE, AND OTHER GENERAL

REQUIREMENTS

ELECTRICAL
117

C7
REQUIREMENTS
C8

INSTRUMENTATION AND CONTROL SYSTEM

REQUIREMENTS

26

C9

SYSTEM PERFORMANCE GUARANTEE REQUIREMENTS

AND PERFORMANCE TESTS

SYSTEM DATA SHEET-B

(DATA TO BE FURNISHED ALONG WITH BID)

C10

SYSTEM DATA SHEET-C (CALCULATIONS/ TECHNICAL

DATA TO BE FURNISHED BY THE VENDOR AFTER AWARD
OF CONTRACT)

C11

SPARES

C12

GENERAL PAINTING REQUIREMENTS

19

C13

MINIMUM INSPECTION REQUIREMENTS FOR AIR

COMPRESSOR

VOLUME - II

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

SECTION:
CONTENTS
SHEET 2 OF 4

SPECIFICATION FOR COMPRESSED AIR SYSTEM

SECTION
NO.

TITLE

NO. OF SHEETS

C14

MINIMUM INSPECTION REQUIREMENTS FOR VALVES

AND SPECIALITY

C15

MINIMUM INSPECTION REQUIREMENTS FOR CARBON

STEEL PIPES

DATA SHEETS
AIR COMPRESSOR
WRITE-UP

10

DATA SHEET A

DATA SHEET - B

D1

AIR DRYING PLANT

WRITE-UP

DATA SHEET A

DATA SHEET - B

D2

D3

PIPING & VALVE SCHEDULE

MOTOR AND VALVE ACTUATOR

D4

DATA SHEET-A

DATA SHEET-B

415 VOLT SWITCH GEAR / PMCC

D5

DATA SHEET A

DATA SHEET B

12
CABLING SYSTEM

D6
DATA SHEET B

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CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

SECTION:
CONTENTS
SHEET 3 OF 4

SPECIFICATION FOR COMPRESSED AIR SYSTEM

SECTION
NO.

TITLE

NO. OF SHEETS

LCP & DCDB

D7
DATA SHEET B

SCHEDULES
F1

SCHEDULE OF PRICES

F2

SCHEDULE OF DEVIATIONS FROM TECHNICAL

SPECIFICATION

F3

SCHEDULE OF DEVIATIONS FROM GENERAL

CONDITION

F4

SCHEDULE OF ESSENTIAL AND RECOMMENDED

SPARE PARTS

F5

SCHEDULE OF MAINTENANCE TOOLS AND TACKLES

F6

SCHEDULE OF WEIGHTS AND DIMENSIONS

F7

SCHEDULE OF BIDDERS EXPERIENCE

F8

DOCUMENT DISTRIBUTION SCHEDULE

F9

SCHEDULE OF GENERAL PARTICULARS

F10

OVERALL TIME SCHEDULE

F11

SCHEDULE OF QUALITY PLAN

F12

SCHEDULE OF PERFORMANCE GUARANTEE

F13

SCHEDULE OF PLACES OF TEST AND INSPECTION

DRAWINGS
MECHANICAL DRAWINGS
1.

COMPRESSORS AND ACCESSORIES FLOW DIAGRAM

2.

COMPRESSOR HOUSE - LAYOUT

ELECTRICAL DRAWINGS
1.

CABLE TRAY MOUNTING ARRANGEMENT CTM1

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3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

SECTION:
CONTENTS
SHEET 4 OF 4

SPECIFICATION FOR COMPRESSED AIR SYSTEM

SECTION
NO.

TITLE

NO. OF SHEETS

2.

CABLE TRAY MOUNTING ARRANGEMENT CTM2

3.

DETAILS OF VERTICAL RACEWAY CTMV-4

4.

LADDER TYPE CABLE TRAY (CTL)

5.

CABLE INSTALLATION PRACTICE IN HORIZONTAL

TRAYS

6.

EARTHING DETAILS INSERTS / RISERS (WELDED /

BRAZED CONNECTIONS)

7.

EARTHING DETAILS MOTOR FRAME EARTHING

(BOLTED CONNECTIONS)

8.

EARTHING DETAILS TRANSFORMER (WELDED /

BOLTED CONNECTIONS)

9.

COMPRESSOR HOUSE SINGLE LINE DIAGRAM

SECTION A

CARBERY INFRASTRUCTURE PTE LTD

VOLUME - II

3 X 660 MW Super Critical TPP at Lalitpur, Uttar

SECTION: A

Pradesh

SHEET 1 OF 2

SPECIFICATION FOR COMPRESSED AIR SYSTEM

SCOPE OF ENQUIRY

SCOPE OF ENQUIRY
1.0

This specification covers the design, manufacture, inspection and testing at

manufacturers works, packing and forwarding, supervision of erection,
testing, commissioning, carrying out of performance tests at site and other
related items of work for the complete plant and equipment inclusive of all
mechanical, electrical, instrumentation & controls of the compressed air
system with air compressors, drying plant, air receivers, control and
monitoring system with necessary interface with DCS for monitoring from the
control room for 3 x 660 MW super critical thermal power plant at lalitpur.

2.0

It is not the intent to specify completely herein all details of design and
construction of the equipment. However, the equipment shall conform, in all
respects to high standards of engineering, design and workmanship and be
capable of performing in continuous commercial operation up to BIDDERs
guarantee in a manner acceptable to PURCHASER who will interpret the
meaning of drawings and specifications and shall have the power to reject any
work or materials which, in his judgement, are not in full accordance
therewith.

3.0

The extent of supply under this contract includes all items mentioned in the
specification and/or schedule, not withstanding the fact that such items may
have been omitted.

4.0

All necessary co - ordination with regard to sub - contracted equipment shall

be carried out by the CONTRACTOR. The PURCHASER will communicate
only with the CONTRACTOR for all matters pertaining to this contract.

5.0

The total price quoted for each equipment shall be firm all inclusive basis and
shall cover all items and services necessary for the successful completion of
the contract. Even if all components of equipment included in this specification
are not explicitly identified and / or listed here, these shall be supplied under
this contract to ensure completeness of the equipment and facilitate proper
operation and easy maintenance of the equipment.

6.0

All the air compressors and accessories shall be supplied, erected, tested and
commissioned within 10 months from the date of LOI.

7.0

The BIDDER shall strictly quote his prices in the format as indicated in
Section-F in the Schedule of Prices of this specification. Presentation of
prices in different formats is not acceptable.

8.0

In the event of conflict between the different clauses of this specification,

drawings,
the stringent requirement as per the interpretation of

CARBERY INFRASTRUCTURE PTE LTD

VOLUME - II

3 X 660 MW Super Critical TPP at Lalitpur, Uttar

SECTION: A

Pradesh

SHEET 2 OF 2

SPECIFICATION FOR COMPRESSED AIR SYSTEM

SCOPE OF ENQUIRY

PURCHASER shall be final and binding on the bidder for which no

commercial implication shall be entertained by purchaser.
9.0

BIDDER shall carefully study all sections of this specification and shall clearly
indicate only in the respective Schedule of Deviations all deviations, if any,
from technical specifications and General Terms and Conditions of the
specifications. If no deviations are indicated in the Schedule of Deviations, it
will be understood that in all respects, the offer conforms to the specification
and PURCHASER reserves the right to evaluate the Bids as such without any
further reference to the BIDDER. If the BIDDER indicates any comments /
deviations on the specification elsewhere in his bid the same will not be
considered / accepted. It is binding on the BIDDER to supply the equipment
and system in accordance with the specification, except for deviations
accepted by PURCHASER. No extra claim on this account after the award of
contract will be entertained by PURCHASER.

SECTION B
PROJECT INFORMATION

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

VOLUME II
SECTION: B
SHEET 1 OF 5

SPECIFICATION FOR COMPRESSED AIR SYSTEM

PROJECT INFORMATION

PROJECT INFORMATION
1.

Owner

: Lalitpur Power Generation company Limited

2.

Owners Engineer

: TATA Consulting Engineers Limited

3.

BOP Contractor

: M/s Carbery Infrastructure Pte Ltd

4.

Purchaser

: M/s Bajaj Infrastructure Development Co. Ltd

5.

Project Title

: Lalitpur Super Thermal Power Project - 3 x 660 MW

Lalitpur, Uttar Pradesh.

6.

Location

: At Mirchwara and Buraugaon near Utari river,

Lalitpur District, U.P, India

7.

Nearest Railway station

: Lalitpur railway station (At a distance of 37 kms

from site) in the connecting railway line between
Jhansi & Bhopal.

8.

Site elevation

: 325 M

9.

Access Road

: Approach to site from national highway which is

about 23 km from Bansi on NH-26 which connects
Jhansi and Sagar.

10.

Nearest Airport

: Gwalior Airport (At a distance 186 km from site)

11.

Nearest Sea port

: Kolkata

12.

Latitude of site

: 2447'0.65''N

13.

Longitude of site

14.

Metrological data

7838'0.74''E

a)

Temperature

i)

Annual mean of daily max.

32.40C

ii)

Annual mean of daily min.

17.50C

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

VOLUME II
SECTION: B
SHEET 2 OF 5

SPECIFICATION FOR COMPRESSED AIR SYSTEM

PROJECT INFORMATION

iii)

Annual mean of monthly max.

45.10C

iv)

Annual mean of monthly min.

1.90C

v)

Maximum extreme temp recorded

46.2C

vi)

Minimum extreme temp recorded

0C

vii)

Temperature to be considered for

design of electrical equipment/devices

50C

viii)

Ambient DBT for performance

guarantee of boiler, ID fan, PA fan,
FD fan & ESP

270C

b)

Relative humidity

i)

Maximum

87%

ii)

Minimum

22%

iii)

Annual mean of maximum

65%

iv)

Annual mean of minimum

49%

v)

Ambient RH for performance

guarantee of boiler, ID fan, PA fan,
FD fan & ESP

c)

Rainfall

i)

Annual variation

3.0 mm to 387.3 mm

ii)

Average annual RF

91.42 mm

d)

Wind Data

i)

Basic wind speed

47 m/s

15.

Languages Spoken in the Region

Hindi

16.

Official language for the Contractor to deal

with

English

60%

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

VOLUME II
SECTION: B
SHEET 3 OF 5

SPECIFICATION FOR COMPRESSED AIR SYSTEM

PROJECT INFORMATION

17.

Tropicalisation

18.

Cooling water inlet temperature

All equipment supplied against

this specification shall be given
tropical and fungicidal treatment
in view of climatic conditions
prevailing at site.

a)

Design (Condenser & PHE secondary

side)

33C

b)

Maximum (Condenser & PHE secondary

side)

36C

Seismic data as per IS 1893: 2002

19.

a)

Zone

Zone-III

b)

Zone factor-Z

0.16

c)

Importance factor (I)

1.75 (as per latest IS1893)

Auxiliary power supply

Auxiliary electrical equipment to be

supplied against this specification will be
suitable for operation on the following
supply system.

(a)

(b)

(c)

(d)

For motors rated above 1500

11000V, 3 phase, 3 wire, 50Hz (Medium

kW

resistance earthed) AC Supply

For motors rated above 200 kW

6600V, 3 phase, 3 wire, 50Hz (Medium

and up to & including 1500 kW

resistance earthed) AC Supply

For motor rated up to & including :

200 kW

415V, 3 phase, 3 wire solidly earthed AC

DC
motor
starters,
DC :
solenoids, DC alarm, control and
protections

Supply
220 V DC, 2 wire, unearthed DC

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

VOLUME II
SECTION: B
SHEET 4 OF 5

SPECIFICATION FOR COMPRESSED AIR SYSTEM

PROJECT INFORMATION

(e)

AC control & protective devices

110 V, 1 phase, 50Hz, 2 wire AC supply.

The single-phase 110V AC supply will be
derived by Contractor by providing 415V/
110V control transformers of adequate
rating with MCCB /MCB on both the
primary and secondary sides.

(f)

Uninterrupted power supply

240 V, 1 phase, 50Hz, 2 wire AC supply

(g)

AC solenoids, space heaters (for

240 V, 1 phase, 2 wire, 50Hz AC system

motors rated 30kW and above)

with solidly earthed neutral. The power

supply will be derived by Contractor by
providing 415V/ 240V transformer of
adequate rating with MCCB/MCB on
primary/secondary sides.

(h)

Solid state controls (including :

24 V DC, 2 wire, supply from (24V DC

solenoid valves)

supply derived from 240 V AC UPS

supply)

(i)

Lighting fixtures

240 V, 1 phase, 2 wire, 50Hz solidly

earthed AC system.

(j)

a. Lighting fixtures and space :

240 V, AC 1 phase, 2 wire, 50Hz solidly

heaters in panels

earthed AC system.

b. Construction power supply

415V, 3 phase, 4 wire, 50Hz solidly

earthed AC supply

(k)

The above voltages may vary as follows:

All devices will be suitable for continuous operation over the entire range of
voltage and frequency indicated below without any change in their performance.

VOLUME II

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

SECTION: B
SHEET 5 OF 5

SPECIFICATION FOR COMPRESSED AIR SYSTEM

PROJECT INFORMATION

i.

AC supply

Voltage variation

10%

Frequency variation

+5% to -5%

Combined voltage & frequency variation

10%
ii.

Note :

DC supply

Voltage variation

+10% to -15%

All the electrical equipment shall be designed for 50 C reference ambient temperatures.

VOLUME - II

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

SECTION: C1
SHEET 1 OF 2

SPECIFICATION FOR COMPRESSED AIR SYSTEM

CODES, STANDARDS AND SYSTEM DESCRIPTION

1.0

CODES AND STANDARDS

All equipment, system and works covered under this specification shall
comply with all currently applicable statutes, regulations and safety codes in
the locality where the equipment will be installed. Also, all equipment shall
conform to the latest applicable Indian or other International Standards
established to be equivalent or superior to the Codes and Standards
specified in Section-D, where relevant Indian standards do not exist. In case
the BIDDER offers equipment conforming to any standards other than those
specified in component specifications, the BIDDER shall furnish copies of
standards translated in English while submitting his proposal.
The latest issue of IS codes prevailing at the time of submission of final offer
shall be applicable. However, if there are any revisions during the execution
of the contract, the same shall be applicable for which no cost implication
shall be entertained by purchaser.
In the event of conflict between the Codes and Standards referred to in the
specification and the requirement of this specification, the latter shall
govern. The list of some of the major standards applicable are furnished
below :
IS 1239 (Part I)

Mild steel tubes

IS 2825

Code of construction for unfired pressure vessels

IS 3589

Electrically welded steel pipes for water, gas and

sewage (150 mm to 2000 mm).

IS 5456

Code of practice for testing of positive displacement

type air compressors & exhausters

IS 7938

Air receivers for compressed air installation

IS 6206

Guide for selection, installation and

maintenance of

air compressor plants with operating pressure up to

10 bars.
BS 1571

Specification

for

testing

positive

displacement

compressors & exhausters.

API 617

Centrifugal compressors for petroleum, chemical and

gas industries.

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

VOLUME - II
SECTION: C1
SHEET 2 OF 2

SPECIFICATION FOR COMPRESSED AIR SYSTEM

CODES, STANDARDS AND SYSTEM DESCRIPTION

2.0

SYSTEM DESCRIPTION

2.1

Totally Seven (7) Nos. (5 operating + 1 auto standby + 1 maintenance

standby) of screw compressors be adopted for meeting the total service
and instrument air requirements for all the three Units. When all three
units under normal operation the air requirement shall be met by Five (5)
numbers of compressor. For meeting the requirement of IA and SA while
2 units are under normal operation and 1 unit are under emergency
condition, Six (6) numbers of compressors will be working and 1
compressor will be in auto stand-by mode. Hence total Seven (7) numbers
of compressors are considered. Also the sixth compressor will be used to
meet the additional air requirement when all three (3) units are under
normal operation. Three compressor operating on load/unload regulation
shall be operating normally to meet the compressed air requirements of all
three units, while the common auto standby compressor cuts in as and
when the operating compressors fail to deliver the air requirements of the
units or in case one of the compressors fails. The compressed air
discharged by the compressors shall be supplied to distribution piping to
various application points (by others) through after-coolers, air receivers
and air driers (for instrument air only). To meet the desired quality of
instrument air, only compressed air required for control and
instrumentation purposes shall be passed through any of the four (4) heat
of compression type air driers three (3) operating and one (1) standby.

2.2

Base duty compressors will be operating on load / unload control, and

stand by Compressors will be operating on auto-start / stop control. Each
compressor will have its own controller with integrated HMI having facility
to operate the compressor in auto/standby mode as well as in manual
mode. In addition, the complete air compressor system shall be operated
from purchasers main plant DCS to load/unload the compressors based
on the instrument air final header pressure to the consumers. Under
normal operating conditions, the complete compressor train will be
controlled from local compressor control panel. Compressors and
associated equipment shall be operable and controlled from local
compressor control panel as well as from main plant DCS.

VOLUME - II

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

SECTION: C2
SHEET 1 OF 11

EQUIPMENT TO BE SUPPLIED, ERECTED /

INSTALLED, TESTED AND COMMISSIONED BY
BIDDER

2.0

EQUIPMENT TO BE FURNISHED, SUPPLIED, ERECTED / INSTALLED,

TESTED AND COMMISSIONED BY BIDDER

2.1

MECHANICAL WORKS:
The following equipment and services shall be provided by the VENDOR.
This shall conform to the respective Data sheet-A / flow diagram:

SL. NO.

EQUIPMENT / DESCRIPTION

QUANTITY
Seven (7) Nos

2.1.1

Oil free screw type compressor including drives,

silencer and other accessories as per the sectionD1 - Data sheet-A

2.1.2

Inter-coolers between the stages as per the sectionD1 - Data sheet-A

Seven (7) Nos.

2.1.3

After-coolers as per the section-D1 - Data sheet-A

Seven (7) Nos.

2.1.4

Air receivers as per the section-D1 - Data sheet-A

Eight (8) Nos.

2.1.5

Air driers as per the section-D2 -Data sheet-A with

online dew point meters

Four (4) Nos.

2.1.6

Piping, valves, specialities and instruments for each

compressor as per the enclosed flow diagram.

2.1.7

Control system as per the flow diagram

One (1) lot.

1 No. for each

compressor.

VOLUME - II

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

SECTION: C2
SHEET 2 OF 11

EQUIPMENT TO BE SUPPLIED, ERECTED /

INSTALLED, TESTED AND COMMISSIONED BY
BIDDER

SL. NO.

2.1.8

2.1.9

EQUIPMENT / DESCRIPTION
Control panel for driers with necessary incoming
switch, selector switches, fuses, connector, required
for successful working of driers

Instrument air, service air, cooling water and air

impulse piping with fittings as per IS:1239 heavy
duty class GI upto terminal points indicated in the
flow diagram/compressor room layout drawings

QUANTITY

1 No. for each drier

One (1) lot.

2.1.10

Companion flanges for all flanged connections

along with fasteners and gaskets

One (1) lot

2.1.11

S.O type, forged carbon steel RF flanges for cooling

water connection for compressors & accessories
and all terminals of service and instrument air
system

One (1) lot

2.1.12

Mandatory spares for Mechanical items and

instruments for each compressor.

One (1) lot.

2.1.13

Maintenance tools required for normal maintenance

and overhaul of compressors and their accessories.

2.1.14

Start-up spares

2.1.15

Foundation bolts and nuts and base frame for all

equipment supplied

One (1) set for each

compressor

One (1) lot for each

compressor. Bidder
shall furnish list of
startup spares
One (1) lot

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CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

SECTION: C2
SHEET 3 OF 11

EQUIPMENT TO BE SUPPLIED, ERECTED /

INSTALLED, TESTED AND COMMISSIONED BY
BIDDER

SL. NO.

EQUIPMENT / DESCRIPTION

QUANTITY

2.1.16

List of recommended spares for three (3) years

trouble free operation.

BIDDER to furnish
these additional items
as recommended
spares with cost for
each item.

2.1.17

Inspection, operation and maintenance manuals

As per distribution
schedule

Lot as required

2.1.18

Erection, testing and commissioning of all

equipment under this contract including minor
chipping work wherever necessary and grouting of
base plates

2.1.19

Minor civil works such as grouting, chipping etc

Lot as required

2.1.20

Painting of all equipment

2.1.21

Any other supply items not specifically mentioned

but deemed necessary for safe, reliable &
satisfactory operation of the plant.

According to section C12

Bidder to furnish

NOTE: Please note that Purchaser reserves the right to increase or decrease the
quantities of recommended spares. Price of recommended spares shall not be
included in the total price. The price adjustment for such increase or decrease of
quantities of recommended spares will be based on unit rates quoted by the Bidder.

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

VOLUME - II
SECTION: C2
SHEET 4 OF 11

EQUIPMENT TO BE SUPPLIED, ERECTED /

INSTALLED, TESTED AND COMMISSIONED BY
BIDDER

2.2

ELECTRICAL WORKS

2.2.1

SCOPE OF WORK

a) HT/LT Drive motors for all rotating mechanical equipment.

b) 415V Switchgears, PMCCS, MCCs & ACDBs.
c) Distribution boards, Starters for AC / DC drives, Fuse boards etc.
d) Electrical system controls from BOP DCS located in Compressor House.
e) Relay testing kit and Laptop for loading the parameterization and Disturbance
analysis software for numerical relays.
f)

All LT Power, Control, Fiber optic cables and cable raceway system with all
cable accessories. If special cables are required (co-axial, twisted pairs,
shielded) they shall be supplied, used and identified. For instrumentation
cable, refer I&C Section C8 of Volume-II.

g) Cable carrier system up to outside of compressor house switchgear building

shall be in purchasers scope, however Cable carrier system including
support system, cable trays, cable laying and cable termination inside the
building cable carrier system shall be in Bidders scope.
h) The supply & laying of all the power, control & instrumentation cables,
earthing flats from the terminal points as indicated elsewhere in the
specification is under the scope of BIDDER. This includes fire proof sealing
and coating.
i)

Passive fire protection system such as fire barriers, fire proof ceiling, and fire
proof painting etc. for cables in CA System Package vendors scope.

j)

All the Installation and erection accessories.

k) Specific Communication Channel required for internal communication

between the various locations coming in CA System Package.
l)

Equipment earthing from risers (risers to be provided by Purchaser) to each

equipment at two points.

m) Electronic earthing for Electronic equipments/panels (two points per

equipment / panel) related to each electronic system in BIDDERs scope like
PLC, IO panels etc shall be provided. These shall be connected to a common

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

VOLUME - II
SECTION: C2
SHEET 5 OF 11

EQUIPMENT TO BE SUPPLIED, ERECTED /

INSTALLED, TESTED AND COMMISSIONED BY
BIDDER

insulated earth bus which shall be further connected by BIDDER to treated

electronic earth pits (earth pits to be provided by Purchaser) through insulated
cables of suitable size. Sizing calculation for this cable shall be furnished for
Purchasers approval.
n) Local starter/control panels, Emergency Local PB control stations and
Junction boxes and Marshalling boxes.
o) Special tools and tackles required for handling, installation, operation and

maintenance of electrical equipment

p) Rubber mats as required shall be provided in front and back of all switch gear
and control panels.
q) Welding sockets, 63A 3ph, 4 Pin sockets
r) Startup and Essential spares
s) Minor Civil & structural works of CAS System package including construction
of support structures of cable trays/raceways, making/sealing brick wall/RCC
opening, welding support structures, , etc, are included in this contract.
t)

All the foundation accessories including base plates/channels, foundation

bolts, wall/column inserts/supports, anchor bolts, etc. as may be required for
all electrical equipment to be supplied by the Bidder.

u) Bidder to give Inputs to Civil contactor for cable trenches, switchgear room
layout, foundations details for all electrical equipment, wall opening, floor
cutouts, Pipe sleeve requirement, Insert plates, Cable chase/ ditch etc.
v) Bidder to coordinate with the Civil Contactor for smooth execution of Electrical
requirements in consultation & approval of Purchaser.
2.3

CIVIL AND STRUCTURAL WORKS

2.3..1

This shall include supply and fixing of all steel inserts, pipe sleeves, anchor
bolts / anchorage, assemblies, bolts, nuts, washers, etc. and grouting of
anchor bolts and below base plates.

2.3.2

All pipe supports required for the piping as required for the equipment
included in this specification.

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

VOLUME - II
SECTION: C2
SHEET 6 OF 11

EQUIPMENT TO BE SUPPLIED, ERECTED /

INSTALLED, TESTED AND COMMISSIONED BY
BIDDER

2.4

INSTRUMENTATION AND CONTROL SYSTEM:

2.4.1

SCOPE OF WORK

The system to be furnished as covered in this volume shall be engineered,

designed, manufactured and supplied as per the requirements specified
herein.
It is not the intent to specify completely all details of design and construction
of equipment, nevertheless the equipment shall conform in all respects to
high standards of engineering design and workmanship and shall be capable
of performing in continuous commercial operation in a manner acceptable to
the Purchaser.
The following Instrumentation and Control system shall be complete with
hardware and software and all other accessories to operate the
compressed air system efficiently, reliably and safely as detailed under
various clauses of this specification.
a)

Complete Field Instrumentation including all field sensors, cables

(Instrumentation cable, control cable, thermocouple compensation
cable, special cables, etc.,), cable trays, erection hardware, Junction
boxes and transmitter racks etc., within bidders battery limits.

b)

Instrumentation for Temperature, Pressure, Level, flow, moisture

traps, etc., required for auto operation of air compressor as indicated
in the CIPL.6071A-640-FD-1132 / P5.

c)

Instrumentation as required for manual/auto start/stop and load /

unload of Air compressors.

d)

Pressure indicators at the outlet of each compressor.

e)

Instrumentation for Temperature, Pressure, moisture traps etc

required for air receivers as indicated in the CIPL.6071A-640-FD-1132
/ P5.

f)

Pressure transmitters and control valve at the outlet of Air receivers for
varying the service air supply depending on Instrument Air load.

g)

Instrumentation for Temperature, Pressure, Level, flow, moisture

traps, timers, humidity measurement, etc., required for auto operation
of Air dryers.

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

VOLUME - II
SECTION: C2
SHEET 7 OF 11

EQUIPMENT TO BE SUPPLIED, ERECTED /

INSTALLED, TESTED AND COMMISSIONED BY
BIDDER

h)

Dedicated Microprocessor based skid mounted controllers for air

compressor control with bidirectional communication link to Main plant
DCS in main control room.

i)

Dedicated Microprocessor based controllers mounted locally for air

dryer control with bidirectional communication link to Main plant DCS in
main control room.

j)

Instrumentation for Temperature & Pressure at one point for each of

the distribution headers for other purchasers systems.

k)

Any Software required to be loaded in the Main plant DCS to control

compressor loading and unloading shall be supplied by the Bidder

l)

Power supply distribution including cabinets.

No UPS shall be envisaged in Bidders scope. Bidder shall generate
required power supply for their control systems with the power supply
given by the Purchaser. For the details of power supply given by the
Purchaser shall be referred to electrical section.

m)

Cables.
All Instrumentation and control (I&C) cables, Data highway cables,
prefabricated cables related to the entire Air Compressor System are
under Bidders scope. All the RTD and Thermostat cables shall be
wired to take care of line resistance as required. Preparation of
Interconnection cable schedule for all I & C cables is included in
Bidders scope.

n)

Vibration Monitoring system for all HT drives.

o)

Essential Spares and Recommended spares, as specified.

p)

All the associated civil structure with steps, inverted L shaped metallic
angle, for mounting the process instrumentation, all associated
mounting accessories etc., are included in Bidders scope.
Maintenance, platforms and access ladders for instruments, equipment
installed at inaccessible heights shall be installed.

q)

Adequate number of test connections of standard size and at suitable

location shall be provided for commissioning and PG test.

r)

Special maintenance tools and tackles, as required.

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

VOLUME - II
SECTION: C2
SHEET 8 OF 11

EQUIPMENT TO BE SUPPLIED, ERECTED /

INSTALLED, TESTED AND COMMISSIONED BY
BIDDER

s)

Erection, field calibration, testing and commissioning of all I&C

equipments included in the scope of BIDDER as per standard methods
and to PURCHASERs satisfaction.

t)

All the hardware and software interface components required to

establish communication link between the compressor skid mounted
controller and Main plant DCS in central control room for control and
monitoring from DCS operator console.

u)

All the required hardwired cables and wiring required for connecting
analog signals and digital contacts from compressed air system to
Main plant DCS for control and monitoring from Main plant DCS
operator console.

v)

Bidder shall do the commissioning of the drives supplied by him and be

responsible for successful and timely completion and commissioning of
the same. The necessary hardware and distribution equipments shall
be included in the Bidders scope.

2.5

ERECTION, COMMISSIONING AND TESTING REQUIREMENTS

2.5.1

General Requirements

2.5.1.1

The BIDDER shall erect all equipment/systems covered in this

specification.

2.5.1.2

The erection work shall include grouting of foundation bolts, base plates,
etc., touch up and finish painting. Only open space for storage shall be
provided by the PURCHASER inside the plant boundary. BIDDER shall
make all arrangements for proper storage of equipment.

2.5.1.3

All temporary piping, fittings, spool pieces, dummy plate, pumps,

instruments, etc., required for erection, commissioning and testing till
handing over.

2.5.1.4

Calibration and commissioning of all instruments and control equipment

supplied under this contract shall be executed by the BIDDER. Hardware
required for erection of all instruments and control equipment covered
under this contract shall be supplied by the BIDDER.

2.5.1.5

The entire works will be carried out with necessary precautions to meet the
rules of local statutory authorities to have the utmost protection to men and

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

VOLUME - II
SECTION: C2
SHEET 9 OF 11

EQUIPMENT TO BE SUPPLIED, ERECTED /

INSTALLED, TESTED AND COMMISSIONED BY
BIDDER

material. A full fledged safety engineer shall be provided by the BIDDER to

be in charge of the supervision of safety requirements at site. It is the
BIDDERs responsibility to provide safety to his personnel and equipment.
2.5.1.6

Grouting the bases of all equipment and structural steel members erected
by the BIDDER is covered in his scope and supply of all grouting materials
is the BIDDERs responsibility. Concrete/cement mortar cubes/briquettes,
etc., shall be tested for their strength by the BIDDER at his cost. Grouting
permits will have to be cleared by the PURCHASER only after which the
BIDDER shall undertake grouting work.

2.5.1.7

Works such as machining and bedding of packers, minor rectification of

foundation bolts, reaming of holes, drilling for dowels, making new dowel
pins, etc., if required are also covered in the BIDDERs scope.

2.5.1.8

BIDDER shall submit a detailed PERT network for all activities. This
master network shall be comprehensive and detailed in all aspects. After
review and approval of this network, the BIDDER shall develop subnetworks and bar charts for all activities. The START and COMPLETION
dates of all construction activities and milestone activities shall be closely
adhered to.

2.5.1.9

The BIDDER shall abide by general safety and security rules formulated by
the PURCHASER.

2.5.1.10 The BIDDER shall maintain record of all non-consumable items such as
tools, tackles, etc., belonging to him to facilitate easy identification and
take-over while closing the site office.
2.5.1.11 Supply and erect metallic tags on the equipment/valves/instruments and
accessories supplied by the BIDDER. The tags and connecting wires shall
be of stainless steel and the size of the tags shall be adequate to
accommodate tag number.
2.5.2

Specific Requirements
Supply of adequate quantity of consumables required for the job, viz.,
welding electrodes, drill bits, tapes scaffolding, welding gas, oil, kerosene,
grease, lubricants, cotton waste, chemicals, etc., required for erection,
commissioning and testing till handing over is covered under this contract.

2.5.2.1

After the Completion of the system and Auxiliaries, the Initial Operations
shall commence. This shall include operation of the compressors and
accessories for six (6) shifts (2.0 hrs per shift) at the rated load. This shall

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

VOLUME - II
SECTION: C2
SHEET 10 OF 11

EQUIPMENT TO BE SUPPLIED, ERECTED /

INSTALLED, TESTED AND COMMISSIONED BY
BIDDER

include operation of the compressed air system as a whole on auto mode

unless otherwise agreed to by the PURCHASER or restricted by system
load conditions. The BIDDER shall ensure availability of his supervisory
personnel to the PURCHASER on round the clock basis. The completion
of initial operations will be certified in writing by the PURCHASER.
2.5.2.2

After the initial operations, the plant shall be on trial operation during which
period all necessary adjustments shall be made while operating over the
full load range enabling the plant to be made ready for performance tests.

2.5.2.3

A trial operation report comprising observations and recordings of various

parameters measured in respect of the trial operation shall be prepared
and submitted to the PURCHASER. This report, besides recording the
details of various observations during the trial operation shall also include
the dates of start and finish of the trial operation and shall be signed by the
representatives of both the parties. The report shall have the recordings of
all details of interruptions that occurred, adjustments made and any repairs
done during the trial operation. Further, based on the trial operation report,
if any additional repairs/ modifications are required, the same shall be
carried out by the BIDDER to the satisfaction of the PURCHASER.

2.6

BID EVALUATION

2.6.1

Bids shall be deemed to be under consideration immediately after they are

opened and until such time official intimation of award / rejection is made by the
Purchaser to the BIDDERS. While the bids are under consideration, BIDDERS
and / or their representatives or other interested parties are advised to refrain
from contacting by any means, the Purchaser and / or his employees /
representatives on matters related to the bids under consideration. The
Purchaser, if necessary, will obtain clarifications on the bids by requesting for
such information from any or all the BIDDERS, either in writing or through
personal contact as may be necessary. BIDDER will not be permitted to change
the substance of the bid after the bid has been opened. No credit shall be given
in tender evaluation if parameters better than those specified are offered by the
BIDDER.

2.6.2

All technical and commercial deviations shall be clearly brought out in respective
schedule of deviations. Any deviations indicated elsewhere in the offer other
than those indicated in the deviations schedule shall not be considered and to be
deemed as withdrawn. The deviation from the specification if acceptable to the
Purchaser, in so far as practicable, will be converted to a rupee value and added
to the bid price to compensate for the deviation from the specification. In
determining the rupee value of the deviations, the Purchaser will use parameters
consistent with those specified in the documents and specifications and other

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

VOLUME - II
SECTION: C2
SHEET 11 OF 11

EQUIPMENT TO BE SUPPLIED, ERECTED /

INSTALLED, TESTED AND COMMISSIONED BY
BIDDER

information as necessary and available to the Purchaser.

2.6.3

BIDDER shall completely study all sections of this specification and indicate all
deviations in the Schedule of Deviations. If no deviations are indicated or except
for the deviations indicated in the Bid, it will be presumed that the Bid conforms
in all respects to the specification and Purchaser reserves the right to evaluate
the Bid without any further reference to the BIDDER. It is binding on the part of
BIDDER to supply the equipment in accordance with the specification except for
the deviations accepted by the Purchaser. No extra claims on this account will
be accepted after the award of the Contract

2.6.4

BIDDER shall furnish all the information called for in Data Sheet-B and various
Schedules of the specification. If the information is omitted to the extent that it
makes impossible for the Purchaser to arrive at any decision, the BID will be
considered non-responsive and such BID may be rejected.

2.6.5

BIDDER shall note that for the purpose of evaluation, mandatory spares,
maintenance tools and tackles will be considered. Recommended spares as
quoted by BIDDERs will not be considered for evaluation. However, the bidder
shall furnish the unit prices as well as the total prices of these items as called for
in the schedules.

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

VOLUME - II
SECTION: C3
SHEET 1 OF 1

MISCELLANEOUS SERVICES FROM THE CONTRACTOR

3.0

MISCELLANEOUS SERVICES FROM THE CONTRACTOR

3.1

Shop Inspection
Shop inspection and tests as per specified codes and standards shall be
arranged by the VENDOR through an inspection agency approved by the
PURCHASER. Adequate number of copies of inspection/test certificates shall be
furnished as per the Distribution Schedule. The BIDDER shall include these
services in his scope. QAP shall also be submitted for PURCHASERs approval.

3.2

Start-up and Commissioning

The VENDORs scope of work shall include erection, trial runs, testing, start-up
& commissioning of the equipment covered in this specification. Wherever insert
plates are provided, welding of supports to insert plates shall also be carried out
by the VENDOR.

3.3

Performance testing of complete compressed air system and individual

equipment to prove the guarantee offered during the bid / detail engineering
stage.

3.4

Design calculations/ drawings and data as called for in the System Data Sheet-C
of equipment/ system shall be furnished by the VENDOR after award of contract.

3.5

Required number of installation manuals, maintenance and operation manuals

shall be prepared by the VENDOR and the same shall be submitted to
PURCHASER.

3.6

Submission of all necessary documentation for approval, final distribution, as

built drawings, RTFs, CD-ROMs etc., of the compressed air system as
elaborated in Section C-10, System Data Sheet C.

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

VOLUME - II
SECTION: C4
SHEET 1 OF 1

EQUIPMENT AND SERVICES TO BE PROVIDED BY OTHERS

4.0

EQUIPMENT AND SERVICES TO BE PROVIDED BY OTHERS

4.1

The equipment to be provided and the work to be performed by others

under this specification shall be as follows:

4.1.1

Passivated DM water supply and return two terminal point near the
Compressor room will be provided for equipment cooling purpose. The
bidder shall indicate the pressure required at the inlet and the pressure at
the outlet.
Design and construction of compressor house. Bidder shall furnish GA
drawings indicating all necessary load data, openings / cut outs, embedded
parts etc., required in the building for installation of all equipment covered
under this specification.

4.1.2

4.1.3

Under slung crane for the maintenance of the compressed air system.
However bidder shall furnish details of heaviest equipment including
compressor, air dryer etc. that will be handled during maintenance for
deciding crane capacity.

4.1.4

Air Conditioning and Ventilation system.

4.1.5

For electrical equipment and services to be provided by others

refer section C7

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

VOLUME - II
SECTION: C5
SHEET 1 OF 1

TERMINAL POINTS

5.0

TERMINAL POINTS

5.1

The scope includes the complete compressed air system package including
compressors, air dryer, air receiver as indicated in this specification / enclosed
drawing.

5.2

Cooling Water
Water for cooling applications will be supplied at one point. The terminal point
shall be about 12M outside the compressor building (as shown in the
drawing). Piping beyond this terminal point will be in the successful bidders
scope. The equipment cooling water shall be returned to the return line header
of the same terminal point. Cooling water allowable pressure drop across
terminal points shall be limited to 5MWC. And allowable temperature rise
across terminal points shall be 8 deg C.
The exact coordinate will be informed to the successful bidder after award of
contract and no commercial implication shall be entertain by the purchaser on
the account of the same.

5.3

Instrument Air : Two tappings at a distance of 1 m from the instrument air

header at outlet of Instrument air Receivers.

5.4

Service Air : Two tappings at a distance of 1 m from the instrument air header
at outlet of common compressed air receiver

5.5

Electrical
For electrical terminal points refer section C7

5.6

Instrumentation & control

For electrical terminal points refer section C8

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

VOLUME - II
SECTION: C6
SHEET 1 OF 4

DESIGN, LAYOUT, MAINTENANCE AND OTHER

GENERAL REQUIREMENTS

6.0

DESIGN, LAYOUT,
REQUIREMENTS

MAINTENANCE

AND

OTHER

GENERAL

The details / data furnished in this section shall be considered by the

BIDDER for the design of compressed air system.
6.1

DESIGN AND CONTROL REQUIREMENTS

6.1.1

The requirement of compressed air will be 3850 m/hr FAD considering the
losses, margins and contingency requirements. When all the three units
are under normal operation, total compressed air required will be 19155
m/hr FAD (Tentative). Under various condition of operation, the working
compressors shall be operating in load / unload mode. The operation of
the system shall be automatic through integral Microprocessor based local
controller and from Main plant DCS in main control room. The
compressors shall operate on energy optimisation mode.

6.1.2

Bidder shall furnish consumption of power under various operating

conditions. Unit No.1 will be commissioned first, there after the subsequent
units will be commissioned with an interval of 4 months each. Bidder to
note that requirement of compressed air during commissioning of the first
unit will be about 50%. Bidder shall also furnish write up on operating
philosophy.

6.1.3

The compressors shall be suitable for delivering the guaranteed capacity

for the climatic conditions and for the variation in the temperature indicated
in this specification

6.1.4

The air compressor shall be designed to ensure a delivery pressure of 8.6

Kg/cm2 (g) at the compressor air system outlet. The capacity of the
compressor shall be guaranteed for the variation in the frequency.

6.1.5

Each compressor shall have its own controller with integrated HMI having
facility to operate the compressor in auto/standby mode as well as in
manual mode. In addition, for the complete air compressor system there
shall be a interfaced to Main plant DCS to load/unload the compressors
based on the instrument air final header pressure to the consumers. Under
normal operating conditions, the complete compressor train will be
controlled from this Main plant DCS in main control room.

6.1.6

Base duty compressors shall be operating on load / unload control, and

stand by Compressors will be operating on auto-start / stop control.

6.1.7

Compressors and associated equipment shall be operable and controlled

from the local panel. In addition, it shall be possible to Start / Stop each
compressor from Main plant DCS in main control room.

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

VOLUME - II
SECTION: C6
SHEET 2 OF 4

DESIGN, LAYOUT, MAINTENANCE AND OTHER

GENERAL REQUIREMENTS

6.1.8

Maximum cooling water inlet temperature shall be considered as 380C.

6.1.9

Maximum velocity of air in pipeline for pipeline sizing shall be 6 - 9 m/sec.

6.1.10

In case of emergency, service air shall be diverted to instrument air line.

One automatic flow control valve shall be used for this purpose.

6.1.11

The continuous motor rating (500 C ambient) shall be at least ten percent
(10%) above the maximum load demand of the driven equipment under
the entire operating range.

6.1.12

When the driver is not directly coupled to the compressor, due

consideration shall be made for losses in power transmission, in addition to
the above margin.

6.1.13

Sound suppressing characteristics shall be considered in the design of

suction air filter design.

6.1.14

Cooler and other lines handling hot air shall be suitably insulated so as to
restrict surface temperature to 600 C.

6.1.15

The pipe joint shall be screwed type for sizes up to 50 NB and flanged for
above 50 NB.

6.1.16

All globe and gate valves shall be outside screw and rising spindle type.

6.1.17

Moisture traps at strategic locations shall be provided in the distribution

network.

6.1.18

There shall be no oil carry over in the compressed air.

The capacity of dryer shall be adequate to supply the required quantity of
instrument air. Quality of air from the air drying plant shall be as per ISO
8573-1, 2001 (E). Solid particle size less than or equal to 1000 particle/m3
(class 2 as per ISO 8573-1, 2001 (E) - table -2), Dew point shall be -40
deg C (class 2 as per ISO 8573-1, 2001 (E)- table -3), Maximum
allowable oil content shall be 0.1 mg/m3 (class 2 as per ISO 8573-1,
2001 (E)- table -5) and residual water shall be 0.117g/m3 (class 7 as per
ISO 8573-1, 2001 (E)- table -4).

6.1.19

6.2

LAYOUT REQUIREMENTS

6.2.1

The preliminary layout of air compressors is furnished in the

COMPRESSOR HOUSE LAYOUT drawings enclosed with this
specification. The bidder shall review the same and furnish their
concurrence / suggestions if any.

6.2.2

The overall dimensions of the compressor room indicated in the bid

drawing are tentative and shall be finalised by the BIDDER.

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

VOLUME - II
SECTION: C6
SHEET 3 OF 4

DESIGN, LAYOUT, MAINTENANCE AND OTHER

GENERAL REQUIREMENTS

6.2.3

The layout of piping for the compressed air system shall ensure that
locations of all valves are such that they are easily accessible.

6.2.4

The overhead piping shall have a minimum working headroom clearance

of 2.5 m.

6.2.5

All piping shall be arranged to provide clearance for the removal of

equipment requiring maintenance and for easy access to valves and other
piping accessories required for operation and maintenance.

6.2.6

Access walkways/ space around the equipment in the compressor room

shall be minimum 1500 mm. Suitable hand railing shall be provided for
personnel safety, wherever required.

6.3
6.3.1

MAINTENANCE REQUIREMENTS

6.3.2

The BIDDER shall provide facilities for carrying out online and off-line
maintenance of all equipment. In general, this should include working
space platforms and safety devices. Under slung crane will be provided by
the PURCHASER.

6.3.3

The BIDDER shall indicate in his offer the capacity of lifting equipment
required, to handle the equipment offered by him.

6.4

OTHER GENERAL REQUIREMENTS

6.4.1

Provision for mounting all instruments required to carry out performance

tests of all equipment covered under this specification shall be
incorporated in the system piping.

6.4.2

For sizing of water piping, the maximum velocity of water in the pipelines
shall be considered as 2.0 to 2.2 m/second.

6.4.3

Compressed air piping shall be sized considering a maximum pressure

drop of 0.3 kg/sq.cm from air receiver/compressor to the farthest
consumption point as specified in IS 6206.

6.4.4

All valves requiring frequent operation in every shift shall be ball valves
(3piece).

The weight and dimensions of the heaviest piece / component required to

be handled during erection and maintenance shall be indicated in the Bid.
The recommended layout of the compressor room showing all the
compressors and accessories with minimum maintenance space shall be
furnished along with the bid.

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

VOLUME - II
SECTION: C6
SHEET 4 OF 4

DESIGN, LAYOUT, MAINTENANCE AND OTHER

GENERAL REQUIREMENTS

6.4.5

All equipment drives shall be capable of starting on full load.

6.4.6

Thermal insulation shall be provided for all hot piping with fluid
temperatures greater than 600C. Insulation shall be of Lightly bonded
mineral wool (density 100 kg/m3) Pipe sections/Mattresses as per IS 8183,
IS 14146 with Aluminium sheathing as per IS 737 - Gr 19000 HZ (New
designation / Gr SIC 1/2H). Finishing cement density shall be 1100 kg/m3.

VOLUME II

CARBERY INFRASTRUCTURE PTE LTD

SECTION:C7

3 X 660 MW Super Critical TPP at Lalitpur, Uttar

Pradesh

SHEET 1 OF 1

CONTENTS
COMPRESSED AIR SYSTEM

SECTION NO.

TITLE

NO. OF SHEETS

C. 7.1

Scope

22

C. 7.2

415 Volt Switchgear / PMCC

22

C. 7.3

Motors & Valve Actuators

C. 7.4

Main Plant DCS Interface

C. 7.5

Cabling System

18

C. 7.6

Local Control Panels / DCDB &

Others

C. 7.7

Testing

13

C. 7.8

Installation

C. 7.9

List of Codes & Standards

C. 7.10

Approved Sub Vendor List

10

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar
Pradesh

VOLUME : II
SECTION: C7.2
SHEET 1 OF 22

415V SWITCHGEARs / PMCCs/ MCCs

COMPRESSED AIR SYSTEM

1.0

SCOPE

1.1

This specification covers the design, manufacture, inspection and testing at

BIDDER's and / or his SUB-VENDOR's works, packing, transportation from
place of manufacture to site, unloading and storing at site, handling at site,
complete erection, site testing, commissioning and handing over in perfect
working condition of the 415V Switchgear for this package.

1.1.1

This Specification shall be read in conjunction with other sections, GA & SLD
drawing and other bid drawings enclosed in Volume-II.

1.2

Required number of 415V PCC, PMCCs, MCCs, power supply distribution

boards and space heating supply distribution boards, etc. shall be provided
wherever required to meet the entire requirement of this package. BIDDER
shall propose the configuration/sources best suited for the system without
sacrificing the standby philosophy, reliability, flexibility of operation. All
switchgear shall have fully draw-out type construction. The 415V switchgear
shall derive power from the respective service transformers located
outdoor/Indoor as indicated (tentatively) in the Table below. The list below
does not list any AC and DC power distribution boards and the same shall be
provided at all load centres as required.

1.3

For feeding the 415 V AC loads of CA System following PMCCs / MCCs shall
be provided as a minimum requirement. Vendor to note that ratings, locations
and numbers of PMCC / MCCs are tentative and shall change depending on
requirement e.g. voltage drop, location of load centres etc.

1.4

Provision shall be provided for feeding specific OWNERs / Purchasers loads

from these panels. The details of OWNERs / Purchasers feeders with load
shall be furnished during detail engineering.
SL.
NO.
1.

SWITCHGEAR
Compressor
House PMCC

LOADS CONNECTED
LT loads related to dryer,
fans etc. and other
OWNERs / Purchasers
load.

SOURCE OF
POWER SUPPLY
From 415 V Station
service switchgear of
unit 1 and unit 2.

2.0

FEEDER DETAILS

2.1

Each of the switchgear/MCC/DB shall be provided with two bus sections, two
incomers and a bus coupler, each rated for 100% of the loads connected to
the switchgear. Distribution of outgoing feeders shall be such as to ensure

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar
Pradesh

VOLUME : II
SECTION: C7.2
SHEET 2 OF 22

415V SWITCHGEARs / PMCCs/ MCCs

COMPRESSED AIR SYSTEM

uniform loading on each bus-sections of the panel during normal operating

conditions.
2.2

For each of the auxiliaries or load, individual feeders shall be provided.

2.3

The switchgears/MCCs shall be provided with suitable number and type of

outgoing feeders for the respective auxiliary loads of the area, power supply
feeders to various panels, lighting, space heating panels, control cabinets and
all other loads encountered in the plant. The feeders distributing power to
MCC and those feeding ACB operated motors only shall be fed from PMCC.
While all other motors rated below 110kw, heaters, cranes, hoist, etc shall be
fed from MCC.
In addition, following feeders shall be provided in each bus section of each
switchgear.
(a)

Spare feeders: 20% spare feeders with minimum of one no. feeder of
each rating and type on each bus section for breaker feeders at least
one of each type and rating shall be provided on each bus section

(b)

Bus VT module: 1 No. for each bus section.

(c)

415/240V, 1 phase Transformer module for panel space heating supply

- 1 no. on each bus.

(d)

415/240V, 1 phase Transformer module for motor space heating supply

- 1 no. on each bus.

(e)

415/110V AC Transformer module for transducer power supply.

(f)

415/110V AC Transformer module for control supply for contactor

controlled motor starters. Control transformer in each bus section shall
be rated for 100% to cater to the requirements of the entire switchboard
/ MCC. There shall be facility for Auto and manual changeover of control
supply from one transformer to another with annunciation of control
supply failure at Main Plant-DCS.

(g)

Any other system/equipment which requires power supply.

(h)

Line VT module 1 No. for each incomer for synchronising purpose.

(i)

DC supply alarm module 1 No.

(j)

For each auxiliary or load, one feeder shall be provided.

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar
Pradesh

VOLUME : II
SECTION: C7.2
SHEET 3 OF 22

415V SWITCHGEARs / PMCCs/ MCCs

COMPRESSED AIR SYSTEM

2.4

Necessary Interposing relays for start & stop and control from Main Plant-DCS
shall be provided in switchgear. Rating of the potential free contact shall be
220V DC, 10A.

2.5

The sizing of each control transformer shall be carried out by the Bidders,
considering the actual load of power contactors, auxiliary contactors,
indicating lamps and other equipment in the module circuit. An additional load
of 15 watts should be considered for each module, for remote auxiliary relays
to be connected in the control circuit of modules. The transformers shall be dry
type and shall have an insulation of class- F or better. Bidder shall also
ensure that Control Transformers shall be adequately designed for meeting
the momentary loading requirements and the voltage drop during this
condition shall not be more than 5%. Control Transformer shall have 2.5%
and 5% toppings.

3.0

SHORT CIRCUIT CURRENTS

3.1

The rated fault level on the 415V buses shall be calculated based on
transformer contribution and motor contribution and in any case shall not be
less than 50kA for 1 sec.

3.2

A margin of 5% over the S.C current thus calculated shall be applied and
rounded off to next higher standard ratings and this value shall be adopted for
the switchgear. If the same works out greater than 50KA, load to be
redistributed to limit the fault rating to 50KA . The momentary current rating
shall be 2.55 times this value.

3.3

Short time current withstand duration for switchgear and all components shall
be considered as one second.

4.0

CONTINUOUS CURRENTS

4.1

The continuous current rating of the bus bars and the incomers of the
switchgears which are fed by the transformers shall be rated at the LV side full
load current of the corresponding transformers with 20% margin rounded off to
the next higher standard rating.

4.2

BIDDER shall work out the sizes of these Transformers. For that Maximum load
demand at any given time (considering diversity factor as one) on a specific
transformer shall be worked out with 10% design margin. Transformer size
shall be selected such that the transformer will be loaded to maximum of 90%
rating at full load for double stream operation (including Owners / Purchasers
load and any future load) and rounded off to next standard rating. For the load
calculation, load factors to be considered shall be 0.9 for continuous loads, 0.4

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar
Pradesh

VOLUME : II
SECTION: C7.2
SHEET 4 OF 22

415V SWITCHGEARs / PMCCs/ MCCs

COMPRESSED AIR SYSTEM

for intermittent loads. Average power factor of 0.8 lag and efficiency of 0.8 to
be considered for LT motors.
4.3

The continuous current rating of the bus bars, incomers, bus couplers of the
switchgear fed from other switchgears shall be the total running load on the
bus due to all the running auxiliaries during any operation condition plus 20%
margin rounded off to the next higher standard rating.

5.0

CONSTRUCTIONAL FEATURES

5.1

Switchgear / MCCs including DBs shall be metal enclosed, single / double

front, indoor, self standing, floor mounted modular type, fully
compartmentalized, dust and vermin proof of uniform height of not more than
2450 mm, easily extensible on both sides having switchboard designation
indicating labels. Proper gasketing shall be provided all around the perimeter
of adjacent panels, panel and base frame, removable covers and doors. All LV
switchboards (PCC, MCC, LDB, etc) shall be fully draw-out type and DBs, LPs
shall be fixed type. MCCs shall be double front and PCC shall be single front.

5.2

CRCA Sheet steel of not less than 2.0mm thickness for load bearing
members, 1.6 mm thickness for non load bearing members and 1.6mm for
panel covers. Gland plates shall be with 3mm thickness-Al for single core
cables.

5.3

The circuit breaker and feeder modules in switchboard and MCCs shall be of
fully draw out construction. In this type of construction it shall be possible to
draw out the chassis without having to unscrew or unbolt any connections to
the equipment mounted on the withdrawable chassis. The power and control
draw out type connections shall be of sliding type. All draw out contacts,
including auxiliary and control wiring shall be of self aligning type.

5.4

Name plate for each incoming, bus coupler and outgoing at front and back on
the fixed portion of the panel shall be provided.

5.5

All panels shall have motor and panel space heaters with independent
switch/MCB and cubicle illumination lamp with door switch.

5.6

Switchgear/MCC shall be divided into distinct vertical sections of:

(a)

Completely enclosed busbar compartment running horizontally.

(b)

Individual feeder modules in multitier arrangement. Module height

shall be minimum 200 mm.

(c)

Enclosed vertical busbars serving all modules in vertical section.

(d)

Vertical cable alley covering entire height and minimum 200mm wide.

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar
Pradesh

VOLUME : II
SECTION: C7.2
SHEET 5 OF 22

415V SWITCHGEARs / PMCCs/ MCCs

COMPRESSED AIR SYSTEM

(e)

A horizontal separate enclosure for all auxiliary power and control

bus, if required.

(f)

Separate metering compartment for ACB feeders.

5.7

Enclosure for PCC shall conform to IP52 or better for busbar rating up to
1600A and IP42 or better for busbar rating more than 1600A. The IP shall be
maintained even with control module withdrawn. However, all MCC and DB
shall be IP52.

5.8

Cable alley shall be minimum 300mm wide and provided with suitable hinged
doors.

5.9

Rear of single front switchboard shall be provided with removable panels.

5.10

All doors shall be with concealed type hinges and captive screws.

5.11

Switchgear/MCC shall be designed such that all component equipment and

busbars (at 100% rating) operate satisfactorily without exceeding their
respective maximum permissible temperature limits of 85oC by resistance
method at ambient temperature of 50 deg C. The final temperature of bus-bar
enclosure shall be limited to 70 deg C or lower at rated current as measured
by thermometer.

5.12

Switchgear/MCC bus bars shall be of uniform cross section throughout the

length and made of high conductivity, aluminium alloy of E91 grade and 63401
WP code. Optional cost shall be provided considering electrolytic grade
copper.

5.13

Busbars shall be sleeved, and with proper clearances, adequately supported

to withstand stresses developed due to short circuits. Material used for
sleeving shall be capable of withstanding maximum temperatures specified in
technical requirements table. Supports shall be of glass reinforced phynolic
material or cast resin. Busbar joints shall be shrouded with moulded epoxy
removable shrouds. Adequate contact pressure shall be ensured by means of
two-bolt connection with plain and spring washers and locknuts. Bimetallic
connectors shall be furnished for connections between dissimilar metals. All
joints shall be silver-plated (8 micron thick min.).

5.14

Breaker draw out arrangement shall be of Castle type.

5.15

Surface Treatment & painting

5.15.1

All metal parts of the panel to undergo Minimum Seven tank Process for
surface treatment (Pre-treatment) that includes de-rusting, cleaning,
chemically degreasing, pickling in acid, cold rinsing, phosphating and

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar
Pradesh

VOLUME : II
SECTION: C7.2
SHEET 6 OF 22

415V SWITCHGEARs / PMCCs/ MCCs

COMPRESSED AIR SYSTEM

passivating followed by spraying with one coats of zinc oxide primer and
baking in oven.
5.15.2

After pre-treatment process, the pre-treated surface to e painted by powder

coating process.

5.15.3

Shade of paint
Panel interior
Panel exterior

5.15.4

: Glossy White- RAL 9010

: 2 coats of epoxy paint of shade
Flint grey RAL7032

The minimum coating thickness of powder coated surfaces after pretreatment shall be min of 80 Microns.

6.0

415V AUXILIARY SYSTEM CONTROL PHILOSOPHY

6.1

Incomers and bus coupler for all switchgears, getting power supply feed
from service transformer secondaries shall be with ACBs. These shall be
remotely operated from Main Plant DCS with electrical interlocks between
incomers and bus coupler such that only two out of three can be closed at a
time. One out of three breakers (Incomers and Bus Coupler) shall trip
automatically based on the selection in Main Plant DCS. However,
momentary paralling shall be possible during manual changeover. These
logics shall be built in switchgear itself.

6.2

Control of all 415V ACB incomer, bus coupler feeders, outgoing distribution
breaker feeders, shall be from Main Plant-DCS. The manual close and open
commands issued from Main Plant -DCS will be hard wired to switchgear via
coupling relay (IPR) located in switchgear.
The selection logics, like trip selection, synchronization breaker selection,
dead bus selection, auto-changeover selection, etc shall be build in Main
Plant DCS and hard wired to switchgear via IPR located in Switchgear.
Breaker ready to close command will be hard wired to Main Plant DCS.
Breaker ready to close command shall be generated by logic built in
switchgear (adding 86 L/O reset, breaker in service, breaker open, spring
charged, breaker in remote, trip circuit healthy, u/v relay healthy, PT MCB
healthy) hard wired or built-in numerical relay logics, to be decided during
post bid discussions.
All the protection trip logics, synchronization logics, control (open and close)
interlock logics, changeover logics, etc, will be built in switchgear itself,
Various status feedbacks, alarms, SOE signals will be hard wired to Main
Plant DCS. This shall include breaker status signals (open, close, lockout

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar
Pradesh

VOLUME : II
SECTION: C7.2
SHEET 7 OF 22

415V SWITCHGEARs / PMCCs/ MCCs

COMPRESSED AIR SYSTEM

relay tripped, remote position, local position, service position, test position,
breaker healthy (i.e trip circuit healthy, spring charged), Bus U/V, Bus PT in
test, PT fuse/MCB operated, etc. However, for process logics and control
philosophy related to drive feeders, I&C section is to be referred.
6.3

For generating Alarms and Sequence of Events recording in Main Plant

DCS on operation of each of the numerical relay protection functions,
communication loop/network of Numerical relays shall be formed and
connected to Main Plant DCS. Each numerical relay (including those
provided for motor drives) shall be looped directly or networked through
Ethernet switches within each switchboard/panel and wired further till Main
Plant DCS.
The communication protocol of numerical relays (IEC 61850/IEC 60870-103/
others) and model shall be decided based on the compatibility with Main
Plant DCS). This protocol shall support transmitting time tagged signals for
SOE purpose.
The relays shall be time synchronized to master clock to 1 m sec time
accuracy. The refresh rate of signals at DCS shall be 1 second. The relays
shall have redundant integrated power supply with provision for taking
redundant 220V DC input.

6.4

Within the switchgear panel, communication cables shall be un-armoured

fiber optic cables, however the inter-panel cables shall be armoured fiber
optic cable.

6.5

Bidder shall provide data-concentrators, gateways, etc to interface to Main

Plant DCS. Bidder shall develop the configuration diagram in association
with Main Plant DCS sub-vendor and furnish for Purchasers approval.

6.6

All the hard wired analog, digital signals and pulse outputs from the panels
of this package shall be wired by this Bidder to respective IO Panel located
in switchgear/MCC/CR buildings covered in this package. The required JBs,
control cables till IO panel are included in Bidders scope.

6.7

Minimum requirement in respect of signals shall be as per this specification.

However, Bidder shall provide additional signals/ contacts/logics /etc as
found necessary during detail engineering. Bidder shall provide necessary
contacts and terminals in respective panels and equipment and wire the
same till JBs and further till IO panel of Main Plant DCS.

6.8

For metering, discrete digital meters, transducers, and multifunction meters

shall be provided as per SLD enclosed with the specification. The digital
meters shall be looped within each switchboard/ Panel and brought at one
point in MBs of respective switchgear panels and connected further to Main

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar
Pradesh

VOLUME : II
SECTION: C7.2
SHEET 8 OF 22

415V SWITCHGEARs / PMCCs/ MCCs

COMPRESSED AIR SYSTEM

Plant-DCS through Remote I/Os.

6.9

The digital meters shall have Modbus RS485/TCP-IP port (model shall be
decided based on the compatibility with Main Plant DCS) The numbers of
meters in one loop shall be limited by refresh rate of 1 sec or lower in Main
Plant DCS.

6.10

Transducers shall be wired till IO panel. For energy metering at the Main
Plant DCS pulse output from the respective electronic energy meter shall be
wired to the DCS.

6.11

All the breaker logic diagrams at switchgear end and DCS end, detailed
input logic diagrams, I/O lists for soft and hard wired signals, etc required for
implementing logics in Main Plant DCS shall be provided by this Bidder. The
sample meters and numerical relays will be tested for compatibility with Main
Plant DCS before finalizing the models. All mapping files of Numerical
relays and digital meters shall be provided by this Bidder. The switchgear
manufacturer shall coordinate with the Main Plant DCS manufacturer for
protocols, mapping, procedures, and for establishing communication. This
Bidder will be responsible in establishing the proper communication during
sample testing, Main Plant DCS FAT and system commissioning at Site.

6.12

Remote Control of non-ACB feeders provided in few MCCs/ DBs shall be via
motorised MCCB. However, all analog and digital signals related to feeders
of these MCC/DBs shall be hardwired to Main Plant DCS.

6.13

Apart from control, protection, monitoring, metering and alarm signals from
and to switchgear including critical feedback signals like malfunction signal
from each of the numerical relays, drive healthiness, control supply failed,
sources paralled beyond preset time, auto changeover failure, trouble
signals, etc shall be hard wired to Main Plant-DCS. These signals shall be
wired till the terminal block of the switchgear and further to Main Plant DCS.

6.14

Synchro-check relay for checking synchronism shall be housed in the

respective switchgears. Dedicated Synchro check relay shall be provided for
all CBs. Incomer Synchro check relay shall be constantly monitoring the
synchronism between Incomer supply and bus supply. Bus Coupler Synchro
check relay shall be constantly monitoring the synchronism between bus
supplies. The synchro check contacts also shall be given as input to Main
Plant-DCS.

6.15

Slow Auto changeover facility shall be provided for all 415V switchgears with
ACB incomers such that the bus coupler is closed automatically, when there
is failure of supply from any one of the incomers and the bus is dead. The
changeover shall be blocked if the incomer has tripped due to a bus fault.
Facility for selection of auto/manual changeover shall be provided in Main

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar
Pradesh

VOLUME : II
SECTION: C7.2
SHEET 9 OF 22

415V SWITCHGEARs / PMCCs/ MCCs

COMPRESSED AIR SYSTEM

Plant-DCS.
6.16

415V switchgear modules can be controlled from switchgear, only when the
modules are in Test position.

6.17

All motor feeders shall be controlled remotely from Main Plant-DCS through
interposing relays located in switchgear. Local operation is envisaged only
when the module is in TEST position. The motor control, monitoring,
metering, annunciation logics will be built as per the approved P&ID and
inputs from switchgear shall be hardwired to Main Plant-DCS. All protection
tripping shall be hardwired in the switchgear itself. Required contacts shall
be provided in the motor modules in the switchboard for the signals to be
hard wired for SOE to Main Plant-DCS. Logics for under-voltage auto-trip
and restart shall be built in switchgear and monitored from Main Plant-DCS.
For further details I&C section to be referred.

7.0

SPECIFIC REQUIREMENTS
Switchgear/PMCCs/MCCs shall comply with requirements indicated below.

7.1

All the incomers and bus couplers of 415V Switchboards and MCCs and
outgoing feeders of 415V switchgear shall have ACB All the modules in
switchgears and MCCs shall be controlled from the Main Plant-DCS through
coupling relays (IPR). The coupling relays shall be located in the switchgear

7.2

The scope of supply shall include all the material as brought out in various
clauses including transducers (where required), interposing relays, and
interconnecting cables for the control and monitoring of the
switchboards/MCCs from the Main Plant-DCS system.

7.3

Each breaker module shall be provided with microprocessor based

multifunction Numerical protective relay with protection, metering and
monitoring functions. All the numerical relays shall be provided with
communication facility. Software for numerical relays shall be supplied and
loaded in Main Plant-DCS. Facility for Relay parameterization, maintenance,
fault recording, fault analysis, trip data and trend recording and displaying
shall be made available at Main Plant-DCS

7.4

For the hardwired signals, BIDDER shall provide the following for control,
indication, measurements, annunciation and sequential event logging in Main
Plant-DCS:
(a)
(b)

Potential free contacts for digital inputs

Transducers for all analogue inputs

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar
Pradesh

VOLUME : II
SECTION: C7.2
SHEET 10 OF 22

415V SWITCHGEARs / PMCCs/ MCCs

COMPRESSED AIR SYSTEM

(c)

Energy/Reactive energy meters with pulse output contacts for

measurement of energy reading in Main Plant-DCS system.

7.5

All circuit breakers (ACBs/MCCBs/MPCBs) shall be of short circuit

performance category P2 as per IS 13947

7.6

All Modules shall have ON, OFF & TRIP indications through LED indication
lamp.

7.7

The breaker/feeder modules shall have service, test and isolate positions.

7.8

The cable alleys shall be liberally designed considering the size and number
of cables, future additions of cables, easy and safe maintenance.

7.9

For each vertical section, a separate set of vertical bus bars shall be provided
to serve the modules.

7.10

The switches, contactors and other power devices shall consider a margin of
about 20% over the name plate current rating of the respective load.

7.11

For breaker control, 2 nos. 220V DC control supply shall be provided with a
manual selection for changing over to either supply. Necessary voltage
monitoring contactors, indication lamps shall be provided.

7.12

Mechanically operated targets to show 'Open', 'Closed', 'Service' and 'Test'

positions of the circuit breaker.

7.13

Mechanically operated, red 'trip' push button, shrouded to prevent accidental

operation.

7.14

Locking facilities in the 'Service', 'Test', and 'Isolated', positions. In test

position the breaker will be tested without energising the power circuits. The
breaker shall remain fully housed inside the compartment in the test position.

7.15

Minimum 6 NO and 6 NC potential free auxiliary contacts, rated 10 A at 240V

A.C. and 1A (inductive breaking at 220 V D.C.) for all circuit breakers and
master trip relays shall be provided after the use of BIDDER in all control and
protection circuits.

7.16

'Red', 'green' and 'amber' indicating lamps to show 'Closed' 'Open', and 'Autotrip' conditions of the circuit breaker when breaker operation is controlled by a
control switch.

7.17

Closing and trip coil shall operate satisfactorily under the following conditions
of supply voltage variation:
Closing coils - 85% to 110% of rated voltage.
Trip coils - 70% to 110% of rated voltage.

7.18

In addition to the adjustable current setting range, short circuit releases shall
be provided with at least four adjustable time delay settings. If it is not
possible to provide the specified adjustable current setting range for the short

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar
Pradesh

VOLUME : II
SECTION: C7.2
SHEET 11 OF 22

415V SWITCHGEARs / PMCCs/ MCCs

COMPRESSED AIR SYSTEM

circuit releases, shunt trip circuit breakers together with necessary protective
relays shall be offered and shall be indicated by the BIDDER.
7.19

Facilities shall be provided for blocking the under-voltage release, if so

required at Site.

7.20

Each of the foregoing releases shall be provided with a single pole, double
throw, and potential free alarm contact rated for 0.5A, 220V D.C.

7.21

The operating mechanism of ACB shall be manually operated spring charging

stored energy type or with motor, opening and closing springs, limit switches
for automatic charging and all necessary accessories. Facility for manual
charging of the closing spring shall be provided. The operating mechanism
shall be trip-free and non-pumping electrically. An anti pumping relay to
achieve electrical anti-pumping feature even if the breaker has provision for
anti-pumping by mechanical arrangement.

7.22

Power operated mechanism shall be

a) Provided with facilities for remote closing and opening operations as per
breaker module designation and respective enclosed control scheme
drawing.

7.23

The control scheme will be as follows for remote control:

Sl.No. Breaker position
selector switch

Service
Local

Test

Remote

Local

Remote

1.

Switchgear
tripping position

Yes

Yes

Yes

Yes

2.

Remote interlock
tripping

Yes

Yes

3.

Switchgear
manual closing

Yes

4.

Remote and auto

closing through
interlocks

Yes

Yes

5.

Switchgear
manual tripping

Yes

Yes

6.

Remote manual
tripping

Yes

Yes

Yes

7.

Local P.B station of motor (For breaker operated motors)

a)

Closing for trial

run

Yes

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar
Pradesh

VOLUME : II
SECTION: C7.2
SHEET 12 OF 22

415V SWITCHGEARs / PMCCs/ MCCs

COMPRESSED AIR SYSTEM

b)

Tripping

Yes

Yes

Yes

Yes

Power operating mechanisms shall be provided with the following additional

features:
a)

Closing of the circuit breaker shall automatically initiate recharging of the

spring ready for the next closing stroke.

b)

The motor shall be mechanically decoupled as soon as the emergency

manual charging handle is coupled.

7.24

20% spare terminals shall be provided for each module.

7.25

All the switchgears / MCCs shall be designed for bottom entry of cable.

7.26

For breaker control in each switchgear 2 Nos. 220V DC control supply shall be
provided with an auto change over to either supply.

7.27

20% spare terminals shall be provided for each module.

7.28

For CT & VT circuits disconnecting type of terminals shall be provided. All

other terminals shall be stud type.

7.29

Insulation Level:
Rated insulation voltage - 1100 V
One minute power frequency withstands voltage - 2.5 KV for power circuits
and 2 KV for control circuits.

7.30

Clearance in air (minimum) - Phase to phase 25.4 mm and Phase to earth

19.0 mm

7.31

One number breaker lifting and handling truck for withdrawing the breakers
from the switchboard shall be provided. The trunk shall be of adequate
mechanical strength for handling the largest breaker & shall shall be with
hydraulic operation mechanism.

7.32

The contacts of coupling relays shall be rated for 10 Amp breaking at 220V
DC and 10 Amp make and continuous current at 220V V DC for electrical
system and that for motors, 10A at110V AC. However, the coil shall be rated
for voltage suitable for Main Plant-DCS and same shall be confirmed by
Purchaser during detail engineering).

7.33

Circuit breaker duty shall involve direct-on-line starting of large induction

motors and also under certain emergency conditions automatic transfer of
loads from one source of supply to other. Motor starting current varies from 6
to 8 times full load current with no. of starts, highest of the following- 6 starts
per hour or no. of starts required as per process and operating requirement or
no. of starts as stipulated in relevant standards.

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar
Pradesh

VOLUME : II
SECTION: C7.2
SHEET 13 OF 22

415V SWITCHGEARs / PMCCs/ MCCs

COMPRESSED AIR SYSTEM

7.34

Circuit Breaker shall not produce any harmful over voltage during autochangeover of supplies and/or during switching off of induction motors. If
required, surge protective devices shall be included in the scope of supply to
limit over voltage.

7.35

Breaking racking in and out handles shall be provided, one no. per switchgear
panel.

7.36

The Circuit Breakers shall have facility to fit accessories viz. Safety shutters,
door interlock, castle key interlock, etc. as and when required.

8.0

MODULE DETAILS

8.1

Incomers & Bus Couplers

8.1.1

All the switchgears & MCC's shall have two incomers and a bus coupler
arrangement.

8.1.2

The incomer modules and bus coupler modules of all the switchgear
continuous current rated above 400A shall be air circuit breaker controlled.
However, for MCC/DB rated 400A and below, motorised MCCB shall be
provided. MCCBs shall be provided with short circuit releases. Adjustable time
delay to be provided for upstream MCCB for protection and coordination

8.1.3

The incomer modules shall be interlocked with their upstream breaker such
that they can be closed only when upstream breaker is closed and trip
automatically when upstream breaker is tripped.

8.1.4

The following minimum protections shall be provided for incomers and bus
couplers.

8.1.5

8.1.6

3 phase inverse time over current and instantaneous protection

Earth fault protection
Trip supervision relay
Line and Bus No volt and U/V relays, voltage available relays, timers, etc
LBB protection

The incomer & bus coupler breaker (ACB) shall be without release. Short
circuit, earth fault and over current protection shall be provided through
numerical relay whereas for under voltage protection separate relay shall be
provided.
CTs shall be provided each for protection and metering.

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar
Pradesh

VOLUME : II
SECTION: C7.2
SHEET 14 OF 22

415V SWITCHGEARs / PMCCs/ MCCs

COMPRESSED AIR SYSTEM

8.1.7

Each switchgear module shall be provided with required numbers of digital

single or Multi function meters. All meters shall be digital type with
communication facility.

8.1.8

Incomer shall have current transformers as per the requirement.

8.1.9

Ratings of incomers and buscoupler shall be same.

8.2

Outgoing Feeder Modules :

8.2.1

Feeders for all drives shall consist of ACB/MCCB/MPCB with contactor as

applicable according to the details described in motor feeders. ACB control
shall be provided for distribution feeders with continuous current rating above
400A, while those rated 400A and below shall be controlled via non-motorised
MCCB.

8.2.2

Open/Close/Trip or ON/OFF/Trip LED type indication lamps for each feeder

shall be provided.

8.2.3

The short circuit release of MCCBs shall be selected such as to avoid

tripping during starting of drives.

8.2.4

Control supply of each module shall be taken through dedicated control

transformer of ratio 415 / 110V.

8.2.5

Two nos. control transformer- 415/110 V shall be provided in each section of

415 V Switchgear.

8.2.6

At least 20% of feeder control modules of each type and rating of module used
subject to minimum of one(1) modules in each bus section shall be provided
as spare. Spare modules shall be completely wired up.

8.2.7

10% of control terminals shall be of 1.1 kV Voltage Grade, shall be provided in

each module as spare subject to a minimum of 2.

8.2.8

Warning markers shall be provided for CAUTION EXTERNAL VOLTAGE.

8.3

VT Modules

8.3.1

Each bus section of switchgears shall be provided with a bus VT module

along with one voltmeter with selector switch, voltage transducer for remote
metering. The accuracy class of VT shall be 1.0 with adequate VA burden.
a) Bus VT modules shall be provided with suitable 415/3 / 110/3 V VTs with
primary and secondary MCBs, interposing VTs for synchronising circuit, etc.

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar
Pradesh

VOLUME : II
SECTION: C7.2
SHEET 15 OF 22

415V SWITCHGEARs / PMCCs/ MCCs

COMPRESSED AIR SYSTEM

b) VT modules in 415V switchgears shall be provided with all necessary relays

for auto changeover function like under voltage relays (2 nos.), under voltage
timer, 220V DC control supply switch & MCBs. Under voltage if provided as
part of the Bus coupler numerical relays having provision to take both bus VT
inputs shall also be acceptable.
c) In case of secondary MCB trip, the under voltage timer operation shall be
blocked.
9.0

CHANGEOVER SCHEME

9.1

All Switchgears/PMCC/MCC with sectionalised buses shall be normally

operated with the bus coupler breaker open.

9.2

Manual changeover/auto changeover between the two normal incomers and

their bus-coupler shall be provided with the following features.

9.2.1

Manual changeover from one incomer to another with momentary paralleling

of the two supplies after checking through synchrocheck relay.

9.2.2

Auto changeover from one incomer to another after trip of first incomer.

9.2.3

If there is a prolonged under voltage on any one of the bus sections, the
respective incoming breaker shall trip and the bus coupler breaker shall close
provided voltage is available on the other bus section. Total changeover time
shall not exceed 1.5 seconds. This auto changeover shall be blocked if the
incoming breaker had tripped either on a bus fault or manually. Changeover
back to the normal source of supply shall be effected manually.

9.2.4

The automatic transfer circuit shall be controlled over by an auto-manual

change-over switch. The bus section breaker shall be allowed to close only if
there is no earth fault or O/C fault on affected section of the 415V switchboard
bus-bars.

9.2.5

Manual live changeover facility shall be provided for all the switchgears.
When planned outage of one of the normal incoming supplies is required, the
respective incomers shall be tripped automatically after the bus section
breaker is closed manually. For this purpose, a selection shall be provided on
the CRT in PLC for selecting the incomer to be tripped. Thus, depending on
the selection made, incomer to bus section A or to bus section B shall be
tripped once bus section breaker is closed manually, thus maintaining
continuity of supply.

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar
Pradesh

VOLUME : II
SECTION: C7.2
SHEET 16 OF 22

415V SWITCHGEARs / PMCCs/ MCCs

COMPRESSED AIR SYSTEM

9.2.6

Manual dead bus closing of a bus-coupler after an intentional manual

trip/outage due to under voltage of any one incomer shall be possible.
However, restoration to normal shall be manual.

9.2.7

A timer with a time delay on pick up of 0.5.-5 sec. for annunciation of the
running breaker failing to trip within a preset time, (i.e. If the two sources
remain paralleled for more than a preset time) shall be provided.

9.2.8

When the normal supply is to be brought back into operation, the incomer
breaker shall be closed whereupon the bus coupler shall trip automatically.

9.2.9

Latest breaker tripping provision shall be included in the changeover scheme

in addition to annunciation.

9.2.10

All hardware required for meeting the functional requirements stated above,
whether specifically listed out in the specification or not, shall be included in
the scope of supply

10.0

MOTOR MODULES

10.1

All motor modules of each shall be provided with adequately rated 415/110V,
two winding, dry type control transformer.

10.2

Motors rated up to 50kW shall be controlled by MPCB with inbuilt

interchangeable electronic trip unit (offering short circuit, over load, phase
failure, phase imbalance, locked rotor, and earth fault protections) and
contactor. Electronic trip unit shall signal the contactor to trip on overload
protection. MCCBs shall be used for motor feeders where higher ratings of
MPCBs are not available.

10.3

Motors rated above 50kW and up to 110kW shall be controlled by motor duty
MCCB with inbuilt microprocessor based over current and short circuit
releases, Contactor and separate thermal over load relay with phase failure,
phase imbalance, locked rotor, and earth fault protections. The over load relay
shall trip the contactor.

10.4

In the motor modules rated above 30 kW necessary circuit with contactors and
MCBs for 240V, 1 phase space heating arrangement will be provided. Heaters
will be switched OFF automatically when the motor is switched ON.

10.5

Motors rated above 110kW will be controlled by ACB. This module will be
provided with interposing relays (IPRs) with coil voltage rated for 24V (to be
confirmed by Purchaser) for receiving circuit breaker/contactor close/open
commands from DCS. Open, Close Feedback, Lock out relay operated and

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar
Pradesh

VOLUME : II
SECTION: C7.2
SHEET 17 OF 22

415V SWITCHGEARs / PMCCs/ MCCs

COMPRESSED AIR SYSTEM

MCC trouble, trip circuit un-healthy alarm, L/R switch position, Service and
test position, EPB operated, etc shall be taken to Main Plant-DCS through
hard-wired (NO/NC) contacts.
10.6

This module will be provided with composite motor protection relay for
protection functions. Protection features will comprise of short circuit, thermal
over load with single phase preventer, phase imbalance, CBCT earth fault
protection and locked rotor protection (2-phases) with associated CTs.

10.7

For motors rated 30 kW and above, one CT (On Y phase) & one ammeter
and one current transducer will be provided for local and remote monitoring.

10.8

For Motors rated above 110kW (including 110kW), three CT & three ammeter
and three transducers for local metering shall be provided.

10.9

More than 30kW capacity motor feeders shall be provided with ammeter.

11.0

CONTROL
Refer clause 6.0 above

12.0

CONTROL ROOM ALARMS / INDICATION / SER POINTS

The Control Room DCS CRTs shall provide indication & alarms for the 415V
auxiliary supply as given below.
Any additional indications / alarms
considered necessary during detailed engineering should also be provided.
Single line diagram of all 415V switchgear & MCC shall be available in CRT.
(a)

Status indication in CRT for all Feeders

Breaker on / Motor running

Breaker off / Motor stopped
Breaker fault/ tripped
Breaker on service
Breaker on test
Breaker selected for remote
Breaker selected for Local
Spring charged
Lockout relay reset
Trip circuit healthy
Display of control status

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar
Pradesh

VOLUME : II
SECTION: C7.2
SHEET 18 OF 22

415V SWITCHGEARs / PMCCs/ MCCs

COMPRESSED AIR SYSTEM

(b)

Alarms in CRT with time stamp signal

13.0
13.1

Breaker auto tripped/L/O Relay operated

Bus under voltage
Sources paralleled beyond preset time
Auto-changeover failed
Numerical relay malfunction
Common outgoing feeder fault
Incoming 220 V DC control supply failed
Bus PT fuse/MCB failed
Bus PT not in service
Trip circuit supervision.
Line VT not in service

METERING AND PROTECTION

Numerical relays shall provide protection and multifunction meters shall
provide metering on the switchgear panels. The minimum protections /
metering required for various typical feeders shall include, but not be limited
to the following:
Incomer
Protections

Inverse time Over

current and
instantaneous
protection

Metering
In Switchgear

In DCS

1 no. MFM for metering

of Current, voltage,
MW, Mvar, power factor
etc for Critical motors.

Current, Voltage, MW,

metering by Multi function
meter connect to Main
Plant-DCS for Critical
Motors
through
MODBUS.
KWH / KVARh meter
pulse output to Main
Plant-DCS for HT motors
only

Inverse time Earth KWh / KVARh meter

fault protection

Under Voltage and

No volt Protection for
Bus and Voltage
available relay for
Line

Three (3) no. Voltmeter

with selector switch.

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar
Pradesh

VOLUME : II
SECTION: C7.2
SHEET 19 OF 22

415V SWITCHGEARs / PMCCs/ MCCs

COMPRESSED AIR SYSTEM

REF protection, LBB

Three (3) no. Ammeter,

one for each phase

DC supply failure
protection
Trip Circuit
supervision relay
separate
Trip Lockout relay
electrically reset type
Bus coupler
Inverse time Over
current protection
Inverse time Earth
fault protection

Current metering (on Y

phase)

Current metering (on Y

phase) transducer

Bus PT/ Line PT Modules

Under voltage
protection
Fuse/MCB failure
protection
No Voltage protection
Motor feeders

One (1) no. Voltmeter

with selector switch.

Three (3) nos. Voltage

transducers.

Current metering (all

Composite motor
phases) for 110kW to
protection (99) to
200KW
cover a minimum of
protections such as
over current, short
Current metering (on Y
circuit protection,
phase) for 30kW to
earth fault, locked
rotor, negative phase 109kW
sequence, Thermal
alarm, core balance,
starting current and
starting time
protection etc.
Trip Lockout relay,
electrically reset type
Trip circuit
supervision separate
Motor feeders (MCCB/MPCB with contactors)

Current metering (all

phases) with three (3)
nos. Current transducer

Bimetallic Thermal
overload relay (with

Current metering (Yphases) with One (1) no.

Current metering (on Y

phase) for 30kW to

Current metering (Yphases) with One (1) no.

Current transducer

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar
Pradesh

VOLUME : II
SECTION: C7.2
SHEET 20 OF 22

415V SWITCHGEARs / PMCCs/ MCCs

COMPRESSED AIR SYSTEM

single phase
preventor)
short circuit
protection (through
MCCB/ MPCB)

109kW

Current transducer

14.0

TESTS

14.1

Certified copies of reports of type tests carried out on similar type and rating of
various equipment (offered under this contract) within last five years from the
date of submission of Bid shall be furnished to the Purchaser for review and
approval. In case the type test reports are not found to be meeting the
specification requirements, the BIDDER shall conduct all such tests under this
contract free of cost to the Purchaser and submit the reports for approval.

14.2

Bidder to indicate the optional cost for conducting Temperature rise test (for a
sample switchgear section with Incomer breaker vertical and one (1) no.
outgoing vertical section with busbar).

14.3

Switchgear design must have been subjected to all type tests as per relevant
standards along with following tests:
(a)
(b)
(c)
(d)
(e)

Temperature rise test on power circuits

Short time current tests on power circuits and earth circuit.
Mechanical operation test
Insulation resistance and 500V DC before/after 1 minute HV test
Electrical sequential operation tests

14.4

The BIDDER shall submit calculations of temperature rise for approval.

14.5

Routine tests as per Latest IS/IEC standards (including those indicated below)
shall be carried out on completely assembled equipment at manufacturers works
in presence of Purchaser or his representatives.
(a)

Operation under simulated service condition to ensure accuracy of wiring,

correctness of control scheme and proper functioning of the equipment.

(b)

All wiring and current carrying parts shall be given appropriate high
voltage test.

(c)

Primary current and voltage shall be applied to all instrument transformers.

(d)

Routine test shall be carried out on all equipment such as circuit breakers,
instrument transformers, relays, meters, contactors, switch, etc.

(e)

Routine test shall be carried out on all equipment such as circuit breakers,

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar
Pradesh

VOLUME : II
SECTION: C7.2
SHEET 21 OF 22

415V SWITCHGEARs / PMCCs/ MCCs

COMPRESSED AIR SYSTEM

instrument transformers, relays, meters, contactors, switch, etc.

(f)

Copies of the test certificates for all bought out items shall be submitted for
the Purchasers approval before despatch of the switchgear.

(g)

Oscillographic test records for closing and tripping timings of the breakers
shall also be furnished.

14.6

In order to permit the Purchaser or his designated representative to be

present for inspection and tests, the BIDDER shall give a minimum of 30 days
advance notice of his intention to carry out tests on equipment/material being
made available for inspection. In the case of tests of long duration, the actual
date of commencement shall be mutually agreed between the BIDDER and
Purchaser.

14.7

The BIDDER shall be responsible for all site/commissioning tests. All

necessary equipment required for testing and commissioning shall be
arranged by the BIDDER. The following minimum tests shall be conducted at
site.

14.7.1

Low voltage Switchgear and Distribution Boards

a) Measurement of insulation resistance of Circuit Breaker in closed and
open positions
b) Measurement of milli-volt drop across Circuit Breaker main contacts
and other joints.
c) Measurement of Circuit Breaker/Contactor operating time for close &
open at nominal voltage and 80% of rated voltage
d) Measurement of resistance, IR value and drop-off/pick-up voltage of
close and trip coils.
e) Healthiness of limit switch contacts
f)

Spring charging motor functional checks

g) Verification of phase sequence and checking of clearances of busbars

between phase to phase and phase to earth
h) Measurement of milli-volt drop across busbar joints
i)

Tightness test

j)

High voltage test on busbar

k) Measurement of CT/PT polarity, ratio and knee point voltage

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar
Pradesh

VOLUME : II
SECTION: C7.2
SHEET 22 OF 22

415V SWITCHGEARs / PMCCs/ MCCs

COMPRESSED AIR SYSTEM

l)

Electrical and mechanical interlock checks

m) Secondary injection of all protection relays by using service settings

and simulation of all protection functions.
n) Secondary injection of all metering circuits

15.0

TECHNICAL REQUIREMENTS

15.1

The 415V switchgears will comply with the particulars indicated in data Sheet
A, section D5, Volume-II

15.2

The Data SheetB, Section D5, Volume-II to be furnished by the BIDDER.

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

VOLUME - II
SECTION: C7.3
SHEET 1 OF 8

MOTORS AND VALVE ACTUATORS

0.0
0.1

SCOPE
This enquiry specification covers the supply, erection, testing and
commissioning works of High and Low Voltage Motors and Actuators as
specified hereafter. It covers the design, engineering, manufacture,
inspection, testing at Vendor's and / or his Sub-Vendor's works, packaging,
transportation from place of manufacture and delivery erection, testing, startup and commissioning and performance testing of the equipment specified.

1.0

A.C. MOTORS

1.1

Motors rated 200 kW and below shall be suitable for 415 V, 3 Phase, 50 Hz
power supply. Motors of rating above 200 kW shall be suitable for 11 kV, 3
phase, 50 Hz power supply.

1.2

This Specification shall be read in conjunction with Other sections, GA &

SLD Drawing and other bid drawings enclosed in Volume-II.

1.3

The motors shall comply with the particulars indicated in enclosed Data
Sheet-A and the Bidder shall furnish the details in Data sheet-B in
respective column attached with the specification (The data sheet to be
submitted separately submitted for different type & rating of the motor).

1.4

The motor rating shall be arrived at considering 15% margin over the duty
point input or 10% over the maximum demand of the driven equipment,
whichever is higher. Motors shall be capable of starting and accelerating
the load with the applicable method of starting without exceeding acceptable
winding temperatures when supply voltage is 80% of the rated voltage for
HT motors and 85% for LV motors. HT motors shall also be capable of
satisfactory operation at full load at a supply voltage of 80% of the rated
voltage for 5 min. commencing from hot condition.

1.5

Motors shall be capable of developing the rated full load torque even if the
supply voltage drops to 70% of the rated voltage. If such operation is
envisaged for a period of one second, the pull out torque of the motor shall
be at least 205% of full load torque.

1.6

Motors shall withstand for 1 second the voltage and torque stresses
developed due to the vector difference between the motor residual voltage
and the incoming supply voltage equal to 150% of the rated voltage during
fast change over of buses.

1.7

Locked rotor current of the HV and LV motor shall not exceed 600% of full
load current inclusive of 20% tolerance.

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

VOLUME - II
SECTION: C7.3
SHEET 2 OF 8

MOTORS AND VALVE ACTUATORS

1.8

The locked rotor withstand time under hot condition at 110% rated voltage
shall be more than the starting time at minimum permissible voltage
specified above by at least three seconds or 15% of the accelerating time
whichever is greater. Provision of speed switch shall be avoided to the
extent possible.

1.12

The degree of protection for the motor enclosure shall be IP-55 for outdoor
& indoor applications and terminal boxes shall also be provided with IP-55.
All motors for outdoor duty shall have detachable metal canopy. For single
core cable termination, gland plates shall be of non-magnetic material. All
motors located in hazardous area shall have flameproof design.

1.13

The ring oiling system shall be adequate for starting and continuous
operation of the motor for at least one half hour without pressure oiling
system in operation. The prior approval of Purchaser is required for any
Lubrication system other then grease lubrication system.

1.14

The maximum double amplitude vibrations for motors upto 1500 rpm shall
be 25 microns and 15 microns upto 3000 rpm. For 415 V motors, maximum
double amplitude vibrations upto 1500 rpm shall be 40 microns and 15
microns up to 3000 rpm.

1.15

Maximum noise level measured at a distance of 1 metre from the outer

surface of the motor shall not exceed 85 dB(A).

1.16

The harmonic voltage factor for motors shall be as per IEC-34, Part 1.

1.17

Variable frequency controller will be provided for motors requiring speed

control.

2.0

COOLING

2.1

Type of cooling for LT motors shall be TEFC and for and for HT motors
CACA/TETV/TEFC. Continuous duty HT motors shall be capable of three
equally spread starts per hour under normal condition or two starts in quick
succession from cold or one hot start, under rated load condition, while
number of starts for LT motors shall be as per relevant standard.

2.2

LT motors will have insulation class F with temperature rise limited to class
B i.e. 70 deg.C over the ambient of 50 deg.C.

2.3

HT motors will have insulation class F with temperature rise limited to 70

deg.C over the ambient of 50 deg.C

2.4

Stress during Bus Transfer:

2.5

The motor may be subjected to sudden application of 150% rated voltage

during Bus transfer due to phase difference between the incoming voltage
and motor residual voltage.

2.6

Hot thermal withstand curve shall have a margin for at least 10% over the full
load curve of the motor to permit relay setting utilizing motor rated capacity.

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

VOLUME - II
SECTION: C7.3
SHEET 3 OF 8

MOTORS AND VALVE ACTUATORS

2.7

Cable terminal boxes of all 11 kV and 6.6 kV motors shall be provided with
quick disconnecting type terminal connectors to facilitate easy disconnection
and removal of the motors without requiring unsealing or otherwise disturbing
the external cable connections and leaving the phase segregated terminal
box intact

2.8

For motors where Differential protection is required two terminal boxes shall
be provided one phase segregated type and one non-phase segregated
type. The start of each winding shall be brought out to one box and the end
to the other.

2.9

In case no differential protection is required star point of the winding shall be

formed in the neutral terminal box to be provided on one side of the motor.
The phase segregated terminal box shall be placed on the other side of the
motor.

2.10

The terminal boxes of all LT motors shall be suitable for termination of FRLS,
XLPE armoured aluminium cables. Easy termination of cables shall be
possible without employing additional adapter boxes.

2.11

Space heaters shall be provided for all LT motors of rating above 30 kW and
all HT motors. Heaters to be automatically OFF when the motor is
switched ON.

2.12

All motors for outdoor duty shall have detachable metal canopy.

2.13

Each motor shall have two earthing terminals.

2.14

All motors shall be energy efficient type with Eff-1 level as per latest revision
of IEEMA-19. Standard.

2.15

The power factor of HT and LT motors shall be equal to or better than the
values indicated below:
HT Motors

: 0.9

LT Motors (Above 37 kW) : 0.88

2.16

All motors shall be suitable for DOL starting.

2.17

Terminal boxes shall have fault withstand capacity equal to at least rated
short circuit level of the system voltage for 0.25 sec. The terminal boxes shall
be reversible to suit cable entry from bottom or top and suitable for
termination of FRLS, XLPE armoured aluminium cables. Each terminal box
to have two inlets to accommodate any parallel cables as required. Separate
terminal boxes to be provided for space heater, RTDs for windings/ bearings,
vibration monitors etc. All terminal boxes shall be provided with two earthing
studs for termination of protective earth conductor.

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

VOLUME - II
SECTION: C7.3
SHEET 4 OF 8

MOTORS AND VALVE ACTUATORS

2.18

Double compression type brass cable glands and crimping type copper lugs
shall be provided for termination. Cage clamp type connectors shall be used
for LT control cables. Amp type lugs shall be used for LT motors of rating
110 kW and above.

2.19

Variable frequency controller shall be provided for motors requiring speed

control.

2.20

All LT motors terminal boxes shall be suitable for terminating FRLS, XLPE
armoured Aluminium cable of size as per approved cable sizing calculation
document for this project.

3.0

ACTUATOR MOTORS

3.1

The actuator motors shall be designed for short time duty (S2) in accordance
with IEC 34-1.

3.2

Each actuator should have a hand wheel for emergency manual operation in
addition to motor drive. Clockwise operation of hand wheel shall cause
clockwise movement of the output drive. The hand wheel shall be clearly
marked with an arrow and the word CLOSE. The hand wheel shall
automatically disengage when the power to the motor is restored i.e. power
drive shall have a preference over manual drive.

3.3

The DC and AC actuator shall be provided with accessories viz., Torque limit
switch, end of travel switch, adjustable limit switch, hand wheel motor,
thermostat, integral starter, etc. Complete actuator shall be tested at factory
as per IS 9334.

3.4

Two normally open and two normally closed or two changeover potential free
contacts corresponding to open and close positions of the valve shall be
provided.

3.5

Actuator shall be weatherproof type with enclosure conforming to IP-67

degree of protection. It should be suitable for out-door use without the need
for canopy. If the IP-68 degree of protection is required due to occasional
submergence, the Purchaser will specify the depth and duration of such
submergence.

3.6

The actuator shall be suitable for installation in any position without

lubrication leakage or other operational difficulty.

3.7

The main gearbox of the actuator shall be special grease filled.

3.8

Each actuator shall have a local mechanical position indicator. It should be

suitable to indicate 0 - 100% position of the valve (continuous type).

3.9

In order to minimise the amount of spare parts required, parts and subassemblies limit / torque switches, limit switch counter gear assembly, torque
switch drive assembly, mechanical position indicator assembly etc.
individually interchangeable / replaceable throughout the models selected.

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

VOLUME - II
SECTION: C7.3
SHEET 5 OF 8

MOTORS AND VALVE ACTUATORS

3.10

The actuator shall be painted with corrosion resistant epoxy resin paint. Paint
shade shall be Grey as per IS-631 grade 5.

3.11

In order to prevent condensation, a space heater shall be provided in the

switch compartment, suitable for continuous operation.

3.12

Actuator mounting dimensions shall be according to ISO-5210. For rising

stem applications, the design must allow the removal of actuator from the
output drive without disturbing the function of valve.

3.13

Limit and Torque Switches

3.13.1

Independent torque and limit switches shall be provided in the actuator. A

minimum of two position limit switches and two torque switches, one each for
each direction of travel, having 2 NO + 2 NC potential free contacts, shall be
supplied. If called for in the data sheet, two additional limit switches shall be
provided for intermediate positions.

3.13.2

Torque switch dial shall be graduated directly in kg-m for easy setting to
desired value within the range specified. Separate dials shall be provided for
CLOSE and OPEN torque switches.

3.13.3

The switches shall individually be enclosed to a minimum of IP-66 protection

class.

3.13.4

Torque and limit switches shall have only stainless steel flaps for better
protection against environmental condition.

3.13.5

Limit switches shall be operated by gear driven cams, which are

mechanically linked to the driving devices. The counter gear used for
counting and tripping the limit switches shall be of metallic construction like
brass etc. No plastic gearing shall be allowed.

3.13.6

To guarantee proper function under high ambient temperatures, torque and

limit switch sensing shall be of mechanical type.

3.13.7

If specified in data sheet, two additional limit switches of 2NO + 2NC contact,
each adjustable at any intermediate position, shall be provided in the
actuator.

4.0

ADDITIONAL REQUIREMENTS FOR HT MOTOR

4.1

Motors shall be capable of starting and accelerating the load with the
applicable method of starting without exceeding acceptable winding
temperatures when supply voltage is 80% of the rated voltage.

4.2

HT motors shall also be capable of satisfactory operation at full load at a

supply voltage of 80% of the rated voltage for 5 min. commencing from hot
condition.

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

VOLUME - II
SECTION: C7.3
SHEET 6 OF 8

MOTORS AND VALVE ACTUATORS

4.3

Motors shall withstand for 1 second the voltage and torque stresses
developed due to the vector difference between the motor residual voltage
and the incoming supply voltage equal to 150% of the rated voltage during
fast changeover of buses.

4.4

Locked rotor current of the HT motors rated 1500 kW and below shall be
limited to 600% (inclusive of 20% tolerance) of the full load current of the
motors and motors rated above 1500 kW shall be limited to 450% (inclusive
of 20% tolerance) of full load current of the motor.

4.5

The locked rotor withstand time under hot condition at 110% rated voltage
shall be more than the starting time at minimum permissible voltage specified
above by at least three seconds or 15% of the accelerating time whichever is
greater. Provision of speed switch shall be avoided to the extent possible.
However, if absolutely necessary, speed switches shall be provided. When a
speed switch is mounted on the motor shaft , the same shall remain
closed for speeds lower than 20% and open for speeds above 20% of
the rated speed. The speed switch shall be capable of withstanding
120% over speed in either direction of rotation. If the speed switch requires
any auxiliary voltage, it shall be suitable for the auxiliary voltage specified in
Section B-Project information of the specification.

4.6

All HT motors shall be provided with vibration pads for mounting vibration
detectors. Vibration monitoring devices shall be provided on DE and NDE
side in X & Y direction for remote DCS/PLC monitoring, alarms and tripping.

4.7

Motors rated 1000 kW and above shall be provided with differential

protection. These motors shall be provided with star connected stator
windings. The 3 nos. current transformers, one for each phase shall be
mounted in a separate compartment in the neutral side terminal box. The
three phases shall be connected to form the star point after they pass through
the CTs.

4.8

When forced oil lubrication or water cooling is required, prior approval

from the Purchaser shall be obtained and the machine shall be suitable for
starting and continuous operation for at least 10minutes without the
availability of lubrication or cooling system. If the bearings are oil lubricated a
drain plug shall be provided to show the precise oil level required for standstill
and running conditions.

4.9

Each bearing shall be provided with a dial type thermometer. Each

thermometer shall consist of 2 potential free contacts. They shall be designed
to close independently at two different temperatures - one for 'Alarm' and
another for 'Trip'. The contact rating of the potential free contacts shall be 1A
at 240V AC & 0.1A at 220V DC. Any auxiliary supply if required shall be
indicated by the bidder. The thermometers shall be located at a convenient
height for easy reading and handling. Flow switches shall be provided for
monitoring cooling water flow if CACW motors are specified. One bearing
shall be insulated to prevent shaft currents.

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

VOLUME - II
SECTION: C7.3
SHEET 7 OF 8

MOTORS AND VALVE ACTUATORS

4.10

At least six resistance type temperature detectors for the stator winding each
having D.C resistance of 100 ohms at 0 oC, embedded in the stator winding
at locations where highest temperatures may be expected shall be provided.
The material of the ETDs shall be platinum. One ETD shall be provided for
each of the motor bearing & shall be wired up to the terminal box. The
temperature detectors shall be of 3 wire, duplex type.

4.11

Separate terminal boxes to be provided for stator leads, rotor leads, space
heater, RTDs for winding bearings temperature, vibration monitors etc. The
three phases shall be segregated by barriers of metal or fibre glass. All
terminal boxes shall be provided with two earthing studs for termination of
protective earth conductor. Double compression type brass cable glands and
crimping type copper lugs shall be provided for termination.

4.12

Cooling for HT motors shall be CACA /TETV / TEFC.

4.13

The following details, in addition to those specified in applicable standards

shall be included on the rating plate.

4.14

Temperature rise of windings in degree centigrade at rated

load, rated
voltage, frequency and ambient conditions and the method of measuring
temperature rise. (Thermometer/ Winding resistance).

4.15

Type of bearings, recommended lubricant, lubricating interval & re-lubricating

quantity.

4.16

Cable boxes of all HT motors shall be provided with quick disconnecting type
terminal connectors to facilitate easy disconnection and removal of the
motors without requiring unsealing or otherwise disturbing the external cable
connections and leaving the phase segregated terminal box intact.

4.17

The insulation system shall withstand steep front impulse voltage of value
given as per Table-1 of IEC-34, Part 15 having front time 0.2 microsecond.

5.0

TESTS

5.1

Tests on all types of motors shall be conducted as per relevant standard.

5.2

All type, routine & acceptance tests as per relevant IS will be conducted on
11 kV motors. For 415V motors and DC motors, if type test certificates are
available for the same rating of the motors offered, the same shall be
furnished, else they shall be conducted.
However, all routine and
acceptance tests shall be conducted on all 415V motors as per relevant
standards.

5.3

For 11000V AC motors, in addition to all the tests specified above,

polarisation index test will be carried out as a routine test on each motor (the
minimum value of polarisation index for all motors will be 2 when determined
according to IS : 7816).

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

VOLUME - II
SECTION: C7.3
SHEET 8 OF 8

MOTORS AND VALVE ACTUATORS

5.4

Di-electric tests to establish the insulation withstand level of motors as

indicated in Clause 4.17 will be performed on a sample coil (identical to those
to be used in the motor quoted for) for each type of motor. These tested
sample coils will not be used in the motors to be supplied.

5.5

Noise level measurement test shall be conducted on one motor of each

type.

6.0

TECHNICAL REQUIREMENTS

6.1

The HT & LT Motors will comply with the particulars indicated in data Sheet
A, section D4, Volume-II.

6.2

The Data SheetB, Section D4, Volume-II to be furnished by the BIDDER.

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar
Pradesh

VOLUME:II
SECTION :C7.5
SHEET 1 OF 18

CABLES AND CABLE CARRIER SYSTEM

1.0

SCOPE

1.1

The scope of work shall include design, engineering, supply, installation, testing and
commissioning of the following: cables, cable carrier system (cable trays, cable tray
support angles, conduits, etc.,) fire proof sealing system for all the cables being supplied
under this contract. The scope of work shall include supply, installation & commissioning
of cable glands, cable lugs, cable termination kits, cable jointing kits, cable clamps, cable
ties, cable identifier tags, cable route markers, etc., for all cables supplied under this
contract.

1.2

Design, engineering, supply, installation, testing and commissioning of all LV power,

control, instrumentation, Main - DCS interface and any special cable for all equipment and
between any two equipment supplied under this contract and those between Bidders and
Purchasers equipment are included in the scope of this contract. Cables to Purchasers
equipment wherever specifically excluded in the specification are not in the scope of this
package .

1.3

This Specification shall be read in conjunction with Other sections, GA & SLD Drawing
and other bid drawings enclosed in Volume-II.

2.0

TERMINAL POINT

2.1

Incoming terminals of Bidders 415 Volt PMCC. However, terminating Purchasers 415
Volt cables at this PMCC is in Bidders scope.

2.2

Control cable to Purchasers upstream 11 kV and 415 Volt switchgears for Inter-panel
tripping is in Purchasers scope. However, terminating Purchasers cables at Bidders
equipment end is in Bidders scope.
Incoming terminals of Bidders 11 kV HT Motors. However, terminating Purchasers 11 kV
cables at these Motors are in Bidders scope

2.3

2.4

2.5

Incoming terminals of Bidders 220 Volt Sub DCDB. However, terminating Purchasers
DC Cables at Sub DCDB is in Bidders scope.
Cable carrier system upto outside of compressor house switchgear building.

3.0

CABLE TYPES

3.1

HT Cables

3.1.1

HT cables will be 11KV (UE) grade suitable for use in medium resistance earthed
system, with stranded & compacted aluminium conductors of grade H4 and class 2,
extruded semi-conducting compound screen, extruded XLPE insulated, extruded semi-

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar
Pradesh

VOLUME:II
SECTION :C7.5
SHEET 2 OF 18

CABLES AND CABLE CARRIER SYSTEM

conducting compound with a layer of non-magnetic metallic tape for insulation screen,
extruded PVC (Type ST 2) inner sheath, single round hard drawn, galvanized steel (for
single core, non magnetic material, Aluminium) wire, confirming to H4 grade, armoured,
pressure extruded FRLS PVC (Type ST 2) outer sheathed, single / multicore
conforming to IS 7098 (Part II), IEC-502 for constructional details and tests.
3.2
3.2.1

3.3
3.3.1

3.4
3.4.1

3.5
3.5.1

LV Power Cables
LV Power Cable shall be 1100 V grade, single / multi core, stranded aluminium conductor
of grade H4, class2 or stranded high conductivity annealed copper, Class 2, XLPE
insulated, with extruded PVC inner sheath, ST-2, single round hard drawn, galvanized
steel (for single core, non magnetic material, Aluminium) wire, confirming to H4 grade
armoured and outer sheath made of pressure extruded FRLS PVC, Type-ST-2
compound conforming to IS 7098 Part-I. The cables used for DC system shall be of
single core type. Minimum conductor cross section of power cables shall be 16-sq. mm
for aluminium cables; below this size, power cables shall be of copper conductor. Power
and Control cables coming in higher than normal temperature areas, heat resistant
cables shall be employed in consultation with Purchaser.
Control Cables
Control cables shall be 1100 V grade, multi core, minimum 1.5 sq. mm cross section,
stranded high conductivity annealed copper conductor having minimum 7 strands,
extruded type A PVC insulated, extruded PVC inner sheathed, galvanised round steel
wire armoured and extruded outer sheath made of FRLS PVC ST-1 compound
conforming to IS1554 Part-I. In situations where accuracy of measurement or voltage
drop in control circuit warrants, higher cross sections as required shall be used.
Trailing Cables(Power and Control)
The 11 kV (UE) and 1100V (E) grade power & control flexible trailing cables shall be with
annealed tinned copper conductor, EPR insulated, PCP inner sheathed, CSP outer
sheathed and conductor screen. Cables shall conform to requirements of IS 9968 & IS
6380 and any other applicable standards.
DC System Cables
1100 V grade, single core cables as specified in LT power cables shall be used.

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar
Pradesh

VOLUME:II
SECTION :C7.5
SHEET 3 OF 18

CABLES AND CABLE CARRIER SYSTEM

4.0

CABLE PROPERTIES

4.1

All single core power cables will have round wire armouring of aluminium, whereas
multicore power cable will have galvanised steel strip armouring.

4.2

The outer sheath of all cables will be of extruded layer of suitable synthetic material
compatible with specified ambient and operating temperature of the cables. The sheath
will be resistant to water, UV radiation, fungus, termite and rodent attack.

4.3

The outer sheath of FRLS PVC compound will meet the following performance
requirements:

a.

The critical oxygen index value shall be minimum 29 when tested at 27+ 20C as per
ASTM-D-2863-77 and the temperature index will be minimum2500C at oxygen index
value of 21 when tested as per NES-715/ASTM-D-2863.

b.

The maximum acid gas generation as determined by titration method shall be less than
20% by weight when tested as per IEC-754-1.

c.

The smoke generation under fire shall have maximum smoke density rating of 60% when
tested as per ASTM-D-2843-7

d.

Tests for Water Absorption -Outer sheathes shall be subjected to tests for water
absorption as per IS 10810.

e.

Tests for Resistance to Ultra Violet Radiation - This test shall be carried out as per DIN
53387. The retention values of tensile strength and ultimate elongation after the tests
shall be minimum 60% of tensile strength and ultimate elongation before test.

f.

Flammability- Cables shall pass test under fire conditions as per IS-10810- Part-53.

g.

The finished FRLS cable shall pass the flammability test as per IS 10810-61 and IEEE383. In addition, it shall also pass flammability test for bunch of cables (Cat A) as per

4.4

IEC-332-3 /IS 10810-62.

Cables for devices mounted on or near hot surfaces shall have heat resistance type outer
sheath.

4.5

Cable Identification

a.

Cable identification shall be provided by embossing on every meter on the outer sheath
the following:
Manufacturers name or trademark

b.

Voltage grade.

c.

Year of manufacturer.

d.

Year of manufacturer.

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar
Pradesh

VOLUME:II
SECTION :C7.5
SHEET 4 OF 18

CABLES AND CABLE CARRIER SYSTEM

e.

Type of insulation,e.g XLPE

f.

No of core and size of cables.

g.

LPGCL
Progressive sequential marking of length of cable in meters at every meter shall be
provided on the outer sheath of the cable.

4.6
4.6.1

Packing
Cables above 300 sq mm shall be supplied in non-returnable steel drums and cables
below 300 sq mm shall be supplied in non-returnable wooden drums. The drums shall be
of heavy construction. All ferrous parts used shall be treated with suitable rust preventive
finish or coating to avoid rusting during transit or storage.

4.6.2

Cable shall be wound and packed on drums in such a manner that it will be properly
sealed and firmly secured to the drum. The ends of each length shall be sealed before
shipment.

4.6.3

A label shall be securely attached to each end of the reel indicating the data as per
relevant IS.

4.7

Drum Length
The cables shall be supplied in non-returnable packing steel drums, each containing
minimum 500 metres length or as required for larger sizes of cable. For smaller sizes of
cables, each drum shall contain 1000 metres or as required length of cable. Allowable
tolerance on individual drum length is 5%.

4.8

Cabling in battery room shall be limited to battery related cables. Cables and ducts of
other system shall not run through battery room.

5.0

DESIGN CRITERIA FOR CABLE SIZING

5.1

Power Cables
Power cable sizes shall be selected on the following basis :

a.

Power cables shall carry the full load current of the circuit continuously under site
conditions considering the condition listed below: :

Ambient design temperature 50 deg. C.

Maximum allowable temperature under normal full load condition and

under short circuit condition based on material selected (XLPE).

Rated short circuit fault current of the switchboard

Ambient temperature for underground cables, 50 deg. C.

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar
Pradesh

VOLUME:II
SECTION :C7.5
SHEET 5 OF 18

CABLES AND CABLE CARRIER SYSTEM

De-rating factors as per manufacturers standard catalogue (most

conservation amongst the approved vendors) shall be considered. In any
case Bidder is responsible to ensure the cable sizes procured are
adequate as per the cable supplier recommendation and laying conditions
encountered.

b.

Full load current considered for MCC/PCC shall include the highest rating
of standby motor/load and spare feeders
Power cables will withstand the fault current of the circuit for the duration not less than
the maximum time taken by the primary protective system to isolate the fault completely
including margin. Fault clearing times for 415V motor feeders and transformer feeders
having high-set instantaneous protection shall be 0.16 secs, whereas tie between two
415V switchgear shall be 0.5 secs, and for incomers and tie feeders 1.0 sec.

c.

For the cables to 415 V motors and feeders protected by MCCB/MPCB/fuse, the cross
section shall be chosen considering short circuit current and cut off time characteristics of
the short circuit protective device.

d.

Voltage dip at motor terminals during starting of motors will be limited to 15% of the rated
voltage.

e.

Total steady state voltage drop from transformer secondary till any of the motor terminals
shall be limited to below 5% during full load running condition.

f.

Power cable route indicators should be provided at an interval not exceeding 200m and
also at turning points of the power cable route wherever practicable.

g.

The conductor XLPE insulation shall be dry cured and sheath materials shall be oil, acid,
alkali resistant and also will be tough enough to withstand mechanical stresses during
handling.

h.

The PVC inner sheath shall be extruded.

i.

Cables shall be so designed and manufactured that no damage occurs during handling,
transit, storage, installation under any operative conditions, which may be subjected to. If
any damage occurs during pulling/laying Bidder will replace the cable. Joints are not
acceptable.

j.

All power cables shall have rodent and termite repulsion properties.

k.

For three core cable, it is considered adequate if the screens of all three cores together
carry the specified fault current for the specified duration since the screens will be in
touching formation.

l.

For single core cable, screen shall be designed to carry the specified earth fault current
for the specified duration.

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar
Pradesh

VOLUME:II
SECTION :C7.5
SHEET 6 OF 18

CABLES AND CABLE CARRIER SYSTEM

m.

The inducted voltage built-up in shields and armour of single core cables carrying
alternating current shall be limited to 25V.

5.2
a.

Control Cables
Current transformer leads shall be checked for the lead burden vis-a-vis the current
transformer VA capacity. Minimum 2.5sqmm cables for within panels, while 4.0sqmm
between independent panels/equipment shall be used for connection of CTs and PTs. In
case 2.5/4.0 sq. mm conductor impose unacceptably high burden on CTs/PTs higher
conductor shall be used. The conductor material shall be copper.

b.

Voltage transformer leads shall be checked for voltage drop which shall be limited to
within 0.2/0.5/1% as per accuracy class specified elsewhere. For tariff metering the
voltage drop shall be limited to 0.2%. In case the voltage drops with 2.5/4 sq. mm
conductors exceed this value, higher conductor sizes shall be used.

c.

The multi-core cables shall have 2 to 4 nos. cores on spare. The grouping of cables for
critical application shall be avoided.

6.0
6.1

CABLE TERMINATIONS
Cables shall be laid in trays /conduits by the Bidder. Also joint markers shall be provided
at each joint.

6.2

All 1100V termination for XLPE/PVC power cables and control cables shall be by Double
compression weather proof type cable glands. Heavy duty, tinned, long barrel copper
lugs shall be used for termination.

6.3

Cable glands shall conform to BS: 6121 and be of robust construction capable of
clamping cable and cable armour firmly without injury to insulation. Cable glands shall be
made of heavy duty brass machine finished and nickel chrome plated. Thickness of
plating shall not be less than 10 micron. All washers and hardware shall also be made of
brass with nickel chrome plating.

6.4

Cable lugs for power cables shall be aluminium solder less crimping type conforming to
IS: 8309 suitable for aluminium conductor cables and for control cables shall be tinned
copper type.

6.5

All 11kV termination kits shall be of heat shrinkable type only and suitable for XLPE
insulation and the same shall have been tested for a short circuit of 40kA for 0.25 sec.
Double compression type cable glands and copper lugs shall be used for termination.

6.6

All 1100V termination for HRPVC power cables and control cables shall be by crimping
type tinned copper lugs and double compression type cable glands.

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar
Pradesh

VOLUME:II
SECTION :C7.5
SHEET 7 OF 18

CABLES AND CABLE CARRIER SYSTEM

6.7

It is the responsibility of the Bidder to ensure the cable size selected matches to the
motor terminal box size. In case of any mismatch, ie, size of motor terminal box falling
short of cable size selected, Bidder shall provide the equivalent copper cable and other
accessories as required within the stipulated time schedule without any cost implication.
Adapter boxes at motor terminal shall be avoided.

7.0
7.1

CABLE JOINTS
Cable joints shall be avoided to the extent possible. No cable joints for HT cables. If
joints are unavoidable due to circuit length, in excess of permissible maximum drum
length, they shall be heat shrinkable type only having a short circuit with stand capacity of
40kA for 0.5 sec. for 11kV cables and 50kA for 0.5 sec. for 1100V grade cables.

7.2

Lugs shall be heavy duty, tinned copper, long barrel type. All cable glands shall be
double compression, weather proof.

8.0

TESTS

8.1

The Contractor will conduct all the routine tests, as per standards, on each drum length
and acceptance tests on drums chosen at random for acceptance of the lot.

8.2

Type test certificates for each type & size of the cable shall be submitted. In case type
test certificate for similar type & size is not available, the same shall be conducted in
presence of Purchaser if Purchaser so desires.

8.3

To prove the fire resistant characteristics, and rodent and termite repulsion property,
each type of cable shall also be subject to the following additional type tests at works:

a)

Oxygen Index Test as per ASTM D 2863. Minimum value of oxygen index shall be 29.

b)

Flammability Tests on finished cable as per the requirements of IEEE-383, IEC-332-1

and Swedish standard SS 4241475 Clause F3.

c)

Smoke generation by outer sheath under fire as per ASTM D 2843. The cables shall
meet the requirements of light transmission of minimum 40% after the test. The test shall
be carried out by extrapolation method beyond temperature at which the material of
sheath may start deformation as per BICC Handbook Chapter- 6 on cable in fire. The
minimum value of temp Index shall be 250C.

d)

Acid gas generation by outer sheath under fire as per IEC-754-1 and the maximum acid
gas generation shall be less than 20% by weight.

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar
Pradesh

VOLUME:II
SECTION :C7.5
SHEET 8 OF 18

CABLES AND CABLE CARRIER SYSTEM

Test for Rodent & Termite Repulsion Property

8.4

The test shall be carried out to note the presence of rodent and termite repelling chemical
in PVC compound. Normal procedure is that a few chippings of the PVC compound are
slowly ignited in a porcelain dish on crucible in a muffle furnace at about 600 Deg.C, The
resulting ignited ash is boiled with a little ammonium acetate solution (10%). A drop of
aqueous sodium sulphide solution is placed on a thick filter paper and it is allowed to
soak. The spot is touched with a drop of above extract. A black spot indicates the
presence of anti-termite & rodent compound.
9.0

CABLE CARRIER SYSTEM

9.1

The cable carrier system shall be designed considering the following:

a.
b.
c.
d.
e.
f.

9.2

Facility for easy laying of cables.

Access to maintenance.
Neat and aesthetic appearance.
Safety of equipment & personnel.
Ground water seepage.
Drainage system for oil and water
Following cable carrier system shall be adopted in various areas as indicated below in
general. All cable routing layouts shall be submitted for Purchasers approval. The list
below is for BIDDERs guidance only. It is not the intent of this specification to specify the
required arrangement for all areas.

Sl. No.
(i)

Cabling Location

Type of cable carrier

system

Control room

: Cable trays in Cable

vault/Trench

False floor (as applicable)

: Cables to be laid on the

cable support arm

(ii)

Switchgear Cum Control : Cable trays in Cable

room Building
trench/Vault

(iii)

MCC Switchgear Room

: Cable trays in trench

(iv)

Road crossings

: Duct banks

(v)

Cable carrier system

connecting outlying areas

: Overhead Cable rack /

Cable trench

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar
Pradesh

VOLUME:II
SECTION :C7.5
SHEET 9 OF 18

CABLES AND CABLE CARRIER SYSTEM

(vi)

Sl. No.

9.3

9.4
9.4.1
9.4.2
9.4.3

9.5

Off-site buildings and

utilities

: Overhead Cable trays /

Cable trench

Type of cable carrier

system

Cabling Location

(vii)

Battery Rooms

: Overhead Cable trays

(viii)

Outdoor areas

: Cable rack / Overhead

Cable trays

The Bidder shall prepare detailed cable routing diagram, cable tray layouts, cable
schedules, interconnection schedules for all cables being supplied under this contract. It
is anticipated that a few cables-supplied outside this contract would be required to be
routed in the cable carrier system being provided by this Bidder. The details of these
cables would be made available to the Bidder to prepare integrated cable layout/routing
drawing considering the cable being installed by others.
Cable Trench
Built in cable trenches shall be provided wherever necessary.
Cable trenches shall be of different sizes depending on the number of cables laid in that
Route.
Preferred working space between the cable support arms and the wall are as follows,
Contactor shall design the trenches accordingly.
Trench depth

Width of Trays

Working Space

1500 mm (5 tiers)

600 mm

750 mm

1200 mm (4 tiers)

600 mm

750 mm

1000 mm (3 tiers)

600 mm

750 mm

700 mm (2 tiers)

300 mm

350 mm

Buried Cables
Cables in trenches shall be laid on 8 cm of riddled sand and covered with 8cm of riddled
sand. Ferro cement slabs shall be provided for covering these trenches in case of HT
cable and Bricks shall be provided for LT cable. On top of Ferro cement slabs / bricks,
the earth shall be back filled, rammed and levelled. Suitable separation shall be provided
when more than one cable is laid in the same trench. The maximum trench depth shall
normally be 1.5 m and thickness of top cover of 75 mm. If the trench is to cross railways
tracks/roads or any load bearing area the cables shall be taken through suitable GI
conduits / pipes / ducts.

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar
Pradesh

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CABLES AND CABLE CARRIER SYSTEM

9.6

Cable Trays

9.6.1

Cable trays of prefabricated ladder and perforated types and the associated accessories
such as coupler plates, tees, elbows, etc., shall be fabricated from 2.5 mm thick mild
steel sheets. Cable tray covers shall be fabricated from 16 gauge (1.70 mm thick) MS
sheets.

9.6.2

Cable trays, accessories and covers shall be hot dip galvanised. Weight of zinc coating
shall be 610gm/sqm as per IS-4759.

9.6.3

The spacing of rungs for ladder type of trays shall be not more than 250 mm.
Vertical raceways shall be formed by either structural members and slotted angles or by
running the prefabricated trays vertically.

9.6.4

Earthing Cables for NGR and surge arresters shall be provided and laid in the cable
trays.

9.6.5

Cable trays layout drawings shall indicate the corridor (in terms of elevation and width)
used by other services like ducts, piping, lighting, etc to avoid interference. Ventilation
and AC ducts and piping shall not be routed inside switchgear room, cable gallery room,
battery room and control room.

9.7

Conduits & Pipes

9.7.1

The galvanised steel conduits shall be used for sizes upto 63.5 mm. The conduits shall
be manufactured by electric resistance welding process and shall be hot dip galvanised.
The conduits and fittings shall comply with IS: 1653, 3837& 2667.

9.7.2

Galvanised steel pipes shall be used for sizes from 80mm on wards. They shall be
medium duty class-B type as per IS. The pipes shall be manufactured by electric
resistance welding and hot dip galvanised. The pipes and fittings shall comply with IS.
Flexible steel conduits shall be manufactured with electro galvanising process. The
flexible conduits and their fittings shall comply with IS: 3480, 4649.

9.7.3

The hume pipes/RCC pipes shall comply with IS:458.

9.8
9.8.1
9.8.2
9.8.3
9.8.4

Cable/Cable tray supports

Cable tray supports shall be fabricated from standard steel structures of different sizes.
The sizes selected shall be adequate for the weight of cables/trays encountered.
The steel members shall be cleaned thoroughly for rust and painted as follows :
For indoor - One shop coat of red oxide zinc chromate primer and two site coats of
aluminium alkali paint.
For outdoor & corrosive areas like battery room - Hot dip galvanised.

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Pradesh

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9.9

Cable Chase
Cable chases of required width and depth shall be provided for routing individual cables
on floor from main trays to equipment by grooving at floor slab and after installation it of
cable it should be filled with sand and sealed with concrete.

10.0

CABLE CARRIER INSTALLATION PRACTICE

10.1

Minimum level difference between two tiers of horizontal cable trays in building, trenches,
shall be 300 mm. In vertical raceways with multi tiers the tiers shall be located atleast
with 400 mm intervals.

10.2

In trenches & tunnels the width of the cable tray shall be limited to 600 mm.

10.3

Separate cable trays/tiers shall be provided for different voltage grade and application
The installation of cables shall be as follows: .
a. HV cables
b. LV cable along with 220V DC, 240V UPS.
c. I&C cables, fibre optic, special communication cables, EPABX, PA system cables.
Space provision shall be provided for Purchasers UPS cables, EPABX -PA system
cables, fibre optic cables and fire alarm and detection cables in respective Bidders trays.
Towards this 20% free space shall be provided on each tray. HV cable shall be
accommodated on the top tray followed by lower voltage grade cables. Separate tray
shall be provided for fibre optic/communication cable.

10.4

Cable trays shall be supported at every 1000 mm interval.

10.5

Cable trays shall be welded to the mounting/carrier structures.

10.6

All outdoor cable trays shall be erected in vertical plane. All Vertical trays (raceways) and
outdoor horizontal cable trays (top most) shall be provided with removable 16 gauge
galvanised MS sheet covers.

10.7

Each continuous laid out length of cable tray shall be earthed at minimum two places by
MS flats of minimum size 25mm x 3mm, the distance between earthing points shall not
exceed 10 metres.

10.8

When cables are taken in vertical raceways /trays and they pass from one floor & other
floor pipe sleeves in concrete shall be provided.

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3 X 660 MW Super Critical TPP at Lalitpur, Uttar
Pradesh

VOLUME:II
SECTION :C7.5
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CABLES AND CABLE CARRIER SYSTEM

10.9

In heat zone areas as far as possible the cables shall be taken away from that area to
avoid heat. If Cabling in heat zones cannot be avoided, the cables shall be terminated in
a junction box of IP 67 protection class away from the heat zones and small length of
cables may be laid from junction box to the respective equipment to facilitate easier
replacement in case of fire. Bunching of cables in the heat zones and boiler areas shall
be avoided and laid in separate groups

10.10

All cables crossing the floors shall be routed through protection pipes embedded in the
floor.

10.11

In transformer yard, cable trench originating from transformer end shall be sand filled and
provided with fire stop (230mm RCC barrier wall) at the point it joins the main trench.

10.12

Redundant cable systems should be separated to ensure that no single event will prevent
a required essential operation.

10.13

The top clearance between bottom of switchgear and top of the tray shall be minimum of
600mm.

10.14

Earthing Cables for NGR and surge arresters shall be provided and laid in the cable tray.

11.0

CABLE INSTALLATION

11.1
11.1.1

Installation
Cables to each circuit will be laid in one continuous length. Cable jointing and splicing will
be avoided. Jointing will be allowed only for the cases where the route length is more
than the maximum possible drum length.

11.1.2

Control and power cables from modules will be terminated in switch fuse units mounted
in local structures.

11.1.3

High-voltage power cables should be installed so that the high voltage cannot be
impressed on any lower voltage system. Methods for achieving this segregation are:

a)

Installation of high-voltage cables in raceways that are separated from low-voltage power
and control cables and from instrumentation cables. Installation of different voltage
classes of high-voltage power cables in separate raceways is also suggested.

b)

Utilization of armoured shielded cables (separate raceways are still suggested).

11.2
11.2.1

Outdoor Cable Installation

Where cables cross roads and water, oil, gas or sewage pipes, the cables will be laid in

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Pradesh

VOLUME:II
SECTION :C7.5
SHEET 13 OF 18

CABLES AND CABLE CARRIER SYSTEM

hume or steel pipes. For road crossings, the pipe for the cable will be buried at not less
than 600 mm. Hume pipes will be preferred to steel pipes from the point of view of
corrosion.
11.2.2

The cables will be tied to tray rungs by means of 3mm dia. nylon cord at an interval of
5000 mm and also at bends.

11.2.3

For good sealing arrangement at entry points, suitable pipe sleeves, adequate in number
and of adequate sizes will be provided in building walls/slabs for passage of cables into a
building from cable trays/racks/cable trenches located outside the building.

11.3

Cables In Trays / on Racks

11.3.1

High-voltage power cables should be segregated from all other cables. Cables installed in
stacked cable trays should be arranged by descending voltage levels, with the higher
voltages at the top.

11.3.2

Cable / tray suppports in trenches shall be at least 75 mm above trench bottom.

11.3.3

The HV and LV power cables will be laid in trays/on racks as follows:

a)
b)
c)
d)

In single layer only without exception.

3 core cables to be laid in touching formation.
Single core cables to be laid in trefoil groups and with ID spacing
No. of runs will be to meet the system requirement

11.3.4

Temp. rise in unventilated tunnels :

The increase in air temperature inside tunnel is given by the following formula: T=W/3P
where; T = increase in temperature over ambient air temperature, C; W = total heat loss
per metre length of all the cables in watts; and P = perimeter of tunnel cross-section in
metres.

11.3.5

Control and instrumentation cables can be laid upto a maximum of three layers in each
tray/rack.

11.3.6

Single core power cables for 3 phase AC circuits laid in trays/racks/ trenches in trefoil
groups will be held in trefoil clamps placed at an interval of 3 m. The trefoil groups of
cables will be additionally tied by means of 3 mm dia. nylon cord as follows:

a) At an interval of 1m when laid in cable trays/racks.

b) At an interval of 750 mm when laid in trenches without cable trays.

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar
Pradesh

VOLUME:II
SECTION :C7.5
SHEET 14 OF 18

CABLES AND CABLE CARRIER SYSTEM

11.3.7

Control cables and small power cables on racks will be run in ladder type cable trays
supported on rack carrier arms. The cables will be tied to tray rung by means of 3 mm
dia. nylon cord at an interval of 5000 mm and also at bends.

11.3.8

The vertical distance between the two racks should be minimum 0.3 m and the clearance
between the first cable and the wall (if racks are mounted on wall) should be 25 mm. The
width of the rack should not exceed 0.75 m in order to facilitate installation of cables

11.4
11.4.1

Bending radius for Cables

The bending radius for various types of cables will not be less than those values specified
by the cable manufacturer.

12.0

TERMINATIONS, CLAMPING AND MISCELLANEOUS DETAILS

12.1

Cable entry to motors, push button stations and other electrical devices will be from the
bottom as far as possible or from the sides. Top entry will be avoided particularly for
outdoor equipment.

12.2

Identification tags made from aluminium sheet will be attached to each end of each cable
by means of GI binding wire. Tags will be additionally put at an interval of 30 metres on
long runs of cables and in pull boxes.

12.3

All cable terminations will be done with solderless tinned copper crimping type lug. Cable
terminations will be done with double compression type brass cable glands. For
transformer feeders, HT motors, LT motors of 110kW and above only Amp make lugs
will be used at both motor and switchgear ends.

a)

Control cable termination: Wago type or equivalent type cage connectors will be used.

b)

Saddle type clamps to suit number of cables to be clamped at a particular location will be
used for clamping cables running along walls, ceilings, structures, etc. at 750mm interval.

c)

The armour and semi-conducting screen of single core cables will be earthed at one end.
The continuity of armour and semi conducting screen will not be broken at each joint. The
unearthed end of armour and screen will be insulated.

13.0

TESTS DURING COMMISSIONING OF CABLE

13.1

Clause no 15 of section C7.7 shall be referred.

CARBERY INFRASTRUCTURE PTE LTD

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Pradesh

VOLUME:II
SECTION :C7.5
SHEET 15 OF 18

CABLES AND CABLE CARRIER SYSTEM

14.0

EARTHING

14.1

Metallic sheaths, screens and armour of all multicore cables will be earthed at both
equipment and switchgear end.

14.2

Sheath and armour of single core power cables will be earthed at switchgear end only.
For long lengths of cables multiple earthing may have to be adopted to safeguard against
the presence of standing voltages under normal as well as fault conditions.

15.0

FIRE PROOF SEALING SYSTEM (FPS)

15.1

Fire proof sealing system will consist of

a)

Fire-stops/fire-seals for sealing of cable/cable tray and conduit/pipe penetrations, both

horizontal and vertical, through brick or RCC walls/floors, to prevent the spread of fire
from one area, which is separated from others by fire-resistant barriers.

b)

`Fire-breaks' provided on long runs of cable racks/trays to prevent the propagation of fire
along the cable rack, within a single fire-area or fire- zone.

15.2

The FPS system will also include all the necessary accessories and equipment required
for supporting, holding in position, fixing and installation of the fire-stop/fire-break.

15.3

The FPS system will comply in all respects with the requirements of the codes and
standards listed below:
IEEE-634
ASTM-E-814
ANSI-IEEE-383
IEC-331
IEC-332
Fire Stop/Fire proof Seal

15.4

The FPS system adopted for cables or cable trays penetrating through walls and floor
openings, or cables passing through embedded conduits/pipes/ pipe-sleeves, constitutes
a `fire stop/seal', which is meant to prevent spreading of fire between areas separated by
fire-resistant barriers (255mm thick RCC wall).
15.5

Fire Break
The fire proofing system, other than fire-stops, adopted to retard flame propagation along
long runs of horizontal or vertical cable trays in the same fire zone or area, in an event of
a fire, will constitute a `fire-break' and will be provided by applying a suitable fire-resistant
coating on cables and cable trays for the required length, with or without a fire resistant

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar
Pradesh

VOLUME:II
SECTION :C7.5
SHEET 16 OF 18

CABLES AND CABLE CARRIER SYSTEM

panel, at the point of the fire break to obtain the fire-rating specified.
15.6

In order to prevent vertical/lateral spread of fire through cables, all cable

tunnels/galleries/trenches through which cable/cable trays pass should be subdivided into
smaller compartments irrespective by provision of walls at interval not more than 30 m
and by sealing the apertures openings with the use of fire stops. The fire rating of fire stop
and of barrier wall should not be less than the rating of building component. Passage
through barrier wall should be provided with fire check doors of the same fire rating.

15.7

Performance Requirements

15.7.1

Requirement of fire stops

a)

The material, design and construction of the fire stops will be such as to provide the firerating of 120 minutes for a fire on any side and meet all requirements listed in this
specification and the relevant codes and standards.

b)

The materials used in the fire stops will be non-hygroscopic, compatible with the type of
cables.

c)

The fire stops will be suitable for retrofitting of cables through the penetration seal without
disturbing the sealing of the cables already existing.

15.7.2

Requirements of fire breaks

Each firebreak will have a fire-rating of 30 minutes and will be capable of withstanding for
the duration specified a fire on any side of the fire break. The coating generally shall be
2mm thick spread over 1.5 m length of cable/carrier system.

15.8
15.8.1

Application of fire proof sealing system

Fire stops will be provided for cable penetration openings listed below

15.8.1.1

The passage of cables/cable trays pipe sleeves/embedded conduits through walls /

floors.

15.8.1.2

Vertical raceways, which carry cables between successive floors, through openings
provided in the RCC floor slab, will be sealed by fire stops at each floor level.

15.8.1.3

Cable entry through openings in floor slabs below HT/LT switchgear, MCCs, various
control and relay panels and other bottom entry panels, will be effectively sealed by fire
stops.

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar
Pradesh

VOLUME:II
SECTION :C7.5
SHEET 17 OF 18

CABLES AND CABLE CARRIER SYSTEM

15.8.2

Location of fire breaks

15.8.2.1

Firebreaks will be provided on both cable rack and trenches as well as at all cable tray
intersections and tee-offs.

15.8.2.2

On linear runs of cable trays between fire stops or fire breaks, fire breaks will be provided
at intervals of 15 metres (or part thereof) on horizontal cable runs and throughout on
vertical cable runs.

15.9

Contractor will furnish the test certificates for the fire stops and fire breaks after award of
contract for Purchasers review. If the certificates are not satisfactory all the tests will be
conducted free of cost. The offered system i.e. fire stops and fire breaks will be identical
(or better) with the system which is successfully type tested for the specified rating i.e. the
composition density of the material, thickness of coating in case of fire breaks and any
other properties of the material / system offered will be identical or better than the tested
system and will be subject to Purchasers approval.

15.10

Performance Tests: Tests on Fire Stops

a)

The fire stops will be subjected to the following type tests:

Fire Rating Test
Hose Stream Test

b)

Type tests will be conducted on different fire stop test specimens described above as per
IEEE-634. The sizes of the fire stop test specimens will be similar to the largest of the
sizes being used in the plant.

c)

Preconditioning of fire stop test specimens:

Before conducting the fire rating and hose stream tests, each test specimen will be
preconditioned for thermal ageing, water immersion and vibration.

d)

Test on Fire Stops:

During the fire rating test, the transmission of heat through the cable penetration fire stop
will not raise the temperature on its unexposed surface above the self ignition
temperature of the outer cable covering, the cable penetration fire stop material, or
material in contact with the cable penetration fire stop, with a maximum temperature limit
on the unexposed surface of 200oC.

e)

Tests on fire breaks:

CARBERY INFRASTRUCTURE PTE LTD

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VOLUME:II
SECTION :C7.5
SHEET 18 OF 18

CABLES AND CABLE CARRIER SYSTEM

Firebreaks will undergo the following tests as per ANSI-IEEE-383:

(i)
Ampacity test
(ii)
Flame test

16.0

TECHNICAL REQUIREMENTS

16.1

The Data SheetB, Section D6, Volume-II to be furnished by the BIDDER.

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar
Pradesh

VOLUME -II
SECTION: C7.6
SHEET 1 OF 5

LOCAL CONTROL PANEL, DCDB & OTHERS

1.0
1.1

1.22

1.3

1.4

1.5

1.6

1.7
1.7.1

CONTROL PANELS & CABINETS

Indoor control panels provided for control of miscellaneous systems related to the
system, etc. as applicable and DBs shall comply with the requirements outlined under
clause 1.7 below.
This Specification shall be read in conjunction with Other sections, GA & SLD
Drawing and other bid drawings enclosed in Volume-II.

All the meters provided on the panel shall be digital type meters in 96 W x 48H with
an accuracy class as specified and better than class1.
For motor circuits, ammeters shall have a suppressed extended scale to indicate the
motor starting current.
The facia annunciation windows if provided on the panel shall conform to
requirements outlined under instrumentation and control section.
The required 240 V, 1 phase AC supply required for panel illumination and receptacle
shall be derived in the control panel itself. However 240V, 1 Phase AC supply for
space heating of panel shall be fed from a separate 1-Phase DB, in scope of this
Bidder
Technical Requirement
The local control panel, DCDB will comply with the particulars indicated below.
SL.
NO.

DESCRIPTION

REQUIREMENTS

Location

Indoor/Outdoor depending
on location

Type of mounting

Wall/Floor

Cable entry

Top/bottom depending on
layout

Paint Finish: Outside/Inside

Flint Grey RAL 7032/

/Grey white- RAL 9002
(epoxy)

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar
Pradesh

VOLUME -II
SECTION: C7.6
SHEET 2 OF 5

LOCAL CONTROL PANEL, DCDB & OTHERS

Supply voltage

Control transformer

415V, 3 phase, 3 wire

Required to derive 110V
control supply

SL.
NO.

DESCRIPTION

Space heater, lighting supply voltage

240V, 1 phase AC

Degree of protection of Enclosure for

Electrical panels/cabinet enclosure

IP 54 class for Indoor & IP

55 class with canopy for
outdoor

REQUIREMENTS

1.7.2

The Data SheetB, Section C7.6B, Volume-II to be furnished by the BIDDER.

1.8

Following miscellaneous equipment will be included in BIDDER's scope.

I.
II.
III.
IV.
V.

Local push button stations (Flame proof type)

Junction boxes (JBs) ( Flame proof type)
Danger boards
Rubber mats
Welding Sockets

2.0

LOCAL PUSH BUTTON STATIONS (LPB)

2.1

Local push button station shall be provided for all the drive motors of the plant (415V
motors) (start / stop push buttons for unidirectional motors, start/stop/reverse push
buttons for bi-directional motors & only start push button for emergency motors) as
per scheme requirement.

2.2

The degree of protection of LPBs shall be IP65 with both canopy and lid for outdoor
and IP54 with lid and hinged door for indoor applications.

2.3

All PBs shall be push to actuate type and the stop PB shall be lockable in off position
as per the scheme requirement.

2.4

Emergency local stop push button should not be lockable. Emergency push buttons
shall be stay put type. For critical loads, two stop push buttons connected in series
shall be provided as per the scheme requirement.

CARBERY INFRASTRUCTURE PTE LTD

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VOLUME -II
SECTION: C7.6
SHEET 3 OF 5

LOCAL CONTROL PANEL, DCDB & OTHERS

2.5

All push buttons shall be provided with 2 nos. NO and 2 nos. NC contacts for various
interlocking purposes. One contact of stop PB shall be directly wired to the
switchgear module for direct tripping and another contact to control system.

2.6

Terminals to be suitable for 2 cores of 2.5 sq mm conductors with 20% spare

terminals.

2.7

All LPBs shall be of Poly Carbonate/ FRP/Di-cast aluminium.

3.0

JUNCTION BOXES (JBs)

3.1

Junction boxes as required for the power plant shall be supplied.

3.2

The JBs used in outdoor areas shall be weatherproof type.

3.3

Junction boxes/ marshalling boxes (JBs/MB) shall be provided to enable running a

large core cables from (JB/MB) to control panels, terminal cabinets, etc.

3.4

All Junction Boxes shall be of polycarbonate /FRP/ Di-cast aluminium.

3.5

Danger boards shall be provided in line with the statutory requirements.

3.6

Rubber mats shall be provided to meet the safety and other statutory requirements.

4.0

DC DISTRIBUTION BOARD (DCDB)

4.1

For feeding the 220V DC loads, 220V DC switchboard shall be provided.

4.2

The switch board shall be provided with Two Incomer and one Bus coupler
arrangement, suitable quantity and type of outgoing feeders for the auxiliaries, control
supplies to various panels / systems. For each load and auxiliary, one separate
feeder shall be provided. In addition, the following feeders shall be provided in
switchboard.
a) Spare feeders 20% of each type and rating with a minimum of two nos. feeders.
This is the minimum quantity required at the time of handing over the plant.

CARBERY INFRASTRUCTURE PTE LTD

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VOLUME -II
SECTION: C7.6
SHEET 4 OF 5

LOCAL CONTROL PANEL, DCDB & OTHERS

b) Two (2) feeders of minimum 50A for OWNERs use.

c) Following feeders of 16A each for OWNERs use:
i)

Control supply for MCCs 6 Nos.

iii)

DC lighting (1.0 KW) - 10 Nos.

4.3

The short circuit current rating of the switchboard shall be arrived considering the
contribution from charger and battery with 5% margin, with a minimum of 25 kA.

4.4

The continuous current rating of the bus bars and incomers for 220V DC
switchboards shall be the maximum DC load (excluding the momentary load) on the
bus plus 20% margin rounded off to the next higher standard rating.

4.5

Specific requirements
Incomer & Bus coupler modules, outgoing feeders, motor modules and space heating
modules shall be provided with all necessary switches, fuses, contactors,
MCB/MCCBs, relays, timers, push button switches, LED indicators, transducers,
space heaters etc.

5.0

WELDING SOCKETS

5.1

Industrial type 63A, 3 ph, 4 pin and 32A. 1 ph, 3 pin (welding purpose) sockets shall
be provided in sufficient number to facilitate extension of power supply to various
machine tools, welding sets etc, in the areas covered under the scope of this
package.

5.2

Welding switch socket outlets shall be provided at every 60m distance. The number
of welding socket outlets for main technological plant units shall be decided based on
requirement, approach etc. Generally the socket outlets shall be provided in such a
manner so that using 30m flexible cable with welding set, total plant area can be
covered. Up to three switch socket outlets shall be looped per feeder circuit.

5.3

The welding switch socket outlets and switch units shall be fed from separate
distribution board.

5.4

3 ph, 63A industrial sockets shall be provided, as required for temporary application.
These shall be fed from separate DBs.

CARBERY INFRASTRUCTURE PTE LTD

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VOLUME -II
SECTION: C7.6
SHEET 5 OF 5

LOCAL CONTROL PANEL, DCDB & OTHERS

6.0

TESTING
The following testing shall be conducted on all equipments at works and necessary
test certificates shall be furnished.
a). IR ( Insulation resistance) test before and after HV test.
b). HV test with 2.5kV Meggar.

7.0

APPLICABLE STANDARDS

SL. NO.

DESCRIPTION

STANDARDS

Switchgear general requirements

IS 4237

Factory built assemblies of

switchgear and control gear for
voltages upto and including 1000V
AC & 1200V DC

IS 8623

Air break switches

Miniature circuit breakers

IS 8828

HRC cartridge fuses

IS 9224

Contactors

IS 2959

Control switches/push buttons

IS 6875

Current transformers

IS 2705

Voltage transformers

IS 3156

10

Relays

IS 3231

11

Indicating instruments

IS 1248

12

Arrangement for bus bars, main

connections and accessories

IS 375

13

Degree of Protection

IS 2147

14

Climate proofing of electrical

equipment

IS 3202

15

Code of practice for phosphating

iron & steel

IS 6005

16

Wrought aluminium and aluminium

alloys for electrical purposes

IS 5082

IS 13947 Part 1 & 2

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VOLUME - II
SECTION: C7.7
SHEET 1 OF 13

ELECTRICAL EQUIPMENT TESTING

WRITE UP

1.0

GENERAL

1.1

Test of all equipment will be conducted as per latest IS. Tests will also confirm
to International Standards IEC / VDE / DIN / BS.

1.2

Routine tests, acceptance tests, special tests and Type tests will be conducted
at works/factory as given in relevant chapters of Electrical Volume

1.3

The site tests and acceptance tests to be performed by contractor are detailed
below.

1.4

The contractor will be responsible for satisfactorily working of complete

integrated system and guaranteed performance.

2.0

SITE TESTS AND CHECKS

2.1

General

2.1.1

All the equipment will be tested at site to know their condition and to prove
suitability for required performance.

2.1.2

The test indicated in following pages will be conducted after installation. All
tools, accessories and required instruments will have to be arranged by
contractor. Any other test that is considered necessary by the manufacturer
of the equipment, Contractor or mentioned in commissioning manual has to
be conducted at site.

2.1.3

In addition to tests on individual equipment some tests / checks are to be

conducted / observed from overall system point of view. Such checks are
highlighted under miscellaneous tests but these will not be limited to as
indicated and will be finalised with consultation of client before charging of the
system.

2.1.4

The Contractor will be responsible for satisfactory working of complete

integrated system and guaranteed performance.

2.1.5

All checks and tests will be conducted in the presence of Clients

representative and test results will be submitted in six copies to Client and
one copy to Electrical Inspector. Test results will be filled in proper proforma.

2.1.6

After clearance from Electrical Inspector, system / equipment will be charged

in step by step method.

2.1.7

Based on the test results clear cut observation will be indicated by testing
engineer with regard to suitability for charging of the equipment or reasons for
not charging are to be brought by the Contractor.

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VOLUME - II
SECTION: C7.7
SHEET 2 OF 13

ELECTRICAL EQUIPMENT TESTING

WRITE UP

2.2
2.2.1

2.3
2.3.1

Trial Run Test

After the successful testing of each equipment as per standard test procedure,
the entire control system will be put on trial run test on actual site conditions
and operation of the system.
Acceptance Test
The acceptance test on the system will be carried out by the contractor as per
mutually agreed test procedures to establish satisfactorily functioning of the
system as a whole and each equipment as part of the system.
SITE TESTS
The tests to be carried out on the equipment at pre-commissioning stage will
include following but not limited to the following:

3.0

TRANSFORMER

3.1

IR test on each winding to ground and between winding.

3.2

Turns ratio test on each tap

3.3

Polarity and vector group test

3.4

Measurement of winding resistance for HV at all taps and also for LV winding.

3.5

IR, wiring and operational tests on all control devices in control cabinet, winding
temperature indicators, etc.

3.6

Checking of earthing wrt transformer tank (flexible from top cover to tank) other
parts, neutrals.

3.7

Check insulators for cracks.

3.8

Measurement of magnetising current and no load loss.

3.9

Measurement of PI value.

3.10

Conducting magnetic balance test

3.11

Testing of Buchholtz relay for alarm and trip conditions

3.12

Testing of Pressure Relief Valve for trip contacts

3.13

Checking of OTI/WTI temperature contacts for the settings and healthiness of

alarm & trip contacts

3.14

Checking for magnetic oil level gauge for the mercury contacts, Oil leakages
and arresting of oil leakages (if there)

3.15

Checking of operation of all valves and ensure their close / open positions.

3.16

Filtration of oil by using Oil filter m/c for improving IR value of Transformer or
improving Transformer Oil Value for water ppm, BDV if required only.

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VOLUME - II
SECTION: C7.7
SHEET 3 OF 13

ELECTRICAL EQUIPMENT TESTING

WRITE UP
3.17

BDV test on Oil samples from top & bottom

3.18

Checking of Oil for acidity, water content and tan delta as per IS 335.

3.19

Checking of other points given in manufacturers commissioning manuals.

3.1

Tan delta test for winding and bushing.

3.2

Resistivity test for oil.

4.0

CURRENT TRANSFORMER

4.1

IR test on each winding, winding to earth and between windings.

4.2

Checking of winding ratios by primary injection set

4.3

Polarity check on each winding

4.4

Continuity check for all windings

4.5

Check for connections to correct taps.

4.6

Testing of CT polarity and CT ratio by primary injection test and CT

characteristics

4.7

Measurement of knee point voltage and secondary winding resistance for the
CTs used for differential protection.

4.8

Checking of continuity and IR values for cables from CT to Marshalling Box.

4.9

Checking tightness of earthing connections.

4.10

Checking of insulator for cracks.

4.11

Check output after loading of the main circuit.

5.0

POTENTIAL TRANSFORMER

5.1

IR test of primary winding by HV megger between windings and earth.

5.2

IR test of secondary winding by LV megger between windings and winding to

earth.

5.3

Checking of voltage ratio.

5.5

Verification of terminal markings and polarity.

5.6

Checking of continuity and IR values for cables from PT to Marsh Box.

5.7

Checking tightness of earthing connections

5.8

Checking of insulator for cracks.

5.1

Check output on charging of the system with connected meters / relays

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Pradesh

VOLUME - II
SECTION: C7.7
SHEET 4 OF 13

ELECTRICAL EQUIPMENT TESTING

WRITE UP
6.0

HT/LT Busduct

6.1

IR measurement before and after HV test.

6.2

HV test.

6.3

Checking tightness of bolts with torque wrench.

6.4

Checking for phase sequence marking.

6.5

Check for clearances between phase to phase and phase to earth.

6.6

Check for minor damages and cracks in supporting insulators and bushings
after cleaning.

6.7

Checking for inspection openings and accessibility for replacement of insulator

etc.

6.8

Check tightness of earthing connections on enclosure.

6.9

Checking of silicagel breather (if there).

6.10

Checking of working of space heater.

6.11

Milli volt drop test

7.0

NGR

7.1

Measurement of resistance.

7.2

IR test by HV megger between terminal and earth.

7.3

Checking of earth connection for terminal and for body.

7.4

Check for isolator operation and continuity of aux. contacts (if applicable).

7.5

Check for temp. rise of enclosure and current flow in the resistances.

8.0

HT SWITCHGEAR

8.1

IR test.

8.2

HV one minute P.F test for busbar and CTs.

8.3

Measurement of contact resistance and timing for HT breakers and vacuum

contactors

8.4

Checking the healthiness of poles & Vacuum bottles

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Pradesh

VOLUME - II
SECTION: C7.7
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ELECTRICAL EQUIPMENT TESTING

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8.5

Test to prove inter changeability of similar parts (including breaker module).

8.6

Testing of relays as per suppliers commissioning manual.

8.7

Testing and calibration of all meters.

8.8

Operation of all relays by secondary injection.

8.9

Testing of CT polarities and CT ratio by primary injection test and CT

characteristics.

8.10

Measurement of knee point voltage and secondary resistance for CTs used for
differential protection.

8.11

IR and voltage ratio test for PTs.

8.12

Functional test of all circuit components for each panel / feeder.

8.13

Test to prove closing / tripping operation at minimum and maximum specified

voltage in test and service position and also measurement of time for above
operation.

9.0

LTSWITCHGEAR / PMCC/ MCC

9.1

IR test before and after HV test.

9.2

HV test with 2.5 kV megger

9.3

Functional test for all feeders

9.4

Testing and calibration of all meters.

9.5

Checking and calibration of overload relays and protective relays as per

supplier commissioning manuals.

9.6

Check operation of contactors from local and remote points.

9.7

Checking of interlockings between incomers / buscoupler and other feeders.

9.8

Test to prove interchangeability of similar parts.

9.9

Tests to prove correct operation of breakers at minimum and maximum

specified control voltages.

9.10

Checking operation of RC circuit (if there) for tripping of circuit breaker after
disappearance of control voltage.

9.11

Checking of earthing connection for neutral earth bus, cable armour location of
E/F CT etc., as per the scheme.

9.12

Check test, services and draw-out position of all the breakers and operations of
mechanical flag indicators and electrical indication lamps.

9.13

Check functioning of various electrical schemes like auto-changeover signalling

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3 X 660 MW Super Critical TPP at Lalitpur, Uttar
Pradesh

VOLUME - II
SECTION: C7.7
SHEET 6 OF 13

ELECTRICAL EQUIPMENT TESTING

WRITE UP
etc.
9.14

Contact pressure test.

9.15

Testing of CT as per CT testing details enclosed above

9.16

Breaker

10.0

ACDB / DCDB / MLDB etc

10.1

IR test before and after HT test.

10.2

HV test by HV megger.

10.3

Checking for functions of components for each module.

10.4

Checking for interchangeability of similar components.

10.5

Checking of tightness of earth connection.

10.6

Testing and calibration of all indicating meters.

10.7

Check output of each feeder after energisation.

11.0

AC MOTORS (INCLUDING SLIP RING MOTOR)

11.1

IR test of stator and rotor windings.

11.2

Heating of both windings up to the permissible temp. limit from heating curve
(only for HT motors).

11.3

Ensure that checking / testing of associated switchboard, cables, relays / meter

interlocking as mentioned in relevant chapters are completed.

11.4

Check tightness of cable connection.

11.5

Winding resistance measurement of stator and rotor.

11.6

Checking continuity of winding.

11.7

Check tightness of earth connections.

11.8

Check space heaters and carryout heating of winding (if required).

11.9

Check direction of rotation in decoupled condition during kick start.

11.10

Measure no load current for all phases.

11.11

Measurement of temperature of body during No-load and load conditions.

11.12

Check for tripping of motor from local / remote switches and from electrical /
technological protection including differential protection.

11.13

Checking of vibration (if required)

11.14

Checking of noise level (if required).

11.15

During load running, measurement of stator and bearing temperatures (if

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar
Pradesh

VOLUME - II
SECTION: C7.7
SHEET 7 OF 13

ELECTRICAL EQUIPMENT TESTING

WRITE UP
applicable) for every half an hour interval till saturation comes.
11.16

Checking tightness of foundation bolts.

11.17

Check operation of speed switch (if there).

11.18

Check continuity of temp. detectors.

11.19

Check alignment, paralleling of shafts, level of lubricating oil etc. as per

manufacturers manual.

11.20

Check contact of slip ring brush and measure brush pressure (150-200
gm/sq.cm).

11.21

For CACW drive check cooling water and system / piping, availability of
pressure cleaning and pressure testing of pipelines etc.

11.22

Check for polarisation index of stator windings R10 / R1 by motorised megger.

(The value should not be less than 2.0). R60/R10 absorbtion co-efficient will
not be less than 1.5

11.23

Dielectric test (only for HT motors).

11.24

Measurement of open circuit rotor winding voltage for slip ring motor.

11.25

For actuator drives following will be checked / tested.

a)

Visual and dimensional

b)

Hydraulic pressure for valves

c)

IR and operation of limit switches

d)

Winding resistance

12.0

MOTORS(DC)

12.1

IR measurement and heating the winding as per heating curve.

12.2

Check for earth connection.

12.3

Winding resistance for field and armature.

12.4

Check running of drive at minimum and maximum specified voltage.

12.5

Check auto start of drive on failure of AC supply (if applicable).

12.6

Check operation of overload relay.

12.7

Measure vibration.

12.8

Check temperature rise on body of drive after required period of continuous

running.

12.9

Measure load currents and no load currents (if possible).

12.10

Check direction of rotation.

12.11

Check continuity of winding.

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar
Pradesh

VOLUME - II
SECTION: C7.7
SHEET 8 OF 13

ELECTRICAL EQUIPMENT TESTING

WRITE UP
12.12

Measurement of RPM.

13.0

BATTERY

13.1

Checking for completion of civil / ventilation requirement of battery room.

13.2

Checking of adequacy of charger output / requirement wrt current required for

battery charging as per the manual.

13.3

Check availability of safety devices, water and first aid box.

13.4

Check polarity of connections between battery and charger.

13.5

Visual inspection test for level and leakages.

13.6

Checking of layout as per approval drawing.

13.7

Checking of IR value from positive to earth and negative to earth.

13.8

Checking of voltage per cell and total voltage between positive negative and
earth to positive / negative and also tap cell voltage (as applicable)

13.9

Checking of tightness of connectors on each cell.

13.10

Checking of capacity test and hourly measurement of specific gravity and

voltage for each cell.

14.0

BATTERY CHARGER

14.1

IR test

14.2

HV test

14.3

Checking voltage ratio of boost and float mode transformers.

14.4

Checking for charging mode of batteries constant current and constant voltage
mode.

14.5

Load test on chargers by running of DC drives and by liquid resistance system.

14.6

Checking of tightness of earthing connections.

14.7

Check for all alarm conditions.

12.8

Checking and calibration of all indicating meters.

14.9

Check functional operation of charger, auto / manual change over from float to
boost and boost to float etc.

14.10

Checking and setting of all relays.

14.11

Check AC ripple in boost and float mode after charging.

14.12

Check polarity of cables connected to battery.

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar
Pradesh

VOLUME - II
SECTION: C7.7
SHEET 9 OF 13

ELECTRICAL EQUIPMENT TESTING

WRITE UP
15.0

CABLES & CABLE SUPPORTING STRUCTURES

15.1

Checking of continuity / phasing and IR values for all the cables before and after
HV test.

15.2

HV test and measurement of leakage current after termination of cable kits (for
HT cables).

15.3

Checking of earth continuity for armour.

15.4

Check for mechanical protection of cables.

15.5

Check for identification (tag number system) distance placement of cable

marker, cable joint etc. as per the cable layout drawing.

15.6

Check earthing of cable structures.

15.7

Check safe head room in gallery area.

15.8

Check clearance from ventilation duct and light fittings for cable structures.

15.9

Check proper fixing of cable structures.

15.10

Check for proper drainage and removal of water (if any).

16.0

INDOOR LIGHTING

16.1

Check dressing of cable.

16.2

Measurement of lux level at various places.

16.3

Check accessibility for replacement of lamps.

16.4

Checking for black spots or poor visibility near operating and indicating
equipments.

16.5

Check for mechanical protection of cables.

16.6

Checking for adequacy of emergency DC light.

16.7

Checking for starting system of periphery lighting.

16.8

Check for auto switching of DC supply on failure of AC.

16.9

Checking of earthing of light panel, socket boards light fittings.

16.10

Checking of type of fittings wrt specification at various locations.

16.11

Check adequacy of support of fittings.

16.12

Check water tightness of outdoor located panels.

17.0

OUTDOOR LIGHTING SYSTEM

17.1

Check lux level of general lighting.

17.2

Check for visibility of insulators, bushings and indicating instruments of

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3 X 660 MW Super Critical TPP at Lalitpur, Uttar
Pradesh

VOLUME - II
SECTION: C7.7
SHEET 10 OF 13

ELECTRICAL EQUIPMENT TESTING

WRITE UP
transformers, breaker and isolator cabinets etc. during night.
17.3

Check for adequacy of escape light during night after failure of general light.

17.4

Check for proper painting of lighting supporting structures.

17.5

Check for automatic switching of light

17.6

Check for earthing connections on light fittings and other control accessories.

17.7

Check for mechanical protection of cables.

17.8

IR measurement of lighting cables.

18.0

EARTHING

18.1

Check tightness of all earth connections.

18.2

Check earthing of all metallic equipments, cable trays, busbar supporting

structures, building column (if steel all elect equipments, pipe lines etc. as per
the drawing / specification)

18.3

Measurement of earth resistance for each electrode.

18.4

Measurement of total earth resistance.

18.5

Measurement of earth loop resistance for E/F path of biggest LT drive.

19.0

LIGHTNING PROTECTION

19.1

Check continuity of all the earth strips / shield wire.

19.2

Check tightness of all connections.

19.3

Measure earth resistance of each electrode and combined system.

20.0

CONTROL RELAY & METERING PANELS

20.1

IR value test by megger.

20.2

Checking of control cable connection.

20.3

Operational test of all components mounted on control panel.

20.4

Testing and calibration of indicating meters.

20.5

Testing of all relays including aux. relays for their pick up drop up values,
operation at all tap (current, voltage and time) etc. as per the manufacturers
commissioning manuals with the help of relay testing kits.

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar
Pradesh

VOLUME - II
SECTION: C7.7
SHEET 11 OF 13

ELECTRICAL EQUIPMENT TESTING

WRITE UP
20.6

Setting of relays as per approved setting table and checking its operation for
one below and one upper settings, in the scheme.

20.7

Measurement of current and voltage in relay operating coils by secondary

injection in CT and PT circuit at switchboard.

20.8

Measurement of current and voltage in relay and meter circuits during loading of
the primary circuit / system.

20.9

Testing of all schemes for their functions as per approved drawings.

20.10

Checking stability of differential protection schemes.

20.20

Checking inter changeability of similar equipments.

20.12

Verification of accessibility of all operating points including resetting knob of

relays.

20.13

Check operation of each annunciation facia, operation of bell / hooter etc. and
sequence of the system.

20.14

Check operation of relays at minimum / maximum control voltage as per the

specification.

20.15

Integrated testing of protective relays for operation of master trip relays and
tripping of breakers from operation of master trip relay.

20.16

Check dressing of cables sealing of openings in gland plate and for provision of
double compression glands.

20.17

Check earthing connection of panels, fixing of panels and openings from side
and bottom.

20.18

Testing of energy / TVM meters and operation of recorders.

20.19

Test working of recorders on failure of AC supply (if applicable).

20.20

Checking and adjustment in trivector meters as per the manufacturers

instructions.

20.21

Checking for operation of all limit switches.

21.0

Variable Speed Drive

21.1

IR Test before and after HV test

21.2

HV test with 2.5 KV megger

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Pradesh

VOLUME - II
SECTION: C7.7
SHEET 12 OF 13

ELECTRICAL EQUIPMENT TESTING

WRITE UP
21.3

Functional test for all feeders

21.4

Testing and calibration of all meters

21.5
21.6

Checking and calibration of overload relays and protective relays as per

manufacturers commissioning manuals.
Check operation of drives from local and remote points.

21.7

Physical checking of all components and wiring.

21.8

Checking of earthing connection for neutral earth bus, cable armour location of
E/F CT etc as per the scheme.

21.9
21.10

Check functioning of various electrical scheme like auto changeover, signaling

etc.
Testing of CT as per CT testing details

22.0

MISCELLANEOUS

22.1

Checking of continuity of the system.

22.2

Checking of phase sequence from overhead line consumer end.

22.3

Checking safe accessibility of all operating points

22.4

Check availability of emergency lighting

22.5

Check availability of control aux. supply.

22.6

Ensure availability of first aid box, fire fighting equipments, earth discharge rods,
rubber mats, rubber glove.

22.7

Check oil drainage system for transformer oil

22.8

Check filling of gravels in transformer pits.

22.9

Check for safe movement of operators control room / switchgear etc., wrt proper
illumination, escape light uncovered openings provision of hand railings in
stairs etc.

22.10

Check proper covering of cable channels.

22.11

Placement of shock treatment chart, danger boards provision of boards

indicating Man on work Do not switch ON Do not switch OFF. EARTHED
etc.

22.12

Provision of route map at gallery entry points for indication of escape.

22.13

Check proper dressing of cables, mechanical protection of cables, placement of

cable markers.

CARBERY INFRASTRUCTURE PTE LTD

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Pradesh

VOLUME - II
SECTION: C7.7
SHEET 13 OF 13

ELECTRICAL EQUIPMENT TESTING

WRITE UP
22.14
22.15

Check sealing of all cable openings including conduits opening with fire
resistance material.
Check sealing of all openings at bottom of electrical panels.

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar
Pradesh

VOLUME - II
SECTION: C7.8
SHEET 1 OF 6

ELECTRICAL EQUIPMENT INSTALLATION

WORK
1.0

GUIDELINES FOR INSTALLATION OF ELECTRICAL EQUIPMENT

1.1

All electrical equipment will be installed in a neat, professional manner so

that it is level, plumb, squat and properly aligned and oriented. Tolerances
will be as established in the Manufacturers drawings. Clearances around
Electrical panels, switchgears will be as per relevant standards.

1.2

This Specification shall be read in conjunction with other sections, GA &

SLD Drawing and other bid drawings enclosed in Volume-II.

1.3

The BIDDER will ensure that instruments and gauges to be used for testing
and inspection have valid calibration and the accuracy can be traced to
National Standards.

1.4

It will be the BIDDERS responsibility to obtain approval from local statutory

authorities including Electrical Inspector/CEA, wherever applicable, for
carrying out any work or for installation carried out which comes under the
purview of such authorities.

1.5

It is the responsibility of the BIDDER to provide watch & ward and security
for the equipment / component parts covered in this contract.

1.6

In order to avoid hazards to personnel moving around the equipment such

as switchgear etc. which is kept charged after installation, before
commissioning, such equipment will be suitably cordoned off to prevent
anyone accidentally going near it.

1.7

The BIDDER will carry out touch-up painting on any equipment, if the finish
paint on the equipment is soiled or marred during installation/handling.

1.8

The BIDDER will ensure workmanship of good quality and will assign
qualified supervisors/engineers and competent labours who are skilled
having valid licence/authorisation/work permit, careful and experienced in
carrying out similar works. The Purchaser will reserve the right to reject
non-competent person employed by the BIDDER, if the workmanship is not
found satisfactory. Wherever required the BIDDER will include loaning of
skilled/unskilled personnel for work by OWNER/Purchaser/ other agencies,
on Man-hour/Manday rates, for normal & overtime work to meet the project
schedule.

1.9

It will be the responsibility of the BIDDER to obtain necessary Licence/

Authorisation/permit for work for his personnel from the Licensing Board of
the locality/state where the work is to be carried out. The persons deputed
by the BIDDERs firm should also hold valid permits issued or recognised
by the Licensing Board of the locality/state where the work is to be carried
out.

CARBERY INFRASTRUCTURE PTE LTD

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VOLUME - II
SECTION: C7.8
SHEET 2 OF 6

ELECTRICAL EQUIPMENT INSTALLATION

WORK

2.0

INSTALLATION WORK SCOPE

2.1

Temporary Lighting Arrangement for The Work Area

The BIDDER will on his own arrange for the temporary lighting arrangement
for the work area to carry out the installation work in the plant premises.

2.2

Construction Power
Construction power including power for testing and temporary lighting will
be made available at one point. The suitable number of outlets to cater to all
the requirements will be provided by the BIDDER.

3.0

EQUIPMENT INSTALLATION

3.1

SWITCHGEARS, MCCs, PCCs, PDBs, CONTROL & RELAY

PANELS

3.1.1

All the AC/DC Switchgears, PMCCs, ACDBs, lighting distribution boards

etc. will be installed in accordance with specified Code of Practice, drawings
furnished and the MANUFACTURERs instructions. The switchgear/panels
will be installed on finished surfaces or concrete or steel sills. These panels
may be bolted on to the foundation pockets or welded to base frame
members as detailed in the drawings furnished by the BIDDER. The
BIDDER will be required to install and align any channel sills, which form
part of the foundations. Proper aligning, joining of various vertical shipping
sections, Busbar connections, inter panel wiring etc. will be the
responsibility of the BIDDER. In joining shipping sections of the switchgear /
panels / control centres together, adjacent housing or panel sections
provided will be bolted together after alignment has been completed. Power
bus enclosures, ground and control splices of conventional nature will be
cleaned and bolted together, being drawn up with torque wrench of proper
size or by other approved means.

3.1.2

The BIDDER will take utmost care in handling instruments, relays and other
delicate mechanisms. The blocking materials / mechanism employed for the
safe transit of the instruments and relays will be removed after ensuring that
the panels/desks have been completely installed and no further movement
of the same would be necessary.

3.2

MOTORS

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ELECTRICAL EQUIPMENT INSTALLATION

WORK
3.2.1

The installation, commissioning of the motors will be as per the applicable

code of practice and the Manufacturers instructions.

3.3

BATTERY AND CHARGERS

3.3.1

Each cell of the battery bank will be inspected for breakage and condition of
cover seals as soon as received at site. Each cell will be filled with
electrolyte in accordance with the Manufacturers instructions. Battery will
be set up on racks as soon as possible after receipt, utilising lifting devices
supplied by the MANUFACTURER. The cells will not be lifted by the
terminals.

4.0

EARTHING & LIGHTNING PROTECTION SYSTEM INSTALLATION

WORK

4.1

The installation work will include unloading at site, storing, laying, fixing,
jointing / termination, testing and commissioning of equipment associated
with the safety earthing system of the plant and lightning protection system
for buildings and allied structures. All welding / brazing equipment,
necessary tools and testing equipment will be furnished by the BIDDER.

4.2

The BIDDER will be responsible if any installation materials are lost or

damaged during installation. All damage and thefts will be made good by
the BIDDER till the installation is handed over to the OWNER.

4.3

The earthing of cable supporting structure, cable carriers, cable trays will be
in the scope of the BIDDER.

4.4

The BIDDER will carry out the lightning protection and earthing of all
equipment / panels / structures as indicated in the Project drawings.
Whether specifically shown in drawings or not, building columns, handrails,
miscellaneous items such as junction / marshalling boxes, field switches,
cable boxes, etc. will be earthed.

4.5

The BIDDER will install bare / insulated, copper / aluminium / steel

conductors, braids etc. required for the system and individual equipment
earthing. All work such as cutting, bending, supporting, painting/coating,
drilling, brazing /soldering/welding, clamping, bolting and connecting on to
structures, equipment frames, terminals, rails or other devices will be in the
BIDDERs scope of work. All incidental hardware and consumables such as
fixing cleats/clamps, anchor fasteners, lugs, bolts, nuts, washers, bitumastic
compound, welding rods, anti corrosive paint as required for the complete
work will be deemed to be included by the BIDDER as part of the
installation work.

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VOLUME - II
SECTION: C7.8
SHEET 4 OF 6

ELECTRICAL EQUIPMENT INSTALLATION

WORK
4.6

If the tap connections (earthing leads) from the floor embedded main
earthing grid to the equipment are more than 500 mm long then the same
will be embedded in floor by the BIDDER where required, together with
associated civil work such as excavation, concreting and surface finish. The
concrete cover over the conductor will not be less than 50 mm.

4.7

The scope of installation of earth connection leads to equipment and risers

on steel structures/walls will include laying the conductors, welding/cleating
at specified intervals, welding/brazing to the main earth grids, risers, bolting
at equipment terminals and coating welded/brazed joints by bitumastic
paint. Galvanised conductors will be touched up with zinc rich paint where
holes are drilled at site for bolting to equipment/structure.

4.8

The scope of installation of the test links will include mounting of the same
at specified height on wall/column by suitable brackets and connections of
the test link to the earth electrode.

4.9

Wherever main earthing conductor crosses cable trenches, they will be

buried below the trench floor.

4.10

Earth leads between earthing riser and equipment earthing terminals will
follow as direct and as short a path as possible.

4.11

Neutral connection will never be used for the equipment earthing.

4.12

Each neutral point of a transformer will be connected to two separate

treated type earth electrodes.

4.13

Track rails will be bonded with the rail boards and connected to the earthing
system. Adjacent railway tracks will be bonded across fish plates.

4.14

Wherever earthing conductor passes through walls, galvanised iron sleeves

will be provided for the passage of earthing conductor. The pipe ends will
be sealed using suitable waterproof compound.

4.15

All connections in the main earth conductors in earth/concrete and

connection between main earthing conductor and earth leads will be of
welded/brazed type. Cad welding type connections will be done only if
specifically indicated.

4.16

Connection between earth leads and earthing terminal provided on the

equipment will be bolted type.

4.17

All joints will be made such that contact resistance is negligible.

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VOLUME - II
SECTION: C7.8
SHEET 5 OF 6

ELECTRICAL EQUIPMENT INSTALLATION

WORK
4.18

All bimetallic connections will be treated with suitable compound to prevent

moisture ingression.

4.19

Metallic conduits and pipes will be connected to the earthing system.

4.20

Lightning protection system down conductors will not be connected to any

earthing conductors above ground level. Also no intermediate earthing
connection will be made from support structure of lightning arrestor.

4.21

Transformer & generator earthing will be directly connected to the earth

electrode.

4.22

Electrodes will as far as practicable, be embedded below permanent

moisture level.

4.23

Wherever required, test pits with concrete covers, for periodic testing of
earth resistivity, will be provided. Installation of rod / pipe / plate electrodes
in test pits will be suitable for watering. All the necessary materials required
for test pits will be supplied and installed by BIDDER. The installation work
will also include connection to main earth grid and civil work such as
excavation.

5.0

TESTING AND COMMISSIONING

5.1

All checks and tests as per the Manufacturers drawings/manuals, relevant

code of installation and commissioning check lists for various electrical
equipment e.g. Transformers, breakers, motors, switchgear, relays, meters
etc. will be carried out.

5.2

All testing equipments required for site will be brought by the BIDDER. Valid
calibration certificates for the testing equipments will be produced.

5.3

The BIDDER will perform operating tests on all switchgear and panels to
verify operation of switchgear/panels and correctness of the
interconnections between various items of the equipment. This will be done
by applying normal AC or DC voltage to the circuits and operating the
equipment for functional checking of all control circuits, e.g., closing,
tripping, control interlock, supervision and alarm circuits. All connections in
the switchgear will be tested from point to point for possible grounds or
short circuit.

5.4

The BIDDER will ensure the continuity of all conductors and joints. The
Purchaser may ask for earth continuity tests, earth resistance
measurements and other tests which in his opinion are necessary to prove
that the system is in accordance with the design, specifications, code of

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar
Pradesh

VOLUME - II
SECTION: C7.8
SHEET 6 OF 6

ELECTRICAL EQUIPMENT INSTALLATION

WORK
practice and Electricity Rules. The BIDDER will bear the cost of all such
tests.
5.5

Insulation resistance tests will be carried out by following rating meggers:

(a)

Control circuits upto 220V

by 500 V megger

(b)

Power circuits, bus bars,

connections up to 11kV

by 1000V megger

Power circuits, bus bars,

connections above 11 kV

by 5000 V motor
operated megger

(c)

6.0

The applicable standards for installation and testing of equipment are

indicated in the table below:
1.

Installation and Maintenance of Transformers

IS:10028

2.

Installation and Maintenance of Switchgear

IS:10118

3.

Installation and Maintenance of Induction Motors

IS:900

4.

Guide for safety procedures and Practices in Electrical

work

IS:5216

5.

Hot dip galvanising

IS:2629

6.

Electrical wiring installations for voltages > 650V

IS:732

7.

Fire safety of buildings (General) Electrical

Installations

IS:1646

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar
Pradesh

VOLUME-II
SECTION: C7.9
SHEET 1 OF 6

LIST OF CODES & STANDARDS

ELECTRICAL

SL. NO.

APPLICABLE STANDARDS

IS

1.

Oil Type- Auxiliary Transformer

2.

Dry type distribution transformer

3.

Numerical relays

4.

Bushing for > 1000V, AC

2099

5.

Bushing for < 1000V, AC

7421

6.

Neutral earthing transformer

3151

7.

LV Switchgear and control panel

13947

8.

Degree of protection for LV Switchgear

2147

9.

13947

12.

Factory built assemblies of low voltage

switchgear and control gear
Specification for metal clad base
materials for printed circuits for use in
electronic and telecommunication
equipment
Electrical insulation classified by thermal
stability
Metal enclosed switchgear

13.

Circuit breakers

14.

Switches and switch isolators above

1000V and up to 11 kV
(Off-Load) isolators

10.

11.

15.

BS

2026/ /
11171
2026 /
11171

IEC

ANSI /
IEEE

60076 /
60726
C75.12.01
IEC 61850
223

60137

171 /
BSEN
60076
7354

60076

60144 /
60947
60439

5921

1271

2757

60085

3427

162

60298

13118

116 / 3659
/ 5311

60056
60265

3078 /
3189
158

60129 /
60156

159

60105

16.

Arrangement for switchgear busbars,

main connection and auxiliary wiring

5578 /
11353

17.

Bus bars (Aluminium)

18.

Bus bar (Copper)

5082 /
2678
282

125 / 1977

19.

Bus bar support insulators

2544

3297

60273

20.

Current transformers

2705

3938

60185

21.

Potential transformers

3156

3491

60186

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar
Pradesh

VOLUME-II
SECTION: C7.9
SHEET 2 OF 6

LIST OF CODES & STANDARDS

ELECTRICAL

SL. NO.

APPLICABLE STANDARDS

IS

BS

IEC

60051
60255

22.

AC Electricity meters

722

23.

Electrical indicating instruments

1248

2692
5685
89

24.

Electrical relays for power system

protection

3231

142

25.

High voltage fuses

9385

26.

HRC Fuses

9224

27.

H.V. Cable Termination

28.

Environmental requirements of
semiconductor devices and integrated
circuits
Factory built assemblies of switchgear
and control gear for voltages up to and
including 1000V AC and 1200V DC

6553

8623

60947

30.

Miniature circuit breakers

8828

3871

31.

HRC cartridge fuse

13703

88

32.

D-Type fuses

8187

33.

Control switches / push buttons

6875

34.

Starters

13947

35.

8084

37.

Interconnecting bus bars for AC voltage

above 1 kV up to and including 36 kV
Code of practice for selection, installation
and maintenance of switchgear and
control gear.
Semiconductor converters

38.

Semiconductor rectifier cells and stacks

39.

Electrical installation and wiring

installation

40.

Environmental testing procedure for

electronic and electrical items

9000

41.

Safety code for semiconductors rectifier

equipment

6619

29.

36.

60018

EN60947-4

60439

60292

10118

60146
3895 /
4540
732

4417

60146

ANSI /
IEEE

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar
Pradesh

VOLUME-II
SECTION: C7.9
SHEET 3 OF 6

LIST OF CODES & STANDARDS

ELECTRICAL

SL. NO.

APPLICABLE STANDARDS

42.

Printed wiring boards

43.

Single and double sided PCB with plain

holes Electromagnetic compatibility
Semiconductor rectifier assemblies and
Thyristor converters
Three phase induction motors

44.
45.
46.
47.
48.
49.
50.
51.
52.
53.

54.
55.
56.
57.

58.
59.

60.
61.

IS

BS

IEC

4417

61000
1995
60148

4999

60034-1

7405

325

Specifications for rotating electrical

machines rating & performance
Specification for turbine type generators

4722

60034-1

5422

60034-3

Methods of determination of efficiency for

rotating electrical machines
Methods for determining synchronous
machine quantities from tests
Single phase small AC and universal
electric motors
Three phase induction motors with type
of protection n
Construction and testing of electrical
apparatus with type of protection e
Designations for types of construction
and mounting arrangement of rotating
electrical machines
Terminal marking and direction of
rotation for rotating electrical machinery
Designation of methods of cooling for
rotation electrical machines
Measurement and evaluation of vibration
of rotating electrical machines
Degrees of protection provided by
enclosure for rotating electrical
machinery
Guide for testing three phase induction
motors
Measurement and evaluation of
Mechanical vibration of rotating electrical
machines
Classification of hazardous areas

4889

60034-2

7306

60034-4

Guide for selection of electrical

equipment in hazardous area

996
9628
6381
2253

60034-7

4728

4999

60034-8

6362

4999

60034-6

4999-142

60034-9

4999

60034-5

4691

4029
12075

5572
5571

60034-34
4999

60034-14

60079

ANSI /
IEEE

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar
Pradesh

VOLUME-II
SECTION: C7.9
SHEET 4 OF 6

LIST OF CODES & STANDARDS

ELECTRICAL

SL. NO.
62.
63.
64.
65.
66.
67.

68.
69.
70.

APPLICABLE STANDARDS

IS

BS

Dimensions of slide rails for electric

motors
Permissible limits of noise level for
rotating electrical machines
Guide for testing insulation resistance of
rotating machines
Procedure for measurement of loss of
tangent angle for coils & bars
Code of Practice Climate Proofing

2968

4999

Degree of protection provided by

enclosure for rotating electrical
machinery
General requirement for electrical
apparatus for explosive gas atmospheres
Impulse voltage withstand test

12065

60034

7816
13508
3202
4691

4999-150

60034-15
12802

Energy efficient three-phase squirrel

cage induction motors
Brass glands for PVC cables

12615

2148

4683

8309

4683

81.

Flame-proof enclosures of electrical

apparatus
Compression type tubular terminal ends
for aluminium conductors of insulated
cables
Code of practice for safety earthing

3043

1013

82.

Rigid conduits

9537

72.
73.
74.
75.

76.
77.
78.
79.
80.

60034-3

13346

Temperature rise measurement of

rotating electrical machines
Type of duty and classes of rating
assigned to rotating electrical machines
Dimensions of flange mounted A.C.
induction motors
Dimensions of three-phase foot mounted
induction motors
Values of performance characteristics for
three-phase induction motors
Dimensions and output ratings for foot
mounted rotating electrical machines
with frame number 355 to 1000
Flameproof ac motors for use in mines

71.

IEC

12824
2223
1231
8789
8223

3682

12943

ANSI /
IEEE

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar
Pradesh

VOLUME-II
SECTION: C7.9
SHEET 5 OF 6

LIST OF CODES & STANDARDS

ELECTRICAL

SL. NO.
83.

APPLICABLE STANDARDS

IS

BS

IEC

BSEN60099

60099

Accessories for rigid steel conduits for

electrical wiring
Fittings for rigid steel conduits for
electrical wiring
Fittings for rigid non-metallic conduits

3837

3480

88.

Flexible steel conduits for electrical

wiring
Flexible non-metallic conduits for
electrical installation
Adaptors for flexible steel conduits

89.

Plugs and socket outlets

1293

90.

Lightning arrester

3070

91.

Code of practice for selection, Installation

and maintenance of transformers

10028

92.

Code of practice for Installation and

maintenance of induction motors

900

93.

2309

94.

Protection of buildings and allied

structures against lightning
Cables

95.

Emergency Standard Power Systems

96.

Stationary cells and batteries - Lead acid

type - With Plante positive plate

1652

6290-2

97.

Quality tolerances for water for storage

battery
Sulphuric acid

1069

4974

266

3031

Rubber and plastic containers for lead

acid storage battery
Sealing compound for lead acid batteries

1146

Synthetic separators for lead acid

batteries
General requirements and methods of
test for lead acid storage batteries

6071

84.
85.
86.
87.

98.
99.
100.
101.
102.

ANSI /
IEEE

2667
3419

6946
4649

6651
60189

10810/
1554 /
7098

IEEE 446

3116

8320

60896

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar
Pradesh

VOLUME-II
SECTION: C7.9
SHEET 6 OF 6

LIST OF CODES & STANDARDS

ELECTRICAL

SL. NO.
103.

APPLICABLE STANDARDS

IS

BS

IEC

ANSI /
IEEE
IEEE 485

104.

Recommended practice for sizing large

lead acid storage batteries for generating
stations and sub-stations
Containers and Vent Plugs

105.

Battery enclosures

UL 1778

106.

IEEE recommended practice for sizing

Ni-Cad batteries for stationary
applications
Climate proofing

IEEE 115

107.
108.
109.
110.
111.
112.

6005

Installation and Maintenance of

Transformers
Installation and Maintenance of
Switchgears
Code and practice for installation,
operation and maintenance of Electric
passenger and goods lifts

10028

Harmonic limits in power systems

114.

Guide for safety procedures and

practices in Electrical work
Indian Electricity Act

116.
117.
118.
119.

CP:1014

Code of practice for phosphate coatings

of iron and Steel
Flame proof cable glands

113.

115.

UL 924

Indian Electricity Act 1910, (As

amended)
Electricity Supply Act, 1948, (As
amended)
Indian Electricity Rules, 1956 (As
amended)
Indian Electricity Act 2003

3189

4821

10118
14665

IEEE-519
5216

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

VOLUME -II
SECTION: C7.10
SHEET 1 OF 10

APPROVED SUB VENDOR LIST

&
INSPECTION REQUIREMENTS

This section gives equipment wise list of approved sub-vendors and the inspection
requirements for quality control.
DEFINITION : QP / INSPECTION CATEGORY
CAT-I:

For these items the Quality Plans are approved by Purchaser and the
final acceptance will be on physical inspection witness by Purchaser .

CAT-II:

For these items the Quality Plans approved by Purchaser. However no

physical inspection shall be done by Purchaser. The final acceptance
by OWNER shall be on the basis review of documents as per approved
QP.

CAT-III:

For these items Main Supplier approves the Quality Plans. The final
acceptance by Purchase shall be on the basis certificate of
conformance by the main supplier.

SL. NO.

TITLE

1.

LT SWITCHGEARS (PCC,
MCC, PMCC, ACDB, DCDB
&)

2.

3.

SERVICE/ AUXILIARY
TRANSFORMER

LDB / MLDB/ SLDB/ LOCAL

DCDB/ LIGHTING PANEL/
LOCAL STARTER PANEL/
JBS

NAME OF SUB VENDORS

SIEMENS KALWA
L&T
AHMEDNAGAR/COIMBATO
RE
SCHNEIDER NASIK
ABB
AREVA
VOLTAMP
EMCO TRANSFORMERS
BHARAT BIJLEE LTD.
KIRLOSKAR
L&T
SIEMENS
ABB
SCHNEIDER
GE
VENUS
ADVANCE
ADLEC

QP / INSPN.
CATEGORY

CAT-I

CAT-I

CAT-II

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

VOLUME -II
SECTION: C7.10
SHEET 2 OF 10

APPROVED SUB VENDOR LIST

&
INSPECTION REQUIREMENTS

TRICOLITE

4.

5.

6.

7.

8.

9.

NON SEGREGATED
PHASE BUSDUCT/
SEGRIGATED PHASE
BUSDUCT

BATTERY

HT MOTORS

LT MOTORS

NUMERICAL RELAYS**

DATA-CONCENTRATORS,
GATEWAYS, ETHERNET
SWITCHES **

CONTROL & SWITCHGEAR

CO. LTD.
BHARAT HEAVY
ELECTRICALS LIMITED
L&T
REEP INDUSTRIES PVT
LTD.
POWERGEAR LTD.
STAR DRIVE,CHENNAI
ENPRO
AMCO
HBL NIFE
AMARA RAJA
EXIDE
HOPPECHEKE
BHEL
CGL
MARATHON ELECTRIC
MOTORS
ABB
KIRLOSKAR
SIEMENS
BHARAT BIJLEE
ABB
CGL
SIEMENS
KIRLOSKAR
AREVA
ABB
SIEMENS
GARRETTCOM
RUGGEDCOM

CAT-I

CAT-I

CAT-I

CAT-I

CAT-I

CAT-I

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

VOLUME -II
SECTION: C7.10
SHEET 3 OF 10

APPROVED SUB VENDOR LIST

&
INSPECTION REQUIREMENTS

10.

11.

12.

13.

14.

15.

OVER LOAD RELAY &

OTHER RELAYS

AUX RELAY

LT POWER CABLES

CONTROL CABLES

HT POWER CABLES

CABLE TRAYS AND

ACCESSORIES

L&T
AREVA
ABB
SIEMENS
GE
AREVA
ABB
SIEMENS
RPG
CCI
UNIVERSAL
NICCO
FINOLEX
RADIANT
DELTON CABLES
POLYCAB
KEI INDUSTRIES LTD.
POLYCAB
CCI
RPG CABLES
NICCO CORP.LTD.
UNIVERSAL
FINOLEX
TORRENT
KEI INDUSTRIES LTD.
CABLE CORPORATION OF
INDIA LTD.
FORT GLOSTER
INDUSTRIES LTD.
RPG CABLES LTD.
UNIVERSAL CABLES LTD
NICCO CORPORATION LTD.
POLYCAB
INDIANA
RELIANCE
PATNI
SADHNA
STERLITE

CAT-III

CAT-III

CAT-I

CAT-I

CAT-I

CAT-II

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

VOLUME -II
SECTION: C7.10
SHEET 4 OF 10

APPROVED SUB VENDOR LIST

&
INSPECTION REQUIREMENTS

16.

17.

18.

19.

20.

21.

22.

MULTI FUNCTION
DIGITAL METER**

ACB

MCCB / MPCB

MCB

PUSH BUTTONS

SELECTOR SWITCHES &

CONTROL SWITCHES

CTs / PTs (LT)

ENERCON
ABB
SIEMENS
SEMS
L&T
SATEC
SIEMENS- 3 WL
L&T -U Power
ABB -SACE
SCHNIDER -Master peck
GE
L&T- Dsine
SIEMENS -3VL
ABB- SACE
SCHNEIDER
GE
SCHNEIDER
ABB
LEGRAND
MDS
SIEMENS
SIEMENS
L&T
SCHNEIDER
BCH
VAISHNO
TECHNIC
KAYCEE
SIEMENS
ALSTOM
L&T
SWITRON
KAPPA
PRAGATI
PROYOG
ABB

CAT-II

CAT-II

CAT-II

CAT-III

CAT-III

CAT-III

CAT-II

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

VOLUME -II
SECTION: C7.10
SHEET 5 OF 10

APPROVED SUB VENDOR LIST

&
INSPECTION REQUIREMENTS

23.

TERMINAL BLOCKS

24.

LIGHTING SYSTEM

25.

LIGHT FITTING
(GENERAL)

26.

27.

LIGHT FITTING (FLAME

PROOF)

LOCAL PUSH BUTTON

STATIONS

28.

TRANSDUCER

29.

BATTERY CHARGER

PHOENIX
WAGO
CAT-III
ELMEX
CONNECTWELL
GE LIGHTING.
BAJAJ ELECTRICALS LTD.
PHILIPS LIGHTING.
CAT-II
CROMPTON GREAVES LTD.
HAVELLS INDIA LTD.
GE
PHILIPS
BAJAJ
CROMPTON
WIPRO
HAVELLS

CAT-II

GE
BAJAJ
CROMPTON
FLEXPRO
PHILIPS

CAT-II

SIEMENS
L&T
BALIGA
BCH
TEKNIK
VAISHNO
ALSTOM
TM
CEAG
FCG
SOUDAN ELECTRICAL
ABB
AMAR RAJA
CHHABI
HBL-Nife
CALDYNE

CAT-I

CAT-II

CAT-I

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

VOLUME -II
SECTION: C7.10
SHEET 6 OF 10

APPROVED SUB VENDOR LIST

&
INSPECTION REQUIREMENTS

30.

31.

32.

33.

34.

35.

36.

37.

38.

39.

SFU

HRC FUSE

CONTROL
TRANSFORMER

SIEMENS
L&T
ABB
SCHNEIDER

CAT-III

SIEMENS
L&T
GE

CAT-III

ECS
G&M
SILCHAR

CAT-II

CONTACTOR

SIEMENS
L&T
ABB
SCHNEIDER
ELECTRONIC OVER LOAD C&S (LG make)
SCHNEIDER
RELAY FOR LT MOTOR
(CONTACTOR
OPERATED)

INDICATING METERS

AE
MECO
RISHAB

SOLID STATE
ANNUNCIATOR

MINILAC
ALLAN

TIMERS

SIEMENS
ABB
ALSTOM

TRANSDUCER FOR OTI/

WTI

PERFECT CONTROL
PRECIMEASURE

THERMOSTAT

VERMA TEFAG
RANUTROL
AI
ANCO
SAI EGO
COMET
JAINSON
DOWELS
JAINSON

40.

GLANDS

41.

LUGS

CAT-III

CAT-III

CAT-III

CAT-III

CAT-III

CAT-II

CAT-III

CAT-III
CAT-III

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

VOLUME -II
SECTION: C7.10
SHEET 7 OF 10

APPROVED SUB VENDOR LIST

&
INSPECTION REQUIREMENTS

42.

LIGHTING RECIPTICLE

ANCHOR ROMA
ABB

CAT-III

43.

LED

BINAY
TECHNIC

CAT-III

44.

45.

46.

47.

PORCELAIN BUSHING

BUSHING CT

RADIATOR

DIGITAL TPI/ OTI/ WTI

48.

PRV/MOG

49.

BUCHHOLTZ RELAY

50.

OIL SURGE RELAY

51.

BREATHER

BHEL
ABB
CGL
ALSTOM
WSI
CJI
BHEL
PRAYOG
PRAGATI
ABB
CGL
BHEL
TTP
CTR
EMCO
NMC
PRADEEP
SUKRAT
ATVUS
ATVAS
BHEL
MR
EASUN-MR
ATVAS
I&C
SUVIDHA
YOGYA
APAR
SAVITA

CAT-II

CAT-II

CAT-II

CAT-III

CAT-II
CAT-II
CAT-III

CAT-II

52.

TRANSFORMER OIL

53.

EPOXY BUSHINGS

BARODA BUSHINGS

CAT-III

54.

GASKETS

GUJRAT CORK
BHARAT CORUB
NU CORK

CAT-III

CAT-II

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

VOLUME -II
SECTION: C7.10
SHEET 8 OF 10

APPROVED SUB VENDOR LIST

&
INSPECTION REQUIREMENTS

55.

INSULATING PAPER

ABB
MUNKSJO
AMOTFORCE

CAT-III

CAT-III

56.

PRE-COMPRESSED
PRESS BOARD

WEIDMAN
RAMAN

57.

TANK STEEL

SAIL
TISCO
ESSAR
RINL
JVSL
ZOLOTO
LEADER
NEO
KHAITAN
CROMPTON
ALSTOM
MARATHON
SARVODAYA
PATSON

58.

59.

VALVES

COOLING FAN

60.

RADIATOR VALVE

61.

COPPER BUSBARS

63.

STEEL- HRCA

TISCO
SAIL
RINL
JINDAL
SUVIDHA
PARMALI WALLACE
BARODA BUSHINGS
INDUSTRIAL
PERFORATION (INDIA)
PRIVATE LIMITED.
PATNY SYSTEMS (P)
LTD.,SECUNDERABAD
RAYCHEM
PLATEK

EARTHING MATERIAL

66.

SLEEVES

67.

SURGE ARRESTORS

CAT-III

CAT-II

HINDALCO

65.

CAT-II

CAT-II

ALUMINIUM BUSBARS

INSULATOR FOR 6.6 KV

HT SWITCHBOARD

CAT-III

STARLITE
BIRLA COPPER

62.

64.

CAT-II

SIEMENS, GERMANY
AREVA, FRANCE
ABB, ITELY

CAT-II

CAT-II

CAT-III

CAT-III
CAT-II

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

VOLUME -II
SECTION: C7.10
SHEET 9 OF 10

APPROVED SUB VENDOR LIST

&
INSPECTION REQUIREMENTS

68.

69.

DOOR SWITCH

TERMINAL STRIP

SIEMENS
KAYCEE
IEC
ESSEN
ELMEX
TOSHA
CONNECT WELL

70.

CABLE JOINT KIT/

TERMINATION KIT

RAYCHEM

71.

HOLLOW INSULATOR, BPI

WS INSULATORS
BHEL
ABB SWEDEN
MODERN INSULATORS
BIRLA NGK
SARVANA
BHEL
WS INSULATORS
MODERN INSULATORS
BIRLA NGK
SHALIMAR
BERGER
NEROLAC
ASIAN
BEC
SEN & CO.
JK TUBE
VIMCO
RASHTRA UDYOG
KLEMMEN
MEGHA
MILIND
ITPL
BHARAT WIRE ROPES
USHA MARTIN

72.

73.

74.

75.

DISC INSULATOR

PAINT

GI CONDUITS

CLAMPS, CONNECTORS
& HARDWARE

76.

SHIELD WIRE

77.

D C MOTORS

78.

79.

VVVFD PANEL-

ACTUATORS

BHEL
ABB
SIEMENS
SCHNEIDER DELHI,
L &T MUMBAI,
SIEMENS NASIK,
ABB BANGALORE
ROTOK,
LIMITORQUE,
AUMA

CAT-III

CAT-III
CAT-II

CAT-II

CAT-II

CAT-II

CAT-III

CAT-III

CAT-III
CAT-I

CAT-I

CAT-I

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

VOLUME -II
SECTION: C7.10
SHEET 10 OF 10

APPROVED SUB VENDOR LIST

&
INSPECTION REQUIREMENTS

80.

81.

82.

83.

84.
85.

WALL WOUNTED
PANELS- / NON PLC
CONTROL PANEL/ /WDB/
SOLINOID/DB/

EH THRUSTER BRAKE

CABLE REELING DRUM

ELECTRONIC SPEED
SWITCH, ZSS,
TILT SWITCH,
MAGNETIC SWITCH
PROXIMITY SWITCH

JASPER,
ICA MUMBAI
IND SWITCH GEAR &
CONTROL MUMBAI,
KEY ELEC KOLKATA
JOLLY ENGG KOLKATA
RITAL
C&S
ELEMAG MUMBAI
WMI MUMBAI
BENGAL TECHNO CRATE
BIDDER TO FURNISH THE
VENDOR LIST FOR
APPROVAL
JAYSHREE PUNE,
PROTO CONTROL PUNE
P G ELECTRONIC MUMBAI

R&F
ALLENBRDLEY
RELAY TESTING KIT WITH OMICRON ELECTRONICS
LAP TOP
DOBLE ENGINEERING
MEGGAR LIMITED
ISA TEST EQUIPMENT

CAT-II

CAT-II

CAT-II

CAT-II

CAT-II

CAT-I

NOTE:
1. Similar items shall be of one make only.
2. For items not indicated above, the Contractor shall obtain approval from
the Purchaser.
3. ** Inspection category for Testing of Numerical relays, Data concentrators,
gateways, Ethernet switches and Digital meters for Interface to BOP-DCS
before finalizing the models, during FAT and during commissioning at Site
shall be CAT-I

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INSTRUMENTATION AND CONTROL SYSTEM

1.0

SCOPE OF WORK
The system to be furnished as covered in this volume shall be engineered,
designed, manufactured and supplied as per the requirements specified
herein.
It is not the intent to specify completely all details of design and construction
of equipment, nevertheless the equipment shall conform in all respects to
high standards of engineering design and workmanship and shall be
capable of performing in continuous commercial operation in a manner
acceptable to the Purchaser.
The following Instrumentation and Control system shall be complete with
hardware and software and all other accessories to operate the
compressed air system efficiently, reliably and safely as detailed under
various clauses of this specification.
a)

Complete Field Instrumentation including all field sensors, cables

(Instrumentation cable, control cable, thermocouple compensation
cable, special cables, etc.,), cable trays, erection hardware, Junction
boxes and transmitter racks etc., within bidders battery limits.

b)

Instrumentation for Temperature, Pressure, Level, flow, moisture

traps, etc., required for auto operation of air compressor as indicated
in the CIPL.6071A-640-FD-1132 / P5.

c)

Instrumentation as required for manual/auto start/stop and load /

unload of Air compressors.

d)

Pressure indicators at the outlet of each compressor.

e)

Instrumentation for Temperature, Pressure, moisture traps etc

required for air receivers as indicated in the CIPL.6071A-640-FD1132 / P5.

f)

Pressure transmitters and control valve at the outlet of Air receivers

for varying the service air supply depending on Instrument Air load.

g)

Instrumentation for Temperature, Pressure, Level, flow, moisture

traps, timers, humidity measurement, etc., required for auto operation
of Air dryers.

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INSTRUMENTATION AND CONTROL SYSTEM

h)

Dedicated Microprocessor based skid mounted controllers for air

compressor control with bidirectional communication link to Main plant
DCS in main control room.

i)

Dedicated Microprocessor based controllers mounted locally for air

dryer control with bidirectional communication link to Main plant DCS
in main control room.

j)

Instrumentation for Temperature & Pressure at one point for each of

the distribution headers for other purchasers systems.

k)

Any Software required to be loaded in the Main plant DCS to control

compressor loading and unloading shall be supplied by the Bidder

l)

Power supply distribution including cabinets.

No UPS shall be envisaged in Bidders scope. Bidder shall generate
required power supply for their control systems with the power supply
given by the Purchaser. For the details of power supply given by the
Purchaser shall be referred to electrical section.

m)

Cables.
All Instrumentation and control (I&C) cables, Data highway cables,
prefabricated cables related to the entire Air Compressor System are
under Bidders scope. All the RTD and Thermostat cables shall be
wired to take care of line resistance as required. Preparation of
Interconnection cable schedule for all I & C cables is included in
Bidders scope.

n)

Vibration Monitoring system for all HT drives.

o)

Essential Spares and Recommended spares, as specified.

p)

All the associated civil structure with steps, inverted L shaped

metallic angle, for mounting the process instrumentation, all
associated mounting accessories etc., are included in Bidders scope.
Maintenance, platforms and access ladders for instruments,
equipment installed at inaccessible heights shall be installed.

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q)

Adequate number of test connections of standard size and at suitable

location shall be provided for commissioning and PG test.

r)

Special maintenance tools and tackles, as required.

s)

Erection, field calibration, testing and commissioning of all I&C

equipments included in the scope of BIDDER as per standard
methods and to PURCHASERs satisfaction.

t)

All the hardware and software interface components required to

establish communication link between the compressor skid mounted
controller and Main plant DCS in central control room for control and
monitoring from DCS operator console.

u)

All the required hardwired cables and wiring required for connecting
analog signals and digital contacts from compressed air system to
Main plant DCS for control and monitoring from Main plant DCS
operator console.

v)

Bidder shall do the commissioning of the drives supplied by him and

be responsible for successful and timely completion and
commissioning of the same. The necessary hardware and distribution
equipments shall be included in the Bidders scope.

2.0

SPARES
1.

Essential Spares
The Essential Spares shall be supplied as detailed below.
For all field Instruments, a min of one (1) or 20% of the quantity of
each type or range, whichever is higher is to be provided.
One no. of microprocessor based controller (programmed) of each
type.

2.

Start-up Spares
Start up spares are those which are required during erection and
commissioning including completion of performance guarantee test
and the same shall be included in the Bidders scope, as required
basis.

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INSTRUMENTATION AND CONTROL SYSTEM

3.

Recommended Spares
Recommended spares required for 3 years of plant operation shall be
included. This shall not be taken for bid evaluation purpose.

2.0
2.1

OPERATION & CONTROL PHILOSOPHY

Capacity control shall be achieved at constant speed by Dual Type Control.
The dual type control system shall permit operation of each compressor in
either of the following two regulations:
(a)
(b)

Continuous Run-Load-Unload Regulation.

Automatic Start-Stop Regulation.

2.2

Under continuous Run-Load-Unload Regulation, the drive motor shall run

continuously while the compressor shall be loaded / unloaded. The
compressor shall be loaded at pre-set (adjustable) cut-in pressure as the
receiver pressure falls and shall be unloaded at a higher pre-set (adjustable)
cut-out pressure, as the receiver pressure rises. With automatic Start-Stop
Regulation, the drive motor shall automatically start at pre-set (adjustable)
cut-in pressure as the receiver pressure falls and automatically stop at a
pre-set (adjustable) higher cut-out pressure as the receiver pressure rises.

2.3

With either mode of regulation, the compressor shall always be in unloaded

condition when the drive motor starts. The un-loaders shall keep the
compressor unloaded till the drive motor achieves specified full speed.

2.4

Base duty compressors shall be operating on load / unload control, and

stand by Compressors shall be operating on auto-start / stop control.

2.5

Each compressor unit shall be provided with its dedicated microprocessor

based controller with integral HMI consisting of LCD display, LED indicators,
START/STOP buttons, EMERGENCY STOP button, Scroll and Function
keys, etc.

2.6

Separate in built control panel for each compressor shall be provided.

Bidder shall confirm dual control mode of operation for the compressors
and submit the scheme for signal exchange between the controllers so that
the compressors works in Load-Unload mode and Auto standby mode
independently. Choice shall be made available from local/remote to select
any of the compressors as Main and the other as Standby.

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INSTRUMENTATION AND CONTROL SYSTEM

2.7

The function keys shall facilitate the following operations:

Manually load / unload the compressors

Call up & programme the settings

Reset a motor over load / emergency stop

Have access to all the data acquired by the controller.

2.8

In addition, hardwired connectivity and communication link with Main plant

DCS in main control room shall be provided for remote control and
monitoring of Air compressor system consisting of all compressors, dryers
and air receivers as per the flow diagram attached.

2.9

All the critical signals from each of the microprocessor based compressor
control panel are hardwired to this Purchasers Main plant DCS in main
control room to realise the following functions

Integration of controllers of individual compressors.

Controlling the instrument air common header pressure (to the
consumers) within programmable limits by starting, loading, unloading
and stopping an appropriate set of compressors through their
respective controllers.
The status of each compressor shall be displayed on the HMI of this
Purchasers Main plant DCS system.
To obtain approximately equal run times on the various air
compressor units, the system shall utilise a Time Levelling Control.
Bidder shall also offer Energy Saver / Optimization packages for the
complete compressed air system. Any software required for the same
to be loaded in the purchasers Main plant DCS in main control room.
The system shall allow for isolation / integration of any of the
compressors into the integrated mode of operation.
Bidder shall terminate all the relevant cables between Bidder's system
and Purchaser's Main plant DCS system at Main plant DCS panel in
Main control room.

2.10

The required pressure at the common header outlet of instrument air

receivers is achieved by regulating the control valve in the outlet of the
common header of service air receivers.

2.11

Pressure transmitters shall be provided to monitor the common air header

pressure. Average/ Mean of the pressure transmitter signals shall be
derived and used for control of the loading of the compressors accordingly
to maintain the header pressure within the set limits (Pressure Band). If one

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INSTRUMENTATION AND CONTROL SYSTEM

of the transmitters fails, its signal shall be ignored. In the unlikely event of
both the transmitters failing, the Master Controller shall automatically put all
the running compressors in their respective Local Control mode. In the
local control mode each compressor shall operate based on their respective
pressure band setting on the skid mounted control system.
2.12

Dew point meter shall be provided at the out let of air drier with local
indication provision.

2.13

Electronic drain traps shall be provided for automatic draining of

condensate. The selected automatic drain traps shall be highly reliable and
maintenance free.

2.14

The Bidder shall furnish the description and details of their system being
offered with suitable reference installations as a part of bid document.

2.15

Pressure transmitter signal shall be used to derive / generate alarm initiating

contacts for the air receiver high and low pressures.

2.16

The dual control units shall be complete with pressure switches, solenoid
valves, control air tubing, air filter (if required) and other accessories as
required for the afore-mentioned operations.

2.17

The controller for the individual compressors shall be capable of displaying

and storing the following data as a minimum:
a)
b)
c)
d)
e)
f)
g)
h)
i)
j)
k)
l)
m)
n)
o)
p)

Discharge air pressure

Pressure switch for suction filter monitoring
LP air inlet pressure
Inter cooler pressure
Lube oil pressure
Lube oil temperature
LP air outlet temperature
HP air inlet temperature
HP air outlet temperature
Discharge air pressure
Discharge air temperature
DP switch across oil filter
Air receiver pressure
Air dryer outlet Dew point meter
Cooling water inlet temperature
Cooling water outlet temperature

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INSTRUMENTATION AND CONTROL SYSTEM

q)
r)
s)
t)

Flow switch at cooling water outlet

Main motor overload status
Compressor Running Hours
Compressor Loaded hours

NOTE: Necessary local instruments shall be supplied as per the attached

P&ID for completeness of the system.
2.18

Local operation
Local start/stop push button stations shall be provided on the local
compressor control panel. Local start command shall be executed only
when all the permissive conditions are satisfied. Lockable type Local stop
push button shall be connected to the MCC/switchgear. Local/remote and
auto/manual selection shall be provided in the HMI as soft selection for all
the compressors.
For motorised valves, integral starters shall be provided. For these drives,
local operation request selector switch shall be provided. This shall be
wired to the Purchasers Main plant DCS for annunciating the request to the
operator who shall issue a local operation permissive command from the
HMI which shall be wired from the Purchasers Main plant DCS to the
integral starter where the signal shall illuminate a lamp indicating to the local
operator that local open and close operations are permitted.

3.0

CONTROL AND MONITORING REQUIREMENTS FOR INDIVIDUAL

COMPRESSORS

3.1

Monitoring, display, warnings and / or shutdown:

a)
b)
c)
d)
e)
f)
g)
h)
i)

Compressor outlet: Temperature, Pressure

Inter stage: Temperature, Pressure, Differential pressure
All Stages: Vibration (X&Y)
Oil in gear box, heater & reservoir: Temperature, Pressure, Level
Air filter & Oil Filter: Pressure difference
Main drive motor: Current, Cooling fluid temperature, Overload
Auxiliary drives: Overload
Inlet guide vanes & Blow off vanes: Position
Service hours: Total running hours, Total in service, Total out service
etc

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3.2

Remote Control / Monitoring

a)

Input commands:
Auto / manual selection
Start
Stop
Automatic Operation/unload
Remote pressure set point

All the necessary start and stop interlocks within the compressor skid
shall be implemented with the microcontroller located in the skid.
b)

Output status
Unit Running
Load/unload
Automatic operation
Warnings
Shutdown

c)

Pushbuttons and switches for compressor control

Start/Stop
Unload/automatic operation
Emergency stop
Manual valve control
Control mode via display: Local control , remote control

d)

Service requirement indications

Air filter
Oil Filter
Oil lifetime
Re-greasing of drive motor bearings
Approach temperature of inter and after cooler
Low oil level reservoir

The above list is minimum requirement and is subjected to Purchasers

approval during detailed engineering.

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4.0

TERMINAL POINTS

a)

Instrument signals
control signals

and : Bidder shall terminate all the instrument

signals and control signals (all signal
exchanges) at Purchasers Main plant DCS
I/O panel in Main control room.

b)

Communication
interface

link : Bidder shall terminate communication link

interface cable at Purchasers Main plant
DCS panel in Main control room.

5.0

VIBRATION MONITORING SYSTEM

Bidder shall provide the following with respect to Vibration Monitoring
system for all the HT drives in Bidders scope:
Vibration pickup with sensitivity of minimum15 mv/mm/ second, degree of
protection IP65. Vibration Transmitters shall be provided for X or Y
directions; velocity pickup for low speed; accelero-meter pickup for high
speed. The field mounted vibration transmitters shall provide isolated one
(1) 4-20 mA DC output and 2 nos. SPDT alarm contacts for high and very
high conditions. In addition, the vibration system shall provide raw signals
from the transducers to carry out all signal analysis in portable Vibration
Analyser for analysing & diagnosis of machine faults.

6.0

SPECIFICATION FOR INSTRUMENTS

The specifications as applicable for the field instruments are as follows:
6.1

Pressure Indicators
Direct reading, pipe mounted Pressure gauges of Stainless Steel
with 6 inch phenolic dial (white dial with black numerals), 316 SS
Bourdon tube, AISI 304 movements and micrometer type adjustable
aluminum pointer an accuracy of +/-0.5% of span including accessories
like siphons for steam services, snubbers for pump discharge
applications and chemical diaphragm for corrosive and oil services and
name plate, etc. Material of accessories shall be SS. IP65 or equivalent
degree of protection for enclosure. Over range protection shall be 50%
above maximum pressure. Armoured capillary of 15 M shall be provided
as required.

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6.2

Pressure Switches
Non indicating type, field mounted Pressure Switches of aluminium
casing (epoxy coated), and 316 SS element and accuracy of +/-1% of
span, including accessories like siphons for steam services, snubbers for
pump discharge applications and chemical diaphragm for corrosive
and oil services, name plate & mounting brackets. Material of
accessories shall be SS. Auto reset micro switch with internal
adjustment for set values with 2 SPDT contacts rated for 0.2 A at 220 V
DC. IP 65 or equivalent degree of protection for enclosure. Over range
protection 50% above maximum pressure. Scale for setting shall be
provided.

6.3

Pressure Transmitters (SMART)

Micro-processor based indicating type (LCD display), rack mounted with
accuracy of +/-0.075% of span, external zero and span adjustment,
self diagnostics, temperature sensor for compensation. Power supply
24 V DC; output signal of 4-20 mA DC. IP 65 or equivalent degree of
protection. Aluminum housing with epoxy coating, Accessories like
snubbers for pump discharge applications and chemical diaphragm
with PVC covered SS armoured capillary (of required length) for
corrosive and oil services, three way manifold, name plate etc.
Material for accessories shall be SS.

6.4

Differential Pressure Indicators

Direct reading type, pipe mounted, bellows or diaphragm operated
differential pressure indicators; SS housing with six (6) inch dial
(white dial with black numerals), with micrometer type pointer, 316 SS
pressure element; an accuracy of +/-0.5%
of
span including
accessories like snubbers for pump discharge application, chemical
diaphragm with PVC covered SS armoured capillary (of required length)
for each limb for corrosive and oil services and 5 way manifold &
name plate, mounting brackets, etc. Material of accessories shall be
SS. IP 65 or equivalent degree of protection. Over range protection
shall be 50% above maximum pressure.

6.5

Differential Pressure Switches

Bellows or diaphragm operated indicating field mounted type; aluminium
casing (epoxy coated); 316 SS pressure element nylon movement; an
accuracy of +/-1% of span within adjustable contact including
accessories like snubbers for pump discharge applications, chemical
diaphragm with capillary (of required length) for each limb for all
corrosive and oil services and 5 way manifold, name plate &
mounting brackets, etc. Material of accessories shall be SS. Auto reset

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micro switch with tamper proof external adjustable set values with 2
SPDT contacts rated for 0.2 A at 220 V DC. IP 65 or equivalent degree
of protection over range protection 50% above maximum pressure.
Repeatability shall be +/- 0.5% FSR.
6.6

Differential Pressure Transmitters

SMART with LCD Indicator + HART
Accuracy: +0.02%
Enclosure: IP65
Epoxy coated Diecast Aluminium / Fibre glass casing 4-20mA DC
output. Zero span and range adjustement
Flow measurements of condensate, steam

6.7

Thermometers
Indicating type, field mounted, filled system with SS capillary (of
required length) with SS armour and six (6) inch dial (white dial with
black numerals with micrometer pointer) housed in aluminium casing
(epoxy coated) with an accuracy of +/-1% of span, response time of
2-4 seconds, auto temperature calibration, linear calibration over
the range and SS bulb with 316 SS thermowell having a process
connection of M33 x 2 thread or 150 RF flanged. Material of accessories
(name plates, mounting brackets, etc.) shall be SS. IP 65 or equivalent
degree of protection for enclosure. Thermowell with Hex head bar stock
assembly. The thermowell construction shall meet the ANSI 19.3-1994
(latest) requirements.

6.8

Thermowells
Pipe/equipment mounted temperature test wells of 316 SS with a
process connection of M33x2 thread or 150 RF flanged. Accessories
like name plate, plug with chain, etc. shall be provided. Material of
accessories shall be SS. Thermowell shall be hex head of barstock
assembly. In case flanged wells are required for any specific
application, the same shall be supplied as required. The thermowell
construction shall meet the ANSI 19.3 (latest) requirements.

6.9

Temperature Switch
Non-indicating type, field mounted, filled system with SS capillary (of
required length) with SS armour housed in Aluminium casing (epoxy
coated) with an accuracy of +/-1% span, auto temperature calibration,
linear calibration over the range and SS bulb with 316 SS thermowell

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having a process connection of M33x2 thread or 150 RF flanged. The

thermowell construction shall meet the ANSI 19.3 (latest) requirements.
Micro switch with reset type with tamper proof externally adjustable set
values with 2 SPDT contacts rated for 0.2 A, 220V DC. IP 65 or
equivalent degree of protection for enclosure. Thermowell with
hex head bar stock assembly. Material of accessories (name plates,
mounting brackets, etc.) shall be SS. Scale shall be provided for
setting. Repeatability shall be +/-0.5% of full scale. Wherever the
ambient temperature shall approximate or exceed the switch set
point, temperature switches designed for cross ambient operation shall
be used.
6.10

Thermocouple Assembly
Duplex , K - Type with accuracy of +/-0.5% of span, response time of
2 to 6 sec, Spring loaded mineral insulated thermocouple assembly
with 316 SS thermowell housed aluminium casing (epoxy coated)
having a
process connection of M33 x 2 thread. Material of
accessories (name plate, etc.) shall be SS. IP 65 or equivalent degree
of protection for enclosure. Thermowell with hex head (with screwed
cover & SS chain) bar stock assembly with ungrounded junction. For
metal temperature measurement, thermocouple pads weldable to M.S
pipes shall be provided with thermocouple extension
wires (of
required length) . Element size shall be 18 AWG. Insulation
resistance at 540 Deg C shall not be less than 5 M ohms. Temperature
devices provided with
thermowells shall be calibrated with the
associated thermowell as an assembly. The thermowell construction
shall meet the ANSI 19.3 (latest) requirements.

6.11

Resistance Temperature Detectors (RTD)

Duplex type, PT 100, with accuracy of +/-0.5% of span, response time
1-2 seconds; Spring loaded mineral insulated three (3) wire RTD
assembly with 316 SS Thermowell housed in aluminium
casing
(epoxy coated) having a process connection of M33 x 2 thread or 150
RF flanged. IP 65 or equivalent degree of protection for enclosure.
Material of accessories (name plate, etc.) shall be SS. Thermowell with
hex head with screwed cover & SS chain, barstock assembly. Element
lead size shall be 18 AWG. The insulation resistance at 540 Deg C
shall not be less than 5M ohms. Repeatability over full range shall be
better than 0.02%. RTDs shall be ungrounded. RTD shall be supplied
as an assembly complete with thermowells meeting ANSI 19.3 (latest)
requirements.

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6.12

Level Gauges
Tubular type level gauges for low pressure upto 7 kg /sq.cm & reflex
type for high pressure water & steam services & vacuum services with
automatic ball check valves, illuminator (240 AC), pyrex/ borosilicate
glass, mica shield, brass guard rods & brass holders. Material of
accessories (name plate, etc.) shall be SS. Tubular glass OD shall be
5/8. Vent & drain valves shall be provided. Connection shall be screwed
or flanged (ANSI class 150 RF).

6.13

Level Switches
External cage magnetic float operated level switches for tanks and
vessels and top mounted level switches for sumps and underground
tanks. The top mounted level switches shall be supplied with still
tubes to suit the requirement. Micro switch with 2 SPDT contacts
rated for 0.2 A, 220 V DC. Material of float & float chord shall be 316
SS & cage material shall be fabricated steel and the material of
accessories shall be SS. IP 65 or equivalent degree of protection
for enclosure.
Accessories like name plate, drain valve for external case type level
switches, mating flange, gaskets (asbestos), fasteners, bolts & nuts,
etc. shall be supplied.
The required pressure vessel assembly for mounting probes are
included in the scope.

6.14

Level Transmitters
Accuracy: +0.5%
Enclosure: IP-65
External cage with CS body and SS wetted parts, 4-20 mA DC output
For all level measurement with two phase fluids and not exceeding
800 mm length for both monitoring and control applications

6.15

Flow Glasses
Online flow glasses for pipe size up to 6" with a rotary wheel (not a
flapper type) suitable for installation on vertical or horizontal pipe
lines, material Pyrex tempered glass. Body meterial shall be carbon
steel, rotor & wetted parts shall be bronze. The material of accessories
shall be SS. IP 65 or equivalent degree of protection for enclosure.
Upto 50 Nb size, connection shall be screwed & above 50 mm Nb
size it shall be flanged - ANSI, 150 RF. Accessories like name plate,
mating flanges with gaskets (neoprene), bolts & nuts, etc. shall be
supplied.

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6.16

Flow Switches
Indicating, Differential pressure, flapper type on line flow switches for
line sizes up to 80 mm with an accuracy of +/-0.5% of span and dial
size of min. 50 mm having 316 SS flapper/SS 316 bellows housed in
die cast aluminium. Micro switch with adjustable range with 2 SPDT
contacts rated for 0.2 A, 220 V DC. IP 65 or equivalent degree of
protection for enclosure. The material of accessories shall be SS.
Repeatability shall be +/-0.5% of span. Over range protection shall be
50% above maximum flow. Setting shall be tamper proof external
adjustment & scale shall be provided for setting. Range spring &
orifice plate shall be SS 316 for DP type. NPT for sizes below 2 & for
sizes above 2 ANSI 150 RF shall be provided. Accessories like name
plate, mating flanges with gaskets, bolts & nuts, pipe assembly with
orifice plate, etc. 5 way mani-fold, pipe, fittings (DP type), etc. shall be
supplied.

6.17

Flow Indicators
Positive displacement type
Accuracy: +0.5% of rate of flow
Enclosure: IP-54
CS body with 316 SS wetted parts
Measurement of flow on oil lines

6.18

Flow Transmitters
DP type SMART+ HART
Accuracy: +0.02%
Refer under "Differential Pressure Transmitters"

6.19

Flow Elements
Meter-run assembly shall be used for line sizes 1.5 & below. Meter
run assembly shall be with carrier rings & corner taps with minimum 20
D upstream & 6 D downstream lengths. Integral orifice transmitter with
meter run can also be used for line sizes 1.5 and below.
Flange taps shall be used for orifice plate assembly for line size 2
thro 8, whereas D & D/2 taps shall be used for line sizes greater than
8.
For in-line flow indicators with line sizes 2 & below, variable area
flowmeters shall be used. All variable flowmeters shall be metal tube
type preferably.

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6.20

Digital Dew Point Meter

Microprocessor based
+/- 2 deg C Dew point Repeatability & 0.3 deg C of dew point
IP-65
Dew point sensor shall be Aluminum oxide type with sintered bronze
sensor guard suitable for on line measurement
At the outlet of air dryer

6.21. Junction Boxes (JB)

All JBs shall be Galvanised. Wall/column mounted junction boxes having
32 (2x16) terminals and cable entry only at the bottom and sealed with fire
proof compound; Screwed terminal type; IP 66 or equivalent degree of
protection for enclosure. Separate terminal blocks shall be used for
analog and digital signal and also for signals with different voltages.
Removable gland plate shall be supplied. JB shall have single lockable
door with gasket, able to open side ways, with common keys. Painting
inside shall be glossy white & outside - IS-5 shade 631. Shield bus for
screw connection shall be provided. Terminal size shall be suitable for 0.5
sq.mm to 2.5 sq.mm wire. Terminal blocks shall be vertical. JB shall have
provision to add 10% additional terminals. Accessories like metal tag
(SS), clamps, fixtures, bolts (SS), nuts (SS), gaskets (neoprene), lock &
key, fire proof compound for sealing, etc. shall be supplied. The grouping of
instruments in JBs is subject to Purchasers approval. All the field Junction
boxes shall have single doors and provision for locking. The doors shall not
have screwed type of locking, but turnable hinge based. The JBs are
subject to approval prior to manufacturing All JBs shall be provided with
individual canopies to avoid ingress of water. All the TBs used shall be
6.6polymide to withstand corrosion and the metallic portion shall be coated
against rust / corrosion. In each JB ,a DC Voltmeter shall be provided to
check the Field Interrogation voltage.
6.22. Interposing Relays (IPR)
Electro magnetic type IPRs with plug-in type connections, suitable
for channel/rail mounting in cabinets; coil rating 24V D.C; 2 set of silver
plated Change over contacts rated for 0.2A 220 V DC. Free wheeling
diode across relay coil (copper) and self reset type status indicator flag
(electronic) shall be provided. All relays shall be mounted in IPR cabinet
& relay base (silver plated) internally wired to the external cabling
termination block in IPR cabinet. Wiring connection shall be cage-clamp

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& termination shall be suitable for 0.5 sq.mm to 2.5 sq.mm size wiring.
Facility to simulate relay operation manually shall be provided. Relays of
different contact interrogation voltages shall be separated by a barrier in
IPR cabinet. Accessories like name plate (SS) with tag & service
inscription, relay base mounting rail/channel, nuts & bolts, etc. shall be
supplied. Three nos. change over contacts shall be wired to external TB in
the Interposing relay cabinet. Status/amps shall be provided. In each
cabinet,a DC Voltmeter shall be provided to check the Field Interrogation
voltage.
6.23. Instrumentation Cables
Instrumentation cables shall be 1100VAC grade, stranded high conductivity
annealed, tinned copper, twisted pair (with min. 20 twists for meter)
extruded PVC insulated with overall and / or individual screening, extruded
PVC inner sheathed, galvanized steel wire armoured, extruded outer
sheathed with FRLS PVC compound. The conductor size shall be minimum
0.5 sq.mm. Triplex cables similar to instrumentation cables can be used for
RTDs. Instrumentation cables carrying digital signals shall have overall
screening along with drain wire and analogue signal carrying cables shall
have each pair screening and overall screening along with each pair drain
wire and overall drain wire. For further details of cables, refer to electrical
volume.
6.24. Control Cables
Control cables shall be 1100V AC grade, multicore, minimum 1.5 sq.mm
cross section, stranded copper conductor having 7 strands, PVC insulated,
inner FRLS PVC sheathed of type ST-1, galvanized steel wire armoured
and outer sheath made of FRLS PVC compound of type ST-1. In situations
where accuracy of measurement or voltage drop in control circuit, warrant,
higher cross sections as required shall be used. For further details of
cables, refer to electrical volume.
6.25. Local Panels
All the local panels shall be galvanised. Indoor/Outdoor located, free
standing vertical type local panels with 2 mm thick sheet material of cold
rolled steel; antivibration pads of 15 mm thick; fluorescent lighting; Double
doors with neoprene gaskets at every 1.5 m; blower & louvers in each

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section with brass mesh; fire proof compound (50 mm thick) for sealing
cable entry (bottom); fire detector for each section; space heater with
thermostatic control for each section (strip type). IP 65 degree of
protection for enclosure. Removable cover plates with locking facility
shall be provided along the bottom of the front desk continuously to
facilitate maintenance work. The length of each cover plate shall not
exceed 1 m. Fluorescent lamp of 40 W shall be provided from one end of
the panel to the other end at continuous length and shall be operated by
the door switches as well as by manual switches. Name plates shall be
provided for all instruments/inserts with Tag. No. & short description of
service engraved. These shall be phenolic overlays (1.6 mm thick), black
background with white lettering & shall be fixed to the panel by stainless
steel screws (counter sunk). Each section of the panels shall be
provided with one each 3 pin receptacles for 240V AC, 1P, 50 c/s & 110
V AC, 1P, 50 c/s. Panel shall be delivered totally wired. All instruments,
inserts and annunciation windows shall be mounted & wiring
connections at these hardwares shall be terminated at site by Bidder.
Quantity shall be as required.
All the Terminal Blocks shall be rust proof and corrosive resistant for
outdoor mounted panels. Terminal Blocks housing material shall be 6.6
polyamide and metallic portion shall be coated against rust/corrosion.
In each Local Panel ,a 24 VDC Voltmeter shall be provided to check the
Field Interrogation voltage.
6.26. Wiring, Termination and Accessories
All the cables are to be treated with anti-rodent treatment.
Instrument wires : Wires carrying 4-20 mA DC or any other low voltage
or current signals. Used for panel internal wiring, tinned copper conductor
of 0.5 sq.mm cross section with seven strands and twisted pair with 20
twists/metre. Insulation material shall be PVC, heat resistant with flame
retarding properties with thickness not more than 0.5 mm and voltage
grade shall be 1100V AC.
Control Wires : Wires used for power supply like 110V AC, 240V AC,
220V DC, + 24V etc. Used for panel internal wiring, tinned copper
conductor of 1.5 sq.mm cross section with seven strands. Insulation
material shall be PVC, heat resistant with flame retarding properties,
voltage grade shall be 1100V.

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Prefabricated
Cable
:
Used
for
interconnection
between
system/marshalling cabinets. Used for panel external wiring, tinned
copper conductor of 0.5 sq.mm cross section with seven strands twisted
pair with 20 twists/metre. Insulation material shall be PVC, heat resistant
with flame retarding properties with thickness not more than 0.5 sq.mm.
Voltage grade shall be 1100V AC. Each prefabricated cable shall have a
minimum of 5 cores as spares and these shall not be connected to end
connectors.
Terminal Block (TB):
Cageclamp type , 1100 V AC grade, vertically mounted, size of 0.5 sq.mm
to 1.5 sq.mm for instrument wires and 1.5 sq.mm to 2.5 sq.mm for
control wires. Clearance between TBs shall be 150 mm and between TB
and bottom plate shall be 250 mm, flame resistant, non-hygroscopic,
decarbonised. Insulation between adjacent terminals or between terminals
& frame work shall be 2 KV RMS for 1 minute . Power supply and signal TB
shall be separate. Signals shall be grouped in TBs in the same order as
that in field junction box so as to provide neat cable layout and wiring.
High voltage and low voltage signals shall be provided on separate TBs,
which are mounted separately.
TBs housing material shall be 6.6 polyamide and metallic portion shall be
coated against corrosion. There shall be no double decker terminals.
Termination Details
Maximum of 2 wires shall be terminated per terminal. Wiring raceways,
strapes shall be flame retardant. All wiring shall be ferruled.(printed Partex
type ferrule shall be used)Wires carrying power and signal wires shall be
routed in separate raceways. Accessories like MCB, cable support fuses,
etc. shall be supplied. Cable entries shall be cemented with fire proof
compound.
6.27. CONTROL VALVES
Multistage, anticavitation, Balanced, modulating, globe type, cage guided,
single ported, diaphragm type of actuator with hand wheel, SMART
Pneumatic positioner, air filter regulator, air lock device, solenoid valve and
limit switches and position transmitters completely tubed with junction box.
Pneumatic Positioner shall be suitable for accepting 4-20mADC signal.
Pneumatic (copper) tubing complete with accessories, fittings, Positioners
shall be provided with input/output/bypass gauges. Local position indicator
& LVDT type position transmitter with 2 wire, 4-20mA DC output. All limit

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switches/position transmitters, E/P converter signals etc., shall be wired out

to external block of actuator and respective junction boxes.
Control valves shall be sized to have an opening of 15% at minimum flow
condition and 85% at maximum flow condition. Noise level shall not
exceed 85 dB at a distance of about 1.5 M from the valve. In case of
predicted noise level above 85dBA, suitable low noise trim shall be
provided. Noise reduction shall achieved through an inherent Trim design
and not through external means.
Leakage class for double seated valve shall not exceed 0.05%, and single
seated valve shall not exceed 0.01%.
The end connections shall be socket welded for sizes below 50 NB and
butt welded for sizes 50 NB and above. Flanged connection shall be
provided for DM water services, with suitable rubber lined interfaces.
Water seal shall be provided for valves that could be subjected to below
atmospheric conditions.
Trim exit velocity shall not exceed 30 m /sec for critical control valves. Feed
control valves and Spray control valves shall have a leakage class of VI and
all other valves shall have a leakage class of V.
The normal flow shall not be more than 62.5% of the CV for 100% valve
opening.
The action of valves on failure of operating media shall be determined by
the process requirements with regard to safe operation and emergency shut
down requirements.
Position transmitter shall be non-contact type.
The control valve design shall be suitable for the required fail-safe
conditions, of process / equipment. The valves shall be supplied and
commissioned as per the fail-safe philosophy required for the process.
Wherever the required turndown is not possible with a standard single
valve, specially designed trims shall be customised and used. Pressure
regulators upstream of control valves would not be envisaged.
All final Control elements (Control valves & control dampers) shall be with
pneumatic or electric actuators. All actuators would be sized so that the final
control elements operate properly even when the upstream pressure
exceeds 110% of maximum value. Pneumatic actuators would be provided
with air failure lock and remote release, limit switches, adjustable minimum

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and maximum stops, load position indicators, positioners, non-contact type

electronic position transmitters and solenoid valves in accordance with the
system requirements.
Control valve sizing shall be accompanied with data sheets. Following tests
shall be carried out for Control valves.
a) 100% radiography tests
b) Magnetic Particle Inspection.
c) Hydrostatic test.
d) CV test etc.
6.28. Solenoid Valves
Direct operated solenoid valves, pilot operated for higher sizes with shut of
class (leakage) VI, body material of brass, plunger material of 316 SS rated
for continuous duty. IP 65 class for enclosure. Insulation class of 'F' for the
solenoid. Body ratings shall suit the pressure and temperature conditions.
6.29. Illuminated push buttons (ILPB)
a) Rectangular, twin block per assembly, One block for START/OPEN
and second block for STOP/CLOSE operation; 2 lamps/block, one
additional lamp for discrepancy indication per assembly, 2NO + 2NC
contacts with 5A 230V AC rating, 110V AC/24V DC lamp rating, 3
watts, series resistance for lamps, colour red / green / amber
b) Same single block with one lamp for forward/reverse/stop operation.
6.30

Push button (PB)

Rectangular, single block, Momentary contact type with engraved
inscription plates, 2NO + 2 NC contacts with 5A, 230V AC rating, colour
red/green/amber.

6.31

Electronic Auto drain Trap

24VDC or 240V AC powered Level based and Timer based Auto Drain
Traps. These shall have an level sensing capability and discharge only
when condensate is present / pre-set time reached, shall have fault
indication if valve is clogged / coil burnt / loss of power supply
connection /electronic unit is faulty with facility to reset, after the fault is

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cleared, shall be fully Automatic, designed to be used in compressed air

system. Other features shall be zero air loss, Zero energy loss, less
maintenance, manual test switch, indication for Valve healthiness, easy
to Replace, weather proof sealing and shall have filter that stops the
flow of particulates.
7

SELECTION OF RANGES FOR INSTRUMENTS

The ranges of the instruments shall be selected based on the philosophy
indicated below:

(a)

For pressure measurements, the maximum operating pressure shall

be within 70 to 80% of the maximum scale range. The operating
range for transmitters shall be 30 - 80% of the specified range of the
instrument.

(b)

For temperature measurement, the maximum operating temperature

shall be within 80 to 90% of the maximum scale range.

(c)

For pressure switches and temperature switches, the set points shall
fall within 40% to 70% of the scale range selected.

(d)

For level measurement, the maximum of the range shall cover the
very high point and the minimum of the range shall be stacked with
overlap to cover permissive, alarm and trip levels.

(e)

For flow measurement, the maximum range shall be fixed at about 10

to 15% above the maximum operating flow.

PERFORMANCE TEST POINTS

(a)

Pressure, temperature and flow test points shall be provided

with performance test requirements.

in line

(b)

Pressure test points shall be complete with root valves and shall
terminate with a nipple.

(c)

Temperature test points shall be provided with thermowell.

(d)

All instruments required for performance testing to prove the

performance of the pump shall be provided by the BIDDER for the
duration of the performance test. These test instruments shall have

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test certificates traceable to International standards and shall be

valid for the duration of the performance test.
9

TESTS AND INSPECTION

After Manufacturing, all instruments shall be tested and calibrated at
Factory. BIDDER shall be responsible in obtaining test certificates related to
calibration of all the Instruments and submit for PURCHASERs approval.
BIDDER shall only allow despatch of these instruments after test certificates
are approved by PURCHASER. The details of the tests to be carried out for
the field instruments shall be as indicated in the subsequent sections and
any other tests as required by the Standards and Codes.

10

TESTS TO BE PERFORMED FOR FIELD INSTRUMENTS

1. Pressure indicators
Calibration Hydro tests (1.5 times max. pr.)
2. Pressure switches
Calibration test / Hydro test / Contact rating test / Accuracy test /
Repeatability
3. Thermometers with contacts
Calibration / Material test / Accuracy test / Bore concentricity: + 5% of
wall thickness / Hydrostatic test for TW (1.5 times max. pr.),functional
test
4. Resistance temperature detector assembly.
Calibration / Material test / Bore concentricity test / Insulation test (< 500
M at 500V DC) as per ISA, Hydro test for TW. Bore concentricity: +
5% of wall thickness, Accuracy test.
5. Thermocouple assembly
Calibration / Material test, Insulation test (> 500 at 500 V, DC) as per
ISA, Hydro static tests (1.5 times max. pr.), Bore concentricity: + 5% of
wall thickness.
6. Thermowells
Material test / Bore concentricity: + 5% of wall thickness / Hydrostatic
test for TW (1.5 times max. pr.)
7. Flow Switch
Material test / Hydrostatic test (1.5 times max. pr.) / function test.

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8 Solenoid valves
Hydrotest / Seat leakage test / CV test / Coil insulation test
8. Junction Boxes
Test for degree of protection / Material test
9. Tests for terminal blocks
Test for moulding for flame resistant, Non-hygroscopic and
Decarbonised / Insulation test between terminals / Insulation between
terminal block and frame.
10. Thermocouple extension cable
Thermo-emf characteristic / Continuity test / Measurement on
capacitance, inductance and loop resistance / Insulation resistance /
High voltage test as per latest IS / Tensile and elongation test / Oxygen
index test / Any other test applicable.
11. Transmitter Racks
Hydro test, air leak test for piping / tubing and fittings. IBR certification
as required for tubing / piping and fittings.
12. Field instruments (Local Instruments, Local Gauges, Transmitters,
Switch Elements, Temperature Elements, Level Instruments,
Thermowells)
Calibration test, Hydro test (1.5 times max. Pr.), contact rating test for
switches, over range test, accuracy test, leak test, Bore concentricity
test: +/-5% of wall thickness & material test for temperature instruments,
Insulation test (<=500Mohm at 500v, dc) as per ISA for RTD /
Thermocouple, seat leakage test & ball check for level gauges, hysterisis
test.
13. Local Instrument Panels
Verification of Degree of protection, Electrical tests, Type tests & Routine
tests as per relevant Indian standards.
Note: Bidder to submit all test certificates for Purchaser review & record.
11

CODES AND STANDARDS

All equipment and services covered under this specification shall comply
with all currently applicable statutes, regulations and safety codes in the
locality where the equipment shall be installed. All codes and standards
refer to in this specification shall be understood to be the latest version on
the date of offer made by Bidder unless otherwise specified.
If such
standards are not existing for any equipment or system, the same shall

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comply with the applicable recommendations of the following professional

institutes :
(a)

National Electricity Manufacturers Association (NEMA)

(b)

The Institute of Electrical and Electronic Engineers (IEEE).

(c)

Instrumentation, Systems and Automation society (ISA).

(d)

American National Standards Institute (ANSI).

(e)

Deutsche Industries Norman (DIN).

(f)

International Electrochemical Commission (IEC).

(g)

Verin Deutschar Eisecnhuttenleutte (VDE)

(f)

Indian Standard Institute (ISI).

11.1

Standards not indicated in the specification are acceptable subject to

approval by the Purchaser if they are established to be equal or superior to
the standards indicated in the specification.

11.2

The BIDDER shall furnish English translation of all standards to which the
equipment and systems offered conform to.

11.3

The following specific codes and standards are applicable:

Instrumentation Symbols and identification
Binary logic diagrams for process operation
Graphic symbols for inst. logic and comp. System
Environmental conditions
Bearing Temperature Monitoring Systems
Valves Seat Leakage
Thermocouples
Measurement & Control, Electrical sensors, Elec.
Position sensors & Sig. Converters for IS two wire
DC systems.

ISA S 5.1
ISA S 5.2
ISA S 5.3
ISA S 71.04
API 670
ANSI B 16.104
ANSI MC 96.1
DIN 19243

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Industrial Pt RTD
Measurement of Fluid Flow by Meter Run
Temperature Measurement
Degree of Protection by Enclosure

DIN 43760/
IEC
751
ISO 5167
ANSI MC 96.1 /
IEC 751
IEC 529

Notes :
All other relevant codes, as applicable, are to be used along with the
above basic codes and of latest version.
The codes and standards specified above are indicative but not
exhaustive.
12

ERECTION, FIELD CALIBRATION , TESTING AND COMMISSIONING

BIDDER shall envisage erection, testing, field calibration and
commissioning of all Instrumentation and Control Equipment supplied under
this contract to the complete satisfaction of the Purchaser / Purchasers
representative.

13

INSPECTION
BIDDER shall conduct functional test at manufacturers works and offer for
Purchasers inspection for the following instruments: Vibration Monitoring
System, and Pressure Transmitters, etc.

14

DATA / DRAWINGS TO BE ENCLOSED WITH THE BID

a) Deviation list .This list shall indicate, deviations if any, from the
technical details indicated in this specification.
b) Item wise confirmation to each clause under of specification.
c) Deviations, if any, shall be specifically listed under Schedule of
Deviations. If no deviation is listed, it will be presumed that the
BIDDER has complied with all the clauses in specification.

15

DATA / DRAWINGS TO BE FURNISHED DURING DETAILED

ENGINEERING
BIDDER shall furnish the following documents for PURCHASERs review
and approval during detailed engineering.

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a) P&I diagrams for all the systems in Bidders scope.

b) Compressor operation & control philosophy.
c) Manufacturers data sheets for all field instruments along with
catalogues.
d) Schedule of Instruments with settings.
e) GA drawings and Wiring diagrams of microprocessor based control
panel.
f) Hardware & Software design manual of microprocessor based controller.
g) Detailed functional write up of microprocessor based controller.
h) JB schedule indicating terminal details.
i) List of hardwired signal exchanges between compressor control panel &
Purchaser's Main plant DCS.
j) Quality plan.
k) Cable schedule.
l) Interconnection Schedule.

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SYSTEM PERFORMANCE GUARANTEE

REQUIREMENTS AND PERFORMANCE TESTS

9.0

SYSTEM PERFORMANCE
PERFORMANCE TESTS

9.1

PERFORMANCE GUARANTEES / TESTS

9.1.1

General Requirements

9.1.1.1

The contractor shall guarantee that the equipment offered shall meet the
ratings and performance requirements stipulated for various equipment
covered in this contract.

9.1.1.2

The guaranteed performance parameters are inclusive of all tolerance

values including measurement uncertainties. No other tolerances shall be
applicable.

9.1.1.3

The contractor shall demonstrate all the guarantees covered herein during
performance guarantee / acceptance test as well as integrated operation of
all the equipment. The various tests which are to be carried out during
performance guarantee / acceptance test are listed in this sub-section. The
guarantee tests shall be conducted by the contractor at site in the
presence of the Purchaser.

9.1.1.4

All costs associated with the tests are included in the price.

9.1.1.5

In case during tests it is found that the equipment / system has failed to
meet the guarantees, the contractor shall carry out all necessary
modifications and / or replacements to make the equipment / system
comply with the guaranteed requirements at no extra cost to the Purchaser
within reasonable period agreed with the Purchaser. However, if the
contractor is not able to demonstrate the guarantees, even after the above
modifications / replacements within sixty (60) days or a reasonable period
allowed by the Purchaser after the tests have been completed, the
Purchaser will have the right to either of the following :
i)

GUARANTEE

REQUIREMENTS

AND

Reject the equipment / system /plant and recover the payments

already made
OR

Accept the equipment / system / plant after levying liquidated damages as

specified hereunder. The liquidated damages for shortfalls in performance
are indicated in clause 9.1.2 for this sub section. The liquidated damages

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REQUIREMENTS AND PERFORMANCE TESTS

shall be pro-rata for the fractional parts of the deficiencies. The

performance guarantee coming under this category shall be called
Category-I guarantees.
ii)

Reject the equipment / plant / system and recover the payments

already made. The performance guarantees under this category
shall be called Category-II Guarantees. Conformance to the
performance requirements under Category II is mandatory.

iii)

Reject the equipment / system /plant and recover the payments

already made
OR

Accept the equipment / system after assessing the deficiency in respect of

the various ratings, performance parameters and capabilities and recover
from the contract price, an amount equivalent to the damages as
determined by the Purchaser. These parameters / capacities shall be
termed as Category-III guarantees which do not attract liquidated
damage.
9.1.2

Guarantees Under Category - I

9.1.2.1

Increase in Auxiliary Power Consumption : If the actual power

consumption exceeds the guaranteed power consumption liquidated
damages shall be payable by the contractor at the rate of Rs.2,41,000/- per
kW excess power consumption, over the base guaranteed figure indicated
by him in his bid.

9.1.3

Guarantees Under Category - II

9.1.3.1

Noise Level : Noise level produced by the compressor shall not exceed 85
DBA measured at a distance of 1.0 m from the edge of equipment under
loaded and free field condition.

9.1.4

Guarantees Under Category - III

9.1.4.1

Performance Guarantee / Acceptance Test

General requirements

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REQUIREMENTS AND PERFORMANCE TESTS

(a)

The performance tests shall be performed using only the Contractor,

vendor or other subcontractor personnel. Purchaser / Purchasers
representative will witness the tests.

(b)

The Contractor shall make the plant ready for the performance guarantee
tests.

(c)

All instruments required for performance testing shall be of the type and
accuracy required by the code and prior to the test, the contractor shall
get these instruments calibrated in an independent test institute. All test
instrumentation required for performance tests shall be supplied by the
contractor and shall be retained by him upon satisfactory completion of
all such tests at site. All costs associated with the supply, calibration,
installation and removal of the test instrumentation shall be include in the
bid price. All calibration procedures and standards shall be subjected to
the approval of the Purchaser. The protecting tubes,
pressure
connections and other test connections required for conducting
guarantee test shall conform to the relevant codes.

(d)

Tools and tackles, thermo-wells (both screwed and welded) instruments/

devices including flow devices, matching flanges, impulse piping & valves
etc., and any special equipment, required for the successful completion of
the tests, shall be provided by the contractor

(e)

The contractor shall submit for approval the detailed Performance Test
procedure containing the following:
i)
ii)
iii)
iv)
v)
vi)
vii)

Object of the test.

Various guaranteed parameters & tests as per contract
Method of conductance of test and test code.
Duration of test, frequency of readings & number of test runs
Method of calculation
Correction curves.
Instrument list consisting of range, accuracy, least count, and location
of instruments.
viii) Scheme showing measurement points
ix) Sample calculation
x) Acceptance criteria
xi) Any other information required for conducting the test
(f)

The Performance / Acceptance test shall be carried out as per the agreed
procedure. The PG test procedure including demonstration tests shall be

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

VOLUME - II
SECTION: C9
SHEET 4 OF 8

SYSTEM PERFORMANCE GUARANTEE

REQUIREMENTS AND PERFORMANCE TESTS

submitted within 90 days of the date of Notification of Award and

finalisation of the PG test procedure shall be done within 180 days from the
date of Notification of Award. After the conductance of Performance test,
the contractor shall submit the test evaluation report of Performance test
results to Purchaser promptly but not later than one month from the date of
conductance of Performance test. However, Contractor shall provide data/
joint protocols after completion of each test. But results shall be submitted
after completion of all tests.
(g)

Test Interruptions
In the event of a test interruption resulting from an Event of Force Majeure
or Purchaser -Caused-Delay, Contractor shall be entitled to relief as
provided in the contract, provided that (except for certain interruptions of
a Availability Test as specified below), the interrupted Performance Test
must be started again and test data that were collected during the
interrupted test must be ignored.
In the event of test interruptions as a result of Force Majeure or Purchaser
Caused-Delay during availability test, where.
i) The total cumulative interruptions time during the test is more than
twenty- four (24) hours.
ii)The total number of interruptions during the test is more than four (4).
The test shall not be deemed a successful Performance test.
Except as provided above, the interrupted test resulting from Force
Majeure or Purchaser -Caused-Delay shall be extended by an amount of
time equal to the length of the interruptions, including time to return to
steady-state operation; the test data that were collected both before and
after the interruption shall be included in the analysis.

(h)

Test Reports
The contractor shall prepare all test reports in which the methods followed,
Instrument readings, graphs, observations, final results obtained etc., shall
be recorded.
Ten (10) copies of each report shall be delivered to purchaser.

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

VOLUME - II
SECTION: C9
SHEET 5 OF 8

SYSTEM PERFORMANCE GUARANTEE

REQUIREMENTS AND PERFORMANCE TESTS

Performance Guarantee / Acceptance Tests which are not covered in this

section shall be carried out as per mutually agreed procedure / test code.
9.1.4.2

9.1.4.3

Performance and Guarantee Tests

(a)

Performance and Guarantee tests shall be conducted in accordance with

the specified in General Technical Conditions of Technical Specifications.
The testing shall be as per API - 617

(b)

The performance guarantee test shall be conducted for Seven (7) days
continuous operation of the boiler at 80% to 100% load. In case the boiler
trips during the test duration the interpretation of performance test shall be
mutually agreed between customer and Vendor.

(c)

In case of any major breakdown in any of the equipment disrupting the

operation of compressed air system, the breakdown period shall be added
to the testing period of 7 days.

(d)

The performance guarantee test shall be conducted to prove

uninterrupted operation of the compressed air system. The compressed
air system shall be operated with its normal auxiliaries without using any
other standby equipment. During the performance guarantee test, the
guarantee parameters of the various equipment as detailed below shall be
demonstrated by the Contractor.

Functional Guarantees
At Shop :
1.
2.

Capacity and discharge pressure of each compressor.

Power consumption of each air compressor at its rated duty point with its
own motor. The tests shall be demonstrated at manufacturers shop.

At Site :
1.
2.
3.
4.

Parallel operations of air compressors.

Dew point of air at the outlet of air drying plants.
Pressure drop across the air drying plants of air compressors.
Vibration & noise level of air compressors

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

VOLUME - II
SECTION: C9
SHEET 6 OF 8

SYSTEM PERFORMANCE GUARANTEE

REQUIREMENTS AND PERFORMANCE TESTS

9.2

Guarantees and Liquidated Damages

9.2.1

Guarantees
The performance and guarantee test shall be conducted in accordance with the
conditions specified in General Technical conditions, and in Clauses above. The
parameter guaranteed by the Bidder shall have no tolerance value whatsoever.

9.2.2

The equipment and systems offered under this specification shall be

guaranteed to meet the following performance.

a)

The air compressor, air receiver, after cooler, intercooler and the air dryers
shall be tested as specified in the respective data sheet-A of Section-D of
the specification.

b)

Noise level produced by the compressor shall not exceed 85 DBA

measured at a distance of 1.0 m horizontally and 1.5 m vertically from the
edge of equipment under loaded and free field condition.

c) Vibration level shall be zone B ( r.m.s displacement 57m and r.m.s velocity
4.5 mm/sec ) as per ISO 10816 part 3.
d) Quality of air from the air drying plant shall be as per ISO 8573-1, 2001 (E).
(i) Solid particle size less than or equal to 1000 particle/m3 (class 2 as per
ISO 8573-1, 2001 (E) - table -2).
(ii) Dew point shall be -40 deg C (class 2 as per ISO 8573-1, 2001 (E) table -3)
(iii) Maximum allowable oil content shall be 0.1 mg/m3 (class 2 as per ISO
8573-1, 2001 (E)- table -5)
(iv) Residual water shall be 0.117g/m3 (class 7 as per ISO 8573-1, 2001 (E)table -4).

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

VOLUME - II
SECTION: C9
SHEET 7 OF 8

SYSTEM PERFORMANCE GUARANTEE

REQUIREMENTS AND PERFORMANCE TESTS

e)

The specific guarantees required are listed below:

Air Compressors

Tolerance

i. Capacity at rated discharge pressure

and 47.5 Hz

- 0.00%

ii. Power consumption of motor at

duty point

+0.00%.

iii Power consumption of motor at

no load
iv. Noise and vibration levels

Intercooler / Aftercooler

same as item (ii) above

+0.00%

Tolerance

i. Air pressure drop across intercooler

& aftercooler

+0.00%

ii. Water pressure drop

+0.00%

Air Dryer
i. Dew point temperature
ii. Air pressure drop

Tolerance
0.00% on lower side
+0.00%

9.2.3

Liquidated Damages

9.2.3.1

If the results of the performance and guarantee tests show that the equipment
has failed to meet the guaranteed parameters, the contractor shall carry out
modifications considered necessary within 90 days of the notification by the
Purchaser. If the equipment fails to meet the guarantee except the power
consumption at the end of the above specified period of 90 days, the Purchaser
may at his discretion reject the equipment.

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

VOLUME - II
SECTION: C9
SHEET 8 OF 8

SYSTEM PERFORMANCE GUARANTEE

REQUIREMENTS AND PERFORMANCE TESTS

9.2.3.2

The power consumption for the compressors shall be measured during the PG
test. If the actual power consumption exceeds the guaranteed power
consumption liquidated damages shall be payable by the contractor at the rate
of Rs.2,41,000/- per kW excess power consumption, over the base guaranteed
figure indicated in the bid. Such liquidated damages may be recovered by the
Purchaser by deduction from the contract price or by enforcing the contract
performance guarantee or in any other manner deemed fit by the Purchaser.
For this purpose the drives of standby equipment shall be considered.

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

VOLUME - II
SECTION: C10
SHEET 1 OF 5

SPECIFICATION FOR COMPRESSED AIR SYSTEM

SYSTEM DATA SHEET-B

DATA TO BE FURNISHED ALONG WITH BID
1.0

GUARANTEED POWER CONSUMPTION

Power input to the terminal of each compressor motor at the rated
compressor parameters:

1.1

Total consumption of operating compressor

1.1.1

On no load

kW

1.1.2

On full load at rated discharge pressure

kW

(Motor rating calculation shall be furnished)

2.0

AIR PRESSURE DROP ACROSS

2.1. Intercooler

kg/sq.cm(g)

2.2. Aftercooler

kg/sq.cm(g)

2.3. Air drier

kg/sq.cm(g)

3.0

Power consumption of air driers

kW

4.0

DEW POINT OF INSTRUMENT AIR

4.1

At atmospheric pressure

deg.C

4.2

At operating pressure

deg.C

5.0

Total cooling water requirement

cu.m/hr

(Break up for compressor cooling, dryer cooling,

intercooler oil cooler and after cooler shall be furnished )
6.0

Cooling water inlet pressure required at terminal point kg/sq.cm(g)

7.0

Cooling water return pressure at terminal point

8.0

Maximum compressor cooling water outlet temperature

At terminal point
deg.C

9.0

List of recommended spares

kg/sq.cm(g)

Nos

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

SPECIFICATION FOR COMPRESSED AIR SYSTEM

10.0
11.0

Heaviest weight of part to be lifted by crane

tonnes

( weight of compressor and dryer to be furnished)

Flow diagram for compressed air system and
G.A. drawings of compressors furnished

Yes/No

12.0

Recommended GA drawing of compressor house

Yes/No

13.0

All data sheets-B duly filled in

Yes/No

14.0

BIDDERs / SUB-VENDORs experience

15.0

16.0

list furnished

Yes/No

Are detailed catalogues/literature for compressors,

drive motors, driers, inter and after
coolers furnished

Yes/No

Are all Foundation details & layout of

piping within the terminal points of scope
of supply furnished.

Yes/No

17.0

kW ratings of drive motors (list out motor

rating of all drive motors)

18.0

Is layout of air, water, lube oil impulse and any

other piping Within Battery limits of the
compressors and accessories furnished

Yes/No

19.0

Motor rating calculation

Yes/No

20.0

List of recommended spares indicating quantities

VOLUME - II
SECTION: C10
SHEET 2 OF 5

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

VOLUME - II
SECTION: C10
SHEET 3 OF 5

SPECIFICATION FOR COMPRESSED AIR SYSTEM

SYSTEM DATA SHEET-C

1.0

1.1

1.2

CALCULATIONS/ TECHNICAL DATA TO BE FURNISHED BY THE

VENDOR AFTER AWARD OF CONTRACT
Drawings/Data/Design Calculations which will be reviewed and approved
i)

PERT chart

ii)

P & I diagram for compressed air system

iii)

GA drawings of compressor with details of all accessories.

iv)

Write up for air dryer

v)

P & I diagram for air dryer

vi)

GA drawings for air dryer

vii)

Write up on control system of air compressors

viii)

Drawings related to control system

ix)

Drawings/data sheets for valves, instruments, filters, strainers, air,

water, impulse and lube oil piping, etc.

x)

GA drawing of compressor room showing layout of compressors,

air, water, lube oil impulse and any other piping within Battery
limits of the compressors and accessories, after coolers, air dryers
and air receivers.

xi)

Quality Assurance Plans & Procedures for all the equipment.

Drawings/Data/Design Calculations which will not be approved and will be

used for reference only
i.

GA drawings of inter and after coolers

ii.

Foundation drawings with load data of air compressor

iii

Design calculations for arriving at guaranteed parameter for

intercoolers, aftercoolers and air dryers.

iv

Shell thickness calculations for intercoolers, aftercoolers and air

receivers.

Design calculations for arriving at parameter for intercoolers,

aftercoolers and air dryers.

vi

GA drawing of air receivers.

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

VOLUME - II
SECTION: C10
SHEET 4 OF 5

SPECIFICATION FOR COMPRESSED AIR SYSTEM

1.3

vii

Operation and Maintenance manuals for all equipment.

viii

RTFs & CD-ROMs of all the as built drawings for the compressed
air system.

All other documents as mentioned in the data sheets-C of section D

and other sections in this specification.
GENERAL
a)

Contract network schedule

b)

Flow diagram for all equipment indicating piping valves, specialities

and instrumentation including performance test scheme, technical
write-ups and performance test procedure

c)

Details of paints and painting material.

d)

Final technical data sheets for all equipment

e)

Installation drawings and manuals for all equipment/systems

f)

Detailed write-up for shop tests and site performance tests

g)

Integrated operation and maintenance manuals for the complete

plant as well as for all individual equipment

h) Test certificates for type/routine and standard acceptance tests

i) As-built drawings for all equipment/systems supplied under this
contract and all buildings / structures / works executed under this
contract incorporating all changes/modifications upto the time of
commissioning / handling over to the Owner.
j) Project Design Manual consisting of studies of all the systems, design
criteria, sizing calculations of all major equipment/systems etc.
k) Materials test certificates and performance test certificates for all
equipment tested at works
l)

Detailed interface schedule for all terminal points identifying terminal

point no., size, material, type of connection, design flow, pressure and
temperature at the terminal points

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

VOLUME - II
SECTION: C10
SHEET 5 OF 5

SPECIFICATION FOR COMPRESSED AIR SYSTEM

m) Storage instructions for all equipment

n) Drawings / data to be required / submitted to statutory authorities
o) Schedule of instruments for performance tests
p) Schedule of shop tests/inspections on all equipment
q) Schedules of places of shop test and inspection for all equipment
r) Detailed write-up on all pre-commissioning and commissioning
activities.
s) Cable schedules and interconnection schedules.
All documents, data sheets, drawing, schedules, lists, etc., to be
submitted by the Contractor/Sub-Contractor against this Contract shall
be submitted on CD-ROMs in addition to the required number of
prints/ reproducible. Any other documents as required will be
intimated to the successful bidder during detailed engineering for
which no commercial implication shall be entertained by the
purchaser.

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

VOLUME - II
SECTION: C11
SHEET 1 OF 5

SPARES

11.0

SPARES
The contractor shall include in his scope the Start-up / Commissioning
Spares as necessary.
The spares shall be delivered at site well in time before the start up and
commissioning of the plant.

11.1

Start-up spares
Start-up spares are those spares which will be required during the start-up
and commissioning of the equipment / systems until performance testing. It
is the responsibility of Contractor to supply all necessary spares as
required until the equipment / systems are handed over to the Owner. The
price of the start-up spares shall be included in the respective equipment /
systems. Adequate stock of start-up spares shall be made available at site
such that the start-up and commissioning of the equipment / systems,
performance testing and handing over of the equipment / systems to the
Owner can be carried out without hindrance and delay. Any unutilised
spares after taking over of the plant shall be handed over to the
Owner/Purchaser. The list of start-up and commissioning spares included
in the scope shall be furnished in the bid.

11.2

Recommended Spares:
The recommended spares are those spares that shall be considered
necessary by the contractor on a standalone basis without considering the
essential spares specified. The owner/Purchaser reserves the right to buy
any of the recommended spares as considered necessary by him. The
price of recommended spares shall be considered with those of the
essential spares. The validity of prices for these spares shall be upto three
(3) years from the date of Taking Over.

11.3
SL NO

Essential spares
DESCRIPTION

Units

Total quantity

Sets

Air Compressors
1

Air intake filter assembly complete with gaskets

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

VOLUME - II
SECTION: C11
SHEET 2 OF 5

SPARES

SL NO

DESCRIPTION

Units

Total quantity

Air intake rubber connector

Nos

All bearings / bushes

Sets

Oil filter assembly complete with gaskets

Sets

Oil pump coupling halves, complete

Sets

Oil pump seal kit

Sets

Seal kit for relief valve

Sets

Seal kit for solenoid valves

Sets

Springs and gaskets for safety valves

Sets

10

Gaskets and seals for inter cooler

Sets

11

Gaskets and seals for after cooler

Sets

Sets

set

1Set for each

type and rating

Air Driers
12

Pre filter and after filter element

13

Valve Actuator
Instrumentation

14

15

For all field Instruments, a min of one (1) or

20% of the quantity of each type or range,
whichever is higher is to be provided.
One no. of microprocessor based controller
(programmed) of each type

VOLUME - II

CARBERY INFRASTRUCTURE PTE LTD

SECTION: C11

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

SHEET 3 OF 5

SPARES

SL NO

DESCRIPTION

Units

Total quantity

ELECTRICAL SPARES
Sl No
1.0

Spares

Quantity

415 V SWITCHGEAR
415 VOLT BREAKER (Spares for each rating
of Breaker)

1.1

Breaker complete with operating mechanism

and truck mounted.

2 Nos.

1.2

Closing & tripping coils each of each type and

rating

4 Nos.

1.3

Fixed and moving contact assemblies of each

breaker

2 Nos.

1.4

Spring charging motors

3 Nos.

1.5

Gaskets

5 Sets

1.6

Auxiliary switch assembly, limiting position

switches

8 Nos. each

415 VOLT SWITCHGEAR

1.7

Bus Bar support insulators

10 Nos.

1.8

Switches of each type

2 Nos.

1.9

Protection Relays of each type

2 Nos.

1.10

Auxiliary relays of each type

2 Nos.

1.11

Interposing relay for PLC each type

2 Nos.

1.12

Clustered type LED of each type

4 Nos.

1.13

CTs of each ratio, type and rating

3 Nos.

1.14

VTs of each ratio, type and rating

3 Nos.

VOLUME - II

CARBERY INFRASTRUCTURE PTE LTD

SECTION: C11

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

SHEET 4 OF 5

SPARES

SL NO

DESCRIPTION

Units

Total quantity

1.15

Meters of each type

2 Nos.

1.16

Control fuses of each rating

10 Nos.

1.17

Transducers of each type and rating

4 Nos.

1.18

Timer each type

2 Nos.

1.19

Disconnecting type Terminal block for CT

wiring

5 Nos.

1.20

Non-disconnecting type Terminal Block

5 Nos.

2.0

MOTOR CONTROL CENTRE

(Spares to be repeated for each make of
MCC)

2.1

Complete assembled Contactor of each rating

5 Nos.

2.2

Complete assembled Auxiliary Contactor of

each rating

5 Nos.

2.3

Auxiliary switches (Limit switches/micro

switches)

5 Nos.

2.4

Bi-metal thermal overload relays with single

phase preventors of each rating.

5 Nos.

2.5

Single phase control transformer 415V/110V

of each rating.

5 Nos.

2.6

Fuses of each type and rating :

Power

10 Nos

Control

10 Nos

2.7

Fuse puller for each type of fuse

5 Nos.

2.8

Current transformers of each type and rating

3 Nos.

VOLUME - II

CARBERY INFRASTRUCTURE PTE LTD

SECTION: C11

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

SHEET 5 OF 5

SPARES

SL NO

DESCRIPTION

Units

Total quantity

3.0

CONTROL PANEL

3.1

Indication lamps (LED)

10 Nos.

3.2

Control fuses of each type and rating

6 Nos.

3.3

Switches of each type and rating

2 Nos.

3.4

Selector switch of each type and rating

2 Nos.

3.5

Push Button

2 Nos.

3.6

Auxiliary relay of each type and rating

2 Nos.

3.7

Timer of each range

2 Nos.

3.8

Annunciation window lamps

10 Nos.

3.9

Meters

3.10

Annunciation cards

11.4

2 Nos. of each type

and rating
5 Nos.

General
In the event of any equipment being changed during engineering, the
contractor shall supply start up spares, essential spares and maintenance
tools pertaining to this equipment.
The contractor shall also note that the Owner/Purchaser, if required, shall
approach directly to the individual equipment manufacturers / suppliers for
procuring recommended spare parts. The Owner/Purchaser shall not
necessarily procure these parts through the Contractor.

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

VOLUME - II
SECTION: C12
SHEET 1 OF 19

GENERAL PAINTING REQUIREMENTS

1.0

SCOPE
The purpose of this specification is to describe the surface preparation
methods, application procedures and type of protective coatings required.
This section covers the painting requirements for the power plant equipment,
structures, piping etc. and any other surface required to be painted. The
painting system should ensure optimal protection of the installation with
minimum need for maintenance, environmental friendly & easy to apply.

2.0

CODES AND STANDARDS

2.1

Painting of equipment shall be carried out as per the contracts indicated

below and shall conform to the relevant IS contract for the material and
workmanship.

2.2

The following Standards may be referred to for carrying out the painting:
IS: 5
IS: 101
IS: 1303
IS: 2379
IS: 1477
IS: 2524
IS: 6278
IS: 13183
IS: 158
IS: 2074
IS: 104
IS: 2932
IS: 2629
BS EN ISO
14713
ISO 8501
ISO 8502

Colours for ready mixed paints and enamels

All Parts and Sections for paint testing
Glossary of terms relating to paints
Colour code for identification of pipelines
Code of practice for painting of ferrous metals in buildings
(Parts I & II)
Code of practice for painting of non-ferrous metals in
buildings (Parts I & II)
Code of practice for white washing and colour washing
Aluminium Paint, heat Resistant specification
Ready mixed paint, brushing, bituminous, black, Lead free,
acid, alkali, water and heat resisting
Ready mixed paint, air drying, red Oxide Zinc Chrome,
priming
Ready mixed paint, brushing, Zinc Chrome, priming
Enamel, synthetic, exterior (a) undercoating (b) finishing.
Recommended Practice for Hot Dip Galvanising
Code of practice for protection of iron & steel structure
against corrosion
Preparation of steel substrates before application of paint &
related Products.
Assessment of dust on steel surface prepared for painting
(Pressure sensitive tape method)

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

VOLUME - II
SECTION: C12
SHEET 2 OF 19

GENERAL PAINTING REQUIREMENTS

ISO 12944
SSPC
SSPC-SP-08
NORSOK M-501
ISO 20340
ASTM
AWWA
SIS : 05-5900

Paints and Varnishes-Corrosion protection of steel structures

by protective paint systems
US Specifications of Steel Structures Painting Council, SSPC
Volumes I and II
Surface preparation by Pickling
Surface preparation & Protective coating
Pre-Qualification test
American standard test method for paints and coatings
American Water Works Association
Swedish Standard for surface preparation

Statutory and Local regulations shall be strictly followed in selection and

application of paint.
3.0

GENERAL
This specification covers the surface preparation, method of application and
material to be used for all coating of equipment, steel structures and piping.
Steel material subjected to surface preparation on shop/site shall have
minimum requirements in accordance with Rust Grade B (SSPC/SSPM
Volume-2).
Coating materials according to SSPC, EN ISO, ASTM, BIS or DIN standards,
shall be used. The paint shall comply with applicable laws, regulations,
ordinances etc., of the local authority, state or the nation pertains to the work.
The materials shall be matched with each other so that they are compatible.
Standards of surface preparation and painting shall give a time to first
maintenance of 10 years.

3.1

APPROVED PAINT MANUFACTURERS

1

Asian Paints (I) Ltd.

Berger Paints India Ltd

Goodlass Nerolac

Jenson & Nicholson (I) Ltd.

CDC carboline (I) Ltd.

Shalimar Paints Ltd.

Addison Paints Ltd.

Grand Polycoat

Bombay Paints

10

International Protective Coatings

11

Ameron, USA

12

Jotun

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

VOLUME - II
SECTION: C12
SHEET 3 OF 19

GENERAL PAINTING REQUIREMENTS

3.2

COATING MATERIALS

3.2.1

The selected coating materials shall be suitable for the intended use and
shall be selected after an evaluation of all relevant aspects such as:

3.2.2

(a)

Corrosion protective properties

(b)

Requirements to health, safety and environment

(c)

Properties related to application conditions, equipment and personnel

(d)

Experience with the coating materials and coating system.

Performance standard as listed below shall be established by paint

manufacturer, the records shall be submitted for review:
(a)

Adhesion test (pull off test)

(b)

Flexibility test

(c)

Salt spray test (min 1000 Hrs)

(d)

Water absorption test

(e)

UV resistance test (external coating)

(f)

Cathodic disbonding test (internal coating)

(g)

Abrasion test (internal coating)

(h)

Impact resistance test

3.2.3

Each product shall have a batch number showing year and month of
manufacture and giving full traceability of production. Shelf life shall be
included in the technical data sheet. All coating materials and solvents shall
be stored in the original container bearing the manufacturer's label and
instructions.

3.2.4

The paint manufacturers shall provide coating system data sheet for each
coating system to be used containing the following information:
(a)

Surface preparation

(b)

Film thickness(min and max)

(c)

Min and max recoating intervals at relevant temperatures

(d)

Mixing ratio, thinner details and coating repair systems

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

VOLUME - II
SECTION: C12
SHEET 4 OF 19

GENERAL PAINTING REQUIREMENTS

3.2.5

The composition of the paint shall be at the discretion of the manufacturer,

provided that the finished product meets the requirements of, state or local
regulatory bodies for the products. All vehicle components for use in the
manufacture of paints and enamels shall meet the ASTM/ ISO Specification
except as otherwise stated. Coating systems shall be selected as per
corrosivity category.

3.2.6

Coating systems are tabulated in ANNEXURE and shall be pre-qualified in

accordance with specification. Coating systems/ alternative coating systems
may be re-subjected to pre-qualification, at the discretion of Purchaser. The
specified coating systems, the number of coats and the coating film
thicknesses given in ANNEXURE are minimum requirements. Top coat
colors should be in accordance with ANNEXURE.
The paint to be applied shall be approved by Purchaser.

4.0

PAINTING SYSTEM PROCEDURE

4.1

All paints & paint material used shall be procured from approved
manufacturers. Paint shall be supplied in manufacturers original containers
with the description of content, specification No., colour, ref no, date of
manufacture, shelf life expiry date & pot life.

4.2

All coating materials and solvents shall be protected from ignition sources
and shall remain within storage temperatures and storage conditions
recommended by the coating manufacturer. All coating materials and
solvents shall be stored in the original container bearing the manufacturer's
label and instructions.

4.3

The sample for testing the paint being used may be taken by the customer
at any time. In general Shop manufactured equipment / component will be
delivered to the site coated with a shop applied system or the
manufacturer's standard finish in accordance with the requirements of this
specification. The contractor shall state the extent of shop coating and field
coating for the equipments supplied.

4.4

For equipment that has received shop prime coat, touch-up prime coat and
additional coats shall be applied in accordance with the coating schedule. It
is responsibility of the Contractor to ensure compatibility between shop and
field applied paint systems.

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

VOLUME - II
SECTION: C12
SHEET 5 OF 19

GENERAL PAINTING REQUIREMENTS

4.5

Necessary Protection shall be provided to the surfaces of all the other

equipment, structures, during surface preparation and painting. Damage to
other surfaces or equipment shall be repaired by the Contractor.

4.6

The Contractor shall submit the following for review and approval by the
Customer:
(a)

Manufacturer's recommended paint scheme for the project

(b)

Latest published product & instructions for application data,

(c)

Procedures for surface preparation and application of recommended

painting scheme.

(d)

Pre qualification for equipments and blasting materials, product,

procedure and personnel qualifications for the paint and painting
systems.

(e)

Painting repair procedures

4.7

The supply of all necessary equipments, weather protection, and scaffolding

for painting to ensure work is carried out in accordance with the
specification and agreed programme.

4.8

Maintenance of the paint work until completion of the contract, this shall
include repair of any damaged areas caused by third party.

4.9

Disposal of painting waste resulting from painting, shall comply with

applicable laws, regulations, ordinances etc., of the local authority, state or
the nation pertains to the work and coating materials.

4.10

It is a mandatory requirement that all operatives working to this procedure

take full cognizance and implement necessary safety precautions.

5.0

PREPARATION OF SURFACES
All surfaces to be painted shall be thoroughly cleaned of all grease, oil,
loose mill scale, dust, rust, weld spatters, sharp edges and any other foreign
matter. Removal of grease and oil contamination shall be in accordance
with SSPC-SP1 prior to cleaning process described below.
Mechanical cleaning by power tool and scrapping with steel wire brushes
shall be adopted to clear the surfaces. However, in certain locations where
power tool cleaning cannot be carried out, hand scrapping may be permitted
with steel wire brushes and/or abrasive paper. Cleaning with solvents shall

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

VOLUME - II
SECTION: C12
SHEET 6 OF 19

GENERAL PAINTING REQUIREMENTS

be resorted to only in such areas where other methods specified above

have not achieved the desired results. Cleaning with solvents shall be
adopted only after written approval of the Purchaser.
The blast cleaned surface shall be checked for signs of salt contamination
as per ISO 8502-6 & 9. The maximum allowable level of contamination shall
be 20 mg/m2. Surfaces that do not meet these criteria shall be reprocessed.
5.1

MECHANICAL CLEANING:
Manual/power tool cleaning shall be done as per grade St-2 or St-3, of ISO
8504-3. This method to be used for repair painting or on already painted
surface and in case of usage on new construction painting prior approval
may be obtained from purchaser.

Hand tool
cleaning
Power tool
cleaning

Condition
surface
Rusted

of ISO 8504- SIS

3
055900
C St2
C St2

SSPC
SP2

Rusted and pitted

D St2

D St2

SP2

Rusted

C St3

C St3

SP3

Rusted and pitted

D St3

D St3

SP3

Grade St-2: Thorough scraping and wire brushing, machine brushing,

grinding etc. This grade of preparation shall remove loose mill scale, rust
and foreign matter. Finally the surface is to be cleaned with a vacuum
cleaner or with clean compressed air or with clean brush. After preparation,
the surface should have a faint metallic sheen. The appearance shall
correspond to the prints designated St-2.
Grade St-3: very thorough scraping and wire brushing, machine brushing,
grinding etc. After preparing the surface, it should have a pronounced
metallic sheen and correspond to the prints designated St-3.

5.2

BLAST CLEANING:

5.2.1

Compressors: Compressed air supply for blast cleaning shall be free of

water and oil. Air compressors shall not be allowed to deliver air at 110deg
C. The blasting activity shall be performed at ambient temperatures above
5C and relative humidity less than 85%. Steel temperature shall be 3C
above dew point. Necessary safety precautions for equipment and operator
shall be adhered to.

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

VOLUME - II
SECTION: C12
SHEET 7 OF 19

GENERAL PAINTING REQUIREMENTS

5.2.2

Abrasives: Abrasives used for blast cleaning carbon steel and alloy steel
shall be
as per ISO 8504-2 and SSPC painting manual. Suggested
abrasives may be chilled iron grit or shot steel and malleable iron grit and
shots non metallic abrasive (aluminium oxide, copper slag, garnet etc.).

5.2.3

Removal of mill scale and rust using abrasives such as grit or shot under
high pressure. The grade of blasting performed in line with the approved
painting scheme.

5.2.4

Surfaces to be coated shall be free of all grease, oil, loose rust, and loose
mill scale. Rust, mill scale, weld spatter, flux, shall be removed by the
methods indicated in the Coating Schedule. Oil and grease shall be
removed by solvent cleaning method as outlined in SSPC - SP 1 prior to
blasting.

5.2.5

The quality and grain size of abrasives and the parameter of their use are to
be chosen to obtain the surface profile depth and cleanliness. Abrasives
shall comply with applicable laws, regulations, ordinances etc., of the local
authority, state or the nation pertaining to the work.

5.2.6

Profile measurements for abrasive blast cleaned surface shall be made with
a Profile comparator and permanent record shall be maintained with
Testex Press-O-Film.

5.2.7

Surfaces prepared for coating shall be coated the same day and before any
visible rusting occurs (the time elapsed between blast cleaning and
commencement of painting shall under no circumstances exceed 4 hours,
but in any case must commence before signs of degradation occur).

5.2.8

The grades of surface finish:

ISO 8501-1

SIS 055900

SSPC NACE

White metal

Sa3

Sa3

SP5

Near White metal

Sa 2

Sa 2

SP10

Commercial blast

Sa2

Sa2

SP6

Brush off blast

Sa1

Sa1

SP7

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

VOLUME - II
SECTION: C12
SHEET 8 OF 19

GENERAL PAINTING REQUIREMENTS

6.0

PAINT APPLICATION

6.1

Paints and other coating materials shall be applied in accordance with the
paint manufacturers instructions. The surface preparation and painting
system shall be as described in ANNEXURE with the following exceptions:

6.2

(a)

Nameplates, code stampings and push buttons

(b)

Concrete brickwork, tile, and glass unless specified by the Purchaser.

(c)

Non-ferrous materials

(d)

Austenitic stainless steel

(e)

Plastic and / or plastic coated materials

(f)

Insulated surface of equipment and pipes except colour coating

wherever required

(g)

Any surface specified by the Purchaser not to be painted.

Painting records shall contain:

(a)

Equipment/components/location painted

(b)

Date of painting

(c)

Paint details such as specification No, colour, date of manufacture,

shelf life, expiry date

(d)

Application equipments

(e)

Ambient conditions at the time of painting

(f)

Surface temperature

(g)

Drying time between coating, DFT and number of coatings

(h)

Appropriate work plan for painting.

7.0

PAINT APPLICATION REQUIREMENTS

7.1

The paint shall be applied in accordance with the paint manufacturers

product data sheet, which shall include the mix ratio, the method of
application, and the use of thinners and over coating times.

7.2

Paint application shall be by brush, roller or spray gun. Local regulations

regarding spray and roller coating shall be observed. A smooth uniform film
shall be applied to the surfaces to be coated.

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

VOLUME - II
SECTION: C12
SHEET 9 OF 19

GENERAL PAINTING REQUIREMENTS

7.3

Painting shall be performed when the temperature of the surface is greater

than 3C above the dew point of the surrounding air and relative humidity of
the air is less than 85% unless local conditions dictate otherwise and the
Customer is in agreement. Guidance on the estimation of the probability of
condensation can be found in ISO 8502-4. The measurement of these
conditions is the responsibility of the Vendor.

7.4

In addition, paints shall not be applied under the following conditions:

(a)

When the surface temperature is greater than 60 C (unless a higher

temperature is agreed by the paint manufacturer)

(b)

When the air temperature is less than approximately 5C, (depending

on local conditions)

(c)

When there is the likelihood of an unfavourable change in weather

conditions within two hours after painting

(d)

When there is a deposition of moisture in the form of rain,

condensation, frost, etc., on the surface.

(e)

When the available light is less than 500 lux.

7.5

Paints shall not be applied within 50 mm of edges which will later have to be
welded. Such weld areas shall be taped/one coat of weldable primer for
distance of 50 mm either side of the weld line.

7.6

When zinc rich primers are used, care shall be taken to mask to avoid any
possibility of over spraying onto duplex, austenitic stainless steels; nickel
alloys or 9% nickel steel components.

7.7

Two pack coatings like Air drying epoxy, Polyurethane coatings etc shall be
mixed in the ratio recommended by manufacturer to ensure proper and
complete curing of the coatings. The base and hardener are to be
separately mixed first to obtain a homogenous mixture. The hardener is to
be added to the base slowly, with continuous mixing / agitation and not the
reverse. Power agitation is preferred over hand mixing.

7.8

Any addition of thinner to achieve the application viscosity should be made

only after the components are thoroughly mixed. Excess thinner is not
recommended, as increase in volume, leads to lower DFT, sagging, longer
curing time, etc.

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

VOLUME - II
SECTION: C12
SHEET 10 OF 19

GENERAL PAINTING REQUIREMENTS

7.9

Coating containing heavy or metallic pigments that have a tendency to

settle shall be kept in suspension by continuous use of a mechanical
agitator whilst being applied, to ensure uniformity over the surface area
(e.g., zinc MIOs pigmented materials).

7.10

Transport and erection of painted structures shall be carried out only after
the drying time specified by the paint manufacturer has elapsed. Handling &
packing of painted material shall be appropriate to avoid damage to
painting, such as the use of non-metallic slings, etc for handling and by
minimising handling after painting.

7.11

All steel equipment shall be provided with priming or coating system to

protect the steel surface during transport, storage, installation and
construction.

8.0

SPRAY APPLICATION:

8.1

Airless or pneumatic spray applications are preferred methods of

application. Spraying shall be carried out keeping the spray gun at the
minimum suitable distance from the work piece and consistently at 90 to
the surface being painted.

8.2

Approval of Purchaser shall be obtained during spray painting which may

cause interference to other works. If spray painting is to be carried out, the
following shall be taken into account:

8.3

The correct spray tips, air pressures, etc, as recommended by the

equipment supplier, shall be used.

8.4

Conventional air spray equipment is used, the correct combination of air

volume, air pressure and fluid flow to give good atomisation to be ensured
to get a defect free painted surface. The major disadvantage of
conventional air spray is that high build coatings can generally not be
applied by this method as most paints have to be thinned to a suitable
viscosity for satisfactory atomisation, and so lose their high build properties.
Vendor shall follow manufactures instruction.

8.5

Air spray (pressure pot) is recommended in cases where large quantities of

paint are to be applied as paint in the tank can be prevented from settling,
reduces application time and also enables the gun to be turned to any angle
to coat objects effectively without spilling paint.

8.6

Airless spray is recommended as high build coatings can be applied without

thinning, very rapid application is possible, giving an economic advantage,

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

VOLUME - II
SECTION: C12
SHEET 11 OF 19

GENERAL PAINTING REQUIREMENTS

compared to conventional spray, overspray and bounce-back are reduced,

leading to reduced losses of material and less dust and fume hazards.
8.7

Each coat shall be applied uniformly and completely over the entire surface.
All runs and sags shall be brushed out immediately or the paint shall be
removed and the surface re-sprayed.

8.8

Very complex structures should be painted by brush instead of spray gun to

avoid overspray, dry spray and unacceptable paint losses.

9.0

BRUSH APPLICATION:

9.1

Brush application may be used under the following circumstances:

(a)

When areas cannot be properly coated by spraying for reasons such

as material or environmental considerations

(b)

For the initial coat of paint to corners, edges, crevices, holes, welds or
irregular surface prior to spray application

(c)

For touch up or repairs to localize damaged paint or areas of

incorrectly applied paint

(d)

Where the paint manufacturer considers the coating material suitable

for brush application.

9.2

Brushes shall be of a style and quality that will permit the proper application
of paint.
Brush applications should be done in two passes that are perpendicular to
each other wet on wet so that a smooth coat, as near uniform in thickness
as possible, is obtained there by avoiding running and droplets. There
should be no deep or detrimental brush marks. Paint shall be worked into all
crevices and corners. Runs and sags shall be brushed out.

9.3

During the application of each coat, all areas such as corners, edges,
welds, small brackets, bolts, nuts and interstices shall receive additional
paint to ensure that these areas have at least the minimum specified dry
film thickness and to ensure continuity of coating.

10.0

ROLLER APPLICATION:
Roller application shall only be used on relatively large surface areas and
only if spraying is not on option. Roller application shall only be used if the
first or priming coat of paint has been applied by brush. Roller application
shall be in accordance with the paint Manufacturers instructions.

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

VOLUME - II
SECTION: C12
SHEET 12 OF 19

GENERAL PAINTING REQUIREMENTS

11.0

GALVANISING:

11.1

GRATINGS AND STEP THREADS

11.1.1

Surface preparation
Gratings and step threads shall be cleaned by acid pickling as per SSPCSP-08.

11.1.2

Hot dip galvanising

The hot dip galvanising shall be done as per IS 2629 .The average mass of
coating shall be 610 gms/m2.

11.1.3

Post galvanising treatment

Immediately after galvanising, post treatment such as chromating shall be
applied to retard white rust attack.

11.1.4

Touch up mechanical damages

The repair of damages coatings shall be done as per the recommended
practice ASTM A 780.

12.0

CORROSIVITY OF ENVIRONMENTS:
Corrosivity category

13.0

C2

Low

C3

Medium

TESTS REQUIRED FOR EVALUATION OF ACCEPTANCE OF COATING

MATERIALS:
TABLE -1
PERFORMANCE TEST OF PAINT
SL. No.
1
2
3

TEST
Abrasion Resistance:
only)
Adhesion:
Dry Heat Resistance:

ASTM TEST METHOD

(topcoat

ASTM D4060
ASTM D4541
ASTM D2485

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

VOLUME - II
SECTION: C12
SHEET 13 OF 19

GENERAL PAINTING REQUIREMENTS

4
5
6
7
8
9
10
11
12
13
14
15
16
SL. No.
17
18

Flexibility: (topcoat only)

Pencil Hardness: (topcoat only)
Salt Fog Resistance:
Weather Resistance:
Test
Density
Dipping properties
Drying time
Flexibility
Hardness
Adhesion ( pull off test)
Abrasion resistance
DFT/Coat
TEST
Storage Stability
Resistance to
i) Humidity for 2000 hrs.
ii) Salt Spray for 2000 hrs.
iii)Accelerated Weathering

ASTM D522, 180 bend

ASTM D3363
ASTM B117, 1000 hours
ASTMG23 Type D
ASTM Test Method
D 1475
D 823
D 1640
D 1737/D 522
D 3363
D 4541
D 968/D 4060
As per SSPC Guidelines
ASTM TEST METHOD
D 1849
D 2247
B 117
D 822

14.0

INSPECTION:

14.1

Inspection will be performed by an inspector authorised by Purchaser. Paint

materials including primers and thinners brought to site by contractor for
application shall be procured directly from manufactures as per specification
and shall be accompanied by manufacturers test certificates.

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

VOLUME - II
SECTION: C12
SHEET 14 OF 19

GENERAL PAINTING REQUIREMENTS

14.2

The painting work shall be subjected to inspection by purchaser at all times.

The vendor shall offer following stage of inspection:

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

VOLUME - II
SECTION: C12
SHEET 15 OF 19

GENERAL PAINTING REQUIREMENTS

(a)
(b)
(c)
(d)

Surface preparation
Primer application
Subsequent coats
Paint qualification test

14.3

Vendor shall provide the expert technical services of the paint manufactures
as and when required by purchaser to ensure both the surface preparation
and applications are carried out as per their recommendations. This service
shall be provided without any obligation to purchaser.

14.4

The following coating inspection & test shall be carried out:

(a)

Ambient and steel temperature, relative humidity and dew point min
twice in a shift.

(b)

Surface finish & profile check each component or once per 10 m2 after
surface preparation.

(c)

Salt contamination test - Free from salt contamination.

(d)

Dry Film Thickness as per ISO 2808 No.6.

(e)

Holiday Test as per ASTM D 5162/ NACE RP 0188.

(f)

Adhesion Test as per ISO 2409 for cross-cut test, or a pull-off test as
per ISO 4624/ ASTM D 4541.

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

VOLUME - II
SECTION: C12
SHEET 16 OF 19

GENERAL PAINTING REQUIREMENTS

ANNEXURE - I
Notes:
1.
2.
3.

4.
5.
6.
7.
8.
9.

Surface preparation shown is as per Swedish Standards SIS 05-5900.

Degreasing will be as per Standard SSPC-SP1.
Incase of insulated surfaces, only primer coats shall be applied.
GM/SS items with piping and G.I. pipes will not be painted. However these
items coming under Fire Fighting System shall be painted Fire Red as per
TAC guidelines. Further SS/GI piping shall be given necessary colour
banding for identification as per approved colour scheme/coding.
All instruments shall be painted as per manufacturer standard practice.
All structural steel items shall be painted at site. Equipment shall be finish
painted at shop.
Method of painting application shall be as per paint manufacturers
recommendation.
Rust preventive coating should be given on HSFG bolt and nut threads.
Machined Surface are to be applied with a coating of Temporary Rust
preventive oil.
Based on above painting schedule, detailed painting schedule will be
prepared by respective package supplier and these be submitted for
Purchasers Approval

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

VOLUME - II
SECTION: C12
SHEET 17 OF 19

GENERAL PAINTING REQUIREMENTS

ANNEXURE - II
1. CONDENSATE/DM WATER STORAGE TANK
Internal
Surface
preparation
Primer

Intermediate
coat

Finish

Blast clean to SA 2.5

2 coats of epoxy zinc
phosphate primer of 40
micron each.

2 coats of solvent free

heay duty epoxy lining,
DFT 100 microns each.

Total DFT
280 microns
2. HFO/LDO STORAGE TANKS
Internal
Surface
Wire brushing
preparation
Primer
NA

External
Blast Clean to SA
2.5
1 coats of HB Epoxy
based zinc
phosphate/anti
corrosive
pigmentation primer
of 100 microns DFT
1 coat of epoxy
based TiO2
pigmented paint of
DFT 50 micron
2 coats of polyamide
cured epoxy finish
paint of 40 micron
each.
230 microns

Underneath of
Bottom Plate
Wire brushing/ hand
tool cleaning to ST-2.
2 coat of high build
coal tar epoxy suitably
pigmented, DFT : 80100 microns each coat.
-

N.A

200 microns

External
Underneath
Blast Clean to SA
Wire brushing/ hand
2.5
tool cleaning to ST-2.
1 coats of HB Epoxy 2 coats of high build
based zinc
coal tar epoxy suitably
phosphate/anti
pigmented (2 pack),
corrosive
DFT: 100 microns
pigmentation primer
of 100 microns
Intermediate
1 coat of epoxy
coat
based TiO2
pigmented paint of
DFT 50 micron
Finish
2 coats of double
2 coats of polyamide NA
boiled linseed oil.
cured epoxy finish
paint of 40 microns
each
Total DFT
230 microns
200 microns
Note: For HFO tank, internal painting is same as that of LDO storage tank. Only
primer to be applied at the outside the tank before insulation (if applicable).

VOLUME - II

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3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

SECTION: C12
SHEET 18 OF 19

GENERAL PAINTING REQUIREMENTS

ANNEXURE - III
SUGGESTED COLOUR CODES FOR PAINTING
SL.
NO.

ITEM/SERVICE
Structures, platforms,
ladders and handrails

1.0

5.0

Fans, pumps, motors,

compressors, blowers
Tanks (without insulation and
cladding)
Outdoor, Stand pipes, vent
pipes
Indoor
Vessels & all other
proprietary equipment
(without insulation &
cladding)
Switchgear

6.0

Control & relay panels

7.0

Transformers

2.0
3.0
3.1
3.2
4.0

COLOUR

IS-5/RAL

COLOUR
(BAND)

IS-5

Dark
Admiralty
Grey

632

Light Grey

631

Aluminium

Aluminium

Light grey

631

Light grey

631
631/707 of
IS 1650

Light grey
Dark
Admiralty
Grey
Signal red

537

Sea green

217

Sea green

217

Sea Green

217

Sea green

217

Sea green

217

f) Potable & filtered water

Sea green

217

g) Service & clarified water

Sea green

217

Light
brown
Light
orange
French
blue
French
blue
French
blue
French

8.0

Machinery guards
Piping (without insulation and
9.0
cladding)
9.1
Water System
a) Boiler feed
Condensate
b)

c)
d)
e)

D M Water
Soft water
Bearing cooling water

410
557
166
166
166
166

VOLUME - II

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SECTION: C12
SHEET 19 OF 19

GENERAL PAINTING REQUIREMENTS

SL.
NO.

ITEM/SERVICE

h) Raw water
Cooling water
i)
Compressed Air System
a) Service air
b) Instrument air
9.3
Oil system

COLOUR

IS-5/RAL

Sea green

217

Sea green

217

Sky Blue
blue

101
101

COLOUR
(BAND)
blue
White
French
blue

IS-5

166

9.2

a)
b)
c)

Fuel oil
Light oil
Lubricating oil

d) Control oil
Transformer oil
e)
9.4
a)
9.5
9.6
9.7
9.8
9.9
9.10
9.11

Gas system
Carbon dioxide
Fire services
Ash slurry pipes
Vacuum pipes
Fuel pipes (Coal)
Drainage
Stand pipes and all Vent
pipes
Bottom Ash system

Light
brown
Dark
Brown
Light
brown
Light
Light
brown

410
412

White
French
Blue
Brilliant
green

166
221

410

Light grey

631

410

Light
Light
orange

557

309

Light grey

631

536
101

Black

410

Aluminum

Light Grey

631

Canary
yellow
Fire red
Black
Sky blue
Light
brown
Black

410

Notes :
1.

This colour code basically refers to IS:2379 for piping with necessary
modifications.

2.

Where band colour is specified, same shall be provided at 10 meter

intervals on long uninterrupted lines and also adjacent to valves and
junctions.

557

Strength
Residual unbalancement

2.2 Casing

2.3 Dynamic balancing of rotating parts

N
O
T
E

Capacity, Power consumption,

3.2 Performance Testing

Measurement

Measurement

Unbalancement

Hydrotest

MPI/LPI

100%

100 %

100%

100%

100%

ASME PTC 10,Section 2

and Data Sheets for
Centrifugal Compressors.

IS 5456 and Data Sheets for

Screw type compressors.

Drawing

Drawing and ISO 1940

Drawing

Manufacturer's NDT procedure

Material specification

Material specification

Material specification

REF. DOCUMENT /
ACCEPTANCE NORM
6

report

Performance test

Inspection report

Inspection report

Hydrotest report

NDT report

TC

TC

TC

FORMAT OF
RECORD
7

REMARKS

SHEET  OF
AGENCY
S M
P
8

A. STATUTORY REQUIREMENTS SHALL BE COMPLIED WITH BY THE VENDOR.

B. MATERIAL TESTS OF SAMPLES DRAWN BY PURCHASER SHALL BE WITNESSED BY PURCHASER.
C. FOR STAGES WITNESSED / DOCUMENTS REVIEWED BY PURCHASER, COPIES OF RELEVANT DOCUMENTS SHALL BE FURNISHED TO PURCHASER.
D. PURCHASERS IDENTIFICATION STAMP ON MATERIALS SHALL BE PRESERVED / GOT TRANSFERRED BY PURCHASER AT APPROPRIATE STAGES.
E. THE EXTENT INDICATED IN COLUMN 5 IS IN VENDORS SCOPE. PURCHASER MAY INSPECT AS PER THIS COLUMN OR RANDOM SAMPLES.
F. COLUMN 6 SHALL BE AS PER PURCHASER APPROVED DRAWINGS / DATA SHEETS / SPECIFICATIONS WHEREVER APPLICABLE.
G. INSTRUMENTS FOR LEAK TESTS AND PERFORMANCE TESTS SHALL HAVE VALID CALIBRATION CERTIFICATE WITH TRACEABILITY TO NATIONAL LEVEL.
H. LEGENDS :
S - SUB - VENDOR, M - MAIN VENDOR,
P- PURCHASER
W - WITNESS,
V - DOCUMENTS REVIEW, H - HOLD POINT.

vibration

Discharge pressure, noise level,

Overall dimensions

3.1 Visual and dimensional inspection

3.0 FINAL :

Soundness

MPI

Surface defects (Castings)

100%

100%

UT

Soundness of forgings

EXTENT

100%

TYPE /
OF CHECK
4

Chem., Mech. properties, Dimns. Review of docs.

CHARACTERISTICS
CHECKED
3

MINIMUM INSPECTION
REQUIREMENTS FOR AIR COMPRESSOR (SCREW TYPE)

SECTION: C13

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

QUALITY ASSURANCE REQUIREMENTS

VOLUME-II

CARBERY INFRASTRUCTURE PTE LTD

2.1 Rotor and Shaft

2.0 IN-PROCESS INSPECTION :

1.1 Raw materials

SR.
COMPONENT / OPERATION
NO.
1
2
1.0 MATERIALS :

Procedure, Personnel qualification

Surface defects

4.3 Welding

4.4 Weld inspection

Strength and leak tightness

Length, Nozzle orientation, etc.

4.7 Visual and dimensional inspection

Surface defects

c) Nozzle and attachment welds

4.6 Hydrostatic test

Soundness

b) T-joints

butt joints (except T joints)

a) Longitudinal and Circumferential

Soundness

Surface check

4.2 NDE of knuckle portion of dished end

4.5 Non-Destructive examination :

Chem., Mech. properties, Dimns.

CHARACTERISTICS
CHECKED
3

Measurement

Visual,

Visual

MPI/LPI

RT

RT

Visual

Review of docs.

MPI

Review of docs.

TYPE / METHOD
OF CHECK
4

100 %

100%

100%

100%

10%

100%

100%

100%

100 %

EXTENT

Drawing

ASME Sec. VIII Div. 1

ASME Sec. VIII Div. 1

ASME Sec. VIII Div. 1

ASME Sec. VIII Div. 1

ASME Sec. VIII Div. 1

ASME Sec. IX

ASME Sec. VIII Div. 1

Material specification

REF. DOCUMENT /
ACCEPTANCE NORM
6

MINIMUM INSPECTION
REQUIREMENTS FOR AIR COMPRESSOR (SCREW TYPE)

Inspection report

Hydrotest report

NDT report

RT report

RT report

Inspection report

WPS, PQR, WPQ

MPI report

TC

FORMAT OF
RECORD
7

AGENCY
M
P
8

REMARKS

SHEET  OF

SECTION: C13

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

QUALITY ASSURANCE REQUIREMENTS

VOLUME-II

CARBERY INFRASTRUCTURE PTE LTD

4.1 Raw materials

INTER COOLER & AFTER COOLER

SR.
COMPONENT / OPERATION
NO.
1
2
4.0 AIR RECEIVER, AIR DRIER,

Chem., Mech. properties, Dimns.

1.1 Body, bonnet, ball, plug, stem

FINAL INSPECTION:

For all valves

3.1 Testing

3.0

Hardness test on trim

Body, seat

Hardness

Body, bonnet, ball, plug, stem disc, Surface defects in machined area
cover, seat,trim

Hydro test

Measurement

PT/MPI

Type test

Endurance

Diapragm

2.0 IN-PROCESS INSPECTION:

Measurement

UT

Hardness

Soundness (for diameter > 50 mm)

Stem

LPI/MPI

Review of docs.

TYPE / METHOD
OF CHECK
4

1.2 Diapragm/seats

Surface defects

Surface examination

alloy steel valves

Body, bonnet, disc, cover for

disc, cover casting/forging

CHARACTERISTICS
CHECKED
3

Drawing

10 %

100%

ANSI B 16.34 /
598

Drawing

ASME B 16.34/API 598

API

AM 203.2 of Sec. VIII Div. 2

ASME B 16.34

Material specification

REF. DOCUMENT /
ACCEPTANCE NORM
6

One/type Drawing

10%

100%

100%

100%

EXTENT

MINIMUM INSPECTION
REQUIREMENTS FOR VALVES AND SPECIALITIES
(RATING ANSI 300 & BELOW)

Inspection report

Hardness report

PT/MPI Report

TC

Hardness report

TC

LPI/MPI Report

TC

FORMAT OF
RECORD
7

REMARKS

W Valves will be selected at

random

V 100 % PT only on
machined hard face
surfaces,weld edge
preparations
V * Random hardness
checking on test samples
for hard faced surfaces

AGENCY
M
P
8

SHEET  OF

SECTION: C14

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh.

QUALITY ASSURANCE REQUIREMENTS

VOLUME-II

CARBERY INFRASTRUCTURE PTE LTD

SR. COMPONENT / OPERATION

NO.
1
2
1.0 MATERIALS:

N
O
T
E

A.
B.
C.
D.
E.
F.
G.
H.

Dimensional,
visual
Visual

Dimensional, visual

Completeness

10 %

10 %

10 %

10 %

10 %

10 %

10 %

10 %

Drawings/data sheets

Drawings/data sheets

Drawings/data sheets

Drawings/data sheets

Inspection report

Inspection report

Inspection report

Inspection report

Inspection report

Inspection report

Inspection report

Inspection report

STATUTORY REQUIREMENTS SHALL BE COMPLIED WITH BY THE VENDOR.

MATERIAL TESTS OF SAMPLES DRAWN BY PURCHASER SHALL BE WITNESSED BY PURCHASER.
FOR STAGES WITNESSED / DOCUMENTS REVIEWED BY PURCHASER, COPIES OF RELEVANT DOCUMENTS SHALL BE FURNISHED TO PURCHASER.
PURCHASERS IDENTIFICATION STAMP ON MATERIALS SHALL BE PRESERVED / GOT TRANSFERRED BY PURCHASER AT APPROPRIATE STAGES.
THE EXTENT INDICATED IN COLUMN 5 IS IN VENDORS SCOPE. PURCHASER MAY INSPECT AS PER THIS COLUMN OR RANDOM SAMPLES.
COLUMN 6 SHALL BE AS PER PURCHASER APPROVED DRAWINGS / DATA SHEETS / SPECIFICATIONS WHEREVER APPLICABLE.
INSTRUMENTS FOR LEAK TESTS AND PERFORMANCE TESTS SHALL HAVE VALID CALIBRATION CERTIFICATE WITH TRACEABILITY TO NATIONAL LEVEL.
LEGENDS :
S - SUB - VENDOR, M - MAIN VENDOR,
P- PURCHASER,
W - WITNESS,
V - DOCUMENTS REVIEW, H - HOLD POINT.

Operational checks

Hydro test

Air test

Operational checks

Body

For steam traps, strainers,filters

3.2 For valves & specialities

Seat

25% of seat leakage test pressure

Hydro test

Hydro test

Air test

MINIMUM INSPECTION
REQUIREMENTS FOR VALVES AND SPECIALITIES
(RATING ANSI 300 & BELOW)

at random

V Valves will be selected

at random

W Valves will be selected

at random

W Valves will be selected

at random

W Valves will be selected

at random

W Valves will be selected

W Valves will be selected at

random
W Valves will be selected at
random

W Valves will be selected at

random

SHEET  OF

SECTION: C14

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh.

QUALITY ASSURANCE REQUIREMENTS

VOLUME-II

CARBERY INFRASTRUCTURE PTE LTD

Low pressure seat leakage test at

Back Seat

Seat

For ball valves

For check valves

For gate and globe valves

Surface defects

1.4 Ferritic alloy steel forgings and fittings

Surface defects

2.2 Weld inspection

RT

10%

100%

100%

100%

100%

100%

100%

100%

100%

ASME B 31.1

ASME B 31.1

ASME B 31.1

ASME Sec. IX

ASME B 31.1

Material specification

Material specification

SA 530/SA 450

Material specification

REF. DOCUMENT /
ACCEPTANCE NORM
6

RT report

RT report

Inspection report

WPS, PQR, WPQ

MPI report

TC

TC

TC

TC

FORMAT OF
RECORD
7

RT Film Review

RT Film Review

REMARKS

SHEET  OF
AGENCY
S M
P
8

STATUTORY REQUIREMENTS WILL BE COMPLIED WITH BY THE CONTRACTOR.

MATERIAL TESTS OF SAMPLES DRAWN BY PURCHASER WILL BE WITNESSED BY PURCHASER.
FOR STAGES WITNESSED / DOCUMENTS REVIEWED BY PURCHASER, COPIES OF RELEVANT DOCUMENTS WILL BE FURNISHED TO PURCHASER.
PURCHASERS IDENTIFICATION STAMP ON MATERIALS WILL BE PRESERVED / GOT TRANSFERRED BY PURCHASER AT APPROPRIATE STAGES.
THE EXTENT INDICATED IN COLUMN 5 IS IN CONTRACTORS SCOPE. PURCHASER MAY INSPECT AS PER THIS COLUMN OR RANDOM SAMPLES.
COLUMN 6 WILL BE AS PER PURCHASER APPROVED DRAWINGS / DATA SHEETS / CONTRACT DOCUMENTS WHEREVER APPLICABLE.
INSTRUMENTS FOR LEAK TESTS AND PERFORMANCE TESTS WILL HAVE VALID CALIBRATION CERTIFICATE WITH TRACEABILITY TO NATIONAL LEVEL.
LEGENDS :
S - SUB - CONTRACTOR, M - MAIN CONTRACTOR, P- PURCHASER,
W - WITNESS,
V - DOCUMENTS REVIEW, H - HOLD POINT.

Soundness

b) Butt joint (Dia 100NB)

A.
B.
N C.
O D.
T E.
E F.
G.
H.

RT

Visual

Review of docs.

MPI

Review of docs.

Cooling water line, Instrument air, Service

air and Miscellaneous water lines)
a) Butt joint (Dia > 100NB)
Soundness

2.3 NDE before PWHT (Not applicable for

Procedure, Personnel qualification

2.1 Welding

2.0 IN-PROCESS INSPECTION :

Chem., Mech. properties, Dimns.

1.3 Fittings

Review of docs.

Review of docs.

Hydrostatic test
Chem., Mech. properties, Dimns.

Review of docs.

TYPE / METHOD EXTENT

OF CHECK
4
5

Chem., Mech. properties, Dimns.

CHARACTERISTICS
CHECKED
3

MINIMUM INSPECTION
REQUIREMENTS FOR CARBON STEEL AND STAINLESS STEEL PIPING
(LOW PRESSURE SYSTEM)

SECTION : C 15

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

QUALITY ASSURANCE REQUIREMENTS

VOLUME-II

CARBERY INFRASTRUCTURE PTE LTD

1.2 Forgings

1.1 steel pipes and tubes

SR.
COMPONENT / OPERATION
NO.
1
2
1.0 MATERIALS :

FINAL :

Visual and dimensional inspection

Completeness

3.1

3.2

b) All other weld joints

plate formed pipes > 100 NB

Paint thk., Identification, etc.

of stubs, Cleanliness, etc.

Weld defects, Length, Location

Surface defects

a) Butt joints in pipes, mitre bends and in Soundness

Miscellaneous water lines)

Instrument air, Service air and

Visual, Measurement

Visual, Measurement

LPI

RT

100 %

100 %

10%

10%

SS - 100%

NDE (Applicable for Cooling water line,

REF. DOCUMENT /
ACCEPTANCE NORM
6
ASME B 31.1

Drawing

Drawing

ASME B 31.1

ASME B 31.1

CS - 10% ASME B 31.1

welds)

MPI/LPI

5
100%

EXTENT

AS - 100%

Surface defects

TYPE / METHOD
OF CHECK
4
HT chart review

nozzles, stubs and attachment

3.0

2.6

NDE after PWHT (butt joints,

2.5

PWHT

CHARACTERISTICS
CHECKED
3
Temp. and time control

Inspection report

Inspection report

LPI report

RT report

MPI/LPI report

FORMAT OF
RECORD
7
HT chart

REMARKS

RT Film Review

SS - Stainless steel

AS - Alloy steel

W CS - Carbon steel

AGENCY
S M
P
8
V

SHEET  OF

SECTION : C 15

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

QUALITY ASSURANCE REQUIREMENTS

VOLUME-II

CARBERY INFRASTRUCTURE PTE LTD

MINIMUM INSPECTION
REQUIREMENTS FOR CARBON STEEL AND STAINLESS STEEL PIPING
(LOW PRESSURE SYSTEM)

COMPONENT / OPERATION

SR.
NO.
1
2.4

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

VOLUME - II
SECTION: D1
SHEET 1 OF 10

SPECIFICATION FOR COMPRESSED AIR SYSTEM

WRITE-UP OF SCREW COMPRESSORS

1.0

SCOPE
This specification covers the general design, materials, construction
features, manufacture, shop inspection and testing at manufacturer's works,
delivery at site, handling at site, erection, testing, commissioning,
performance testing and handing over of Air/ Gas Compressors and
Accessories.

2.0

CODES AND STANDARDS

2.1.

The design, materials, construction, manufacture, inspection, testing

and performance of the air/ gas compressors and accessories shall
comply with all currently applicable statutes, regulations and safety codes
in the locality where the equipment is to be installed. The equipment shall
also conform to the latest applicable Indian or equivalent standards.
Other international standards are also acceptable, if these are established
to be equal or superior to the listed standards. Nothing in this
specification shall be construed to relieve the CONTRACTOR of this
responsibility.

2.2.

The following are some of the important codes and standards relevant to
this specification.
API 614

Lubrication, Shaft sealing, Control oil systems and Auxiliaries

for Petroleum, Chemical, and Gas Industry Services

API 617

Axial and Centrifugal Compressors and Expander Compressors for Petroleum, Chemical, and Gas Industry

API 618

Reciprocating Compressors for Petroleum, Chemical, and Gas

Industry Services

API 619

Rotary Type Positive Dispiacement Compressors for

Petroleum, Chemical and Natural Gas Industries

API 672

Packaged, Integrally Geared Centrifugal Air Compressors for

Petroleum, Chemical, and Gas Industry Services

ASME SEC.
VIII DIV.1

Boiler and Pressure Vessel Code

VOLUME - II

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

SECTION: D1
SHEET 2 OF 10

SPECIFICATION FOR COMPRESSED AIR SYSTEM

WRITE-UP OF SCREW COMPRESSORS

3.0

TEMA

Standards of
Association

the

IS 2825

Code for Unfired Pressure Vessels

IS 5456

Testing of Positive Dispiacement Type Air Compressors and

Exhausters-Code of Practice

IS 6206
IS 7938

Guide for Selection, Installation and Maintenance of Air

Specification for Air Receivers for Compressed Air Installation

IS 11780

Code for Selection and testing of rotary screw air compressors

(Oil Flooded)

IS 13124

Reciprocating
Conditions

Gas

Tubular

Exchanger

Compressors

Manufacturers

Technical

Supply

DESIGN AND CONSTRUCTION FEATURES

The compressor shall be of screw type as specified in data sheet A.

3.1.

SCREW COMPRESSORS

3.1.1. Casinq
Casing shall be of barrel type made of cast iron or fabricated steel for
moderate pressure applications, cast steel or stainless steel for high
pressure applications or as specified in data sheet A. For water injected
applications the casing shall be of stainless steel or as specified in data
sheet A. Casing shall have built-in air passages either as cast or machined.

3.1.2. Rotors
Rotors shall be of asymmetric profile. The material of construction of rotors
shall be as specified in data sheet A. The rotors shall be dynamically
balanced before and after mounting timing gears and thrust collars. The
rotors shall be ultrasonically tested. For non-lubricated screw compressors
rotors shall be lined with PTFE.
3.1.3. Gears

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

VOLUME - II
SECTION: D1
SHEET 3 OF 10

SPECIFICATION FOR COMPRESSED AIR SYSTEM

WRITE-UP OF SCREW COMPRESSORS

Gear pair shall be used to step up speed of the compressor. Helical gear
hardened to minimum 55 RC shall be used. Gear shall be shrink fit on drive
shaft and shall mesh with pinion mounted on extended portion of male rotor.
Gears shall be designed as per AGMA standards.
3.1.4. Bearings
The rotors shall be carried in heavy duty ball and roller bearings to take
radial and axial loads or journal bearings with thin babbitt metal lining.
3.1.5. Air- Oil Separator
In case of lubricated screw compressors, high efficiency air-oil separation
system shall be provided to ensure removal of oil.
4.0

ACCESSORIES
Accessories such as intake filter, silencer, inter-coolers, after -coolers, oilcoolers, receivers, control cabinet etc. shall be supplied to make the system
complete in all respects.

4.1.

INTAKE FILTER
The intake filter shall be generally as per IS 6206. The type of intake filter
shall be as specified in data sheet A. The filter shall be designed to
retain particles of one (1) micron and above with ninety-seven (97)
percent efficiency. In case of cloth filter, the filter element may be of
nylon, polypropylene or woollen cloth attached to the wire netting .

4.2.

INTER-COOLERS
For multi stage compressors, inter-coolers shall be provided. These shall
be of shell and tube type, with removable tube bundles. The tubes shall
have sufficient thickness to withstand the operating pressure and shall be
carefully expanded into the tube sheets. Capacity of inter-coolers shall be
twenty (20) percent more than the compressor capacity or as specified in
data sheet A. Design pressure shall be twenty-five (25) percent more than
the working pressure or as specified in data sheet A. The material of
construction and design shall be as specified in data sheet A.

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

VOLUME - II
SECTION: D1
SHEET 4 OF 10

SPECIFICATION FOR COMPRESSED AIR SYSTEM

WRITE-UP OF SCREW COMPRESSORS

4.3.

AFTER-COOLERS AND OIL-COOLERS

The construction features, design etc. shall be as per inter-coolers
described above. Capacity of after-coolers and oil-coolers shall be twenty
(20) percent more than the compressor capacity or as specified in data
sheet A. Design pressure shall be twenty-five (25) percent more than the
working pressure or as specified in data sheet A.

4.4.

RECEIVERS
Receivers shall generally conform to IS 7938. Receivers shall be provided
with two (2) suitably sized safety valves to relieve the full compressor
discharge capacity individually and shall be set at a pressure 1.25 times
the operating pressure. The material of construction and design shall be
as specified in data sheet A.

4.5.

SHAFT SEALS
Shaft seals shall be provided to restrict or prevent process gas leaks to the
atmosphere or seal fluid leaks in to the process gas stream over the range
of specified operating conditions. The various types of shaft seals are
mentioned below.
(a)

Labyrinth shaft seal

(b)

Mechanical(contact) shaft seal

(c)

Restrictive ring shaft seal

(d)

Liquid film shaft seal

(e)

Single dry gas seal

(f)

Double dry gas seal

(g)

Tandem dry gas seal

(h)

Tandem dry gas seal with labyrinth

Shaft seals may be one or combination of the above types or as specified

in Datasheet-A.

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

VOLUME - II
SECTION: D1
SHEET 5 OF 10

SPECIFICATION FOR COMPRESSED AIR SYSTEM

WRITE-UP OF SCREW COMPRESSORS

5.0

MOTOR RATING
Motor shall be of suitable rating considering compressor
requirements. Motor rating shall be calculated as follows:
(a)

(b)

6.0

power

If compressor shaft input power requirement is 100 KW and above,

Motor rating in KW shall be =
1.10 x SKW
nt
If compressor shaft input power requirement is less than 100 KW,
Motor rating in KW shall be - 1.12 x SKW
nt
Where,
SKW = Shaft Power at selected speed in KW
nt = Efficiency of transmission

CAPACITY CONTROL
Capacity control shall be achieved either by speed variation or at
constant speed as specified in data sheet A. In case where capacity
control is to be achieved at constant speed, following methods are
generally available. Data sheet A shall be referred for method to be
actually employed.
(a)
(b)
(c)
(d)
(e)
(f)
(g)

6.1

Automatic start-stop of the compressor

Automatic load-unload of the compressor
Throttling of suction valve
By-passing air or gas from delivery to suction inlet
Increasing clearance volume by a clearance pocket
Variable filling using a by-pass valve.
Movable inlet guide vanes.

DUAL TYPE CONTROL

Capacity control by start-stop and load-unload of compressors is also
known as 'dual type control', and same is described below.

6.1.1. The dual type control system shall permit operation of each compressor
in either of the following two regulations :
(a)

Continuous Run-Load-Unload Regulation.

(b)

Automatic Start-Stop Regulation.

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

VOLUME - II
SECTION: D1
SHEET 6 OF 10

SPECIFICATION FOR COMPRESSED AIR SYSTEM

WRITE-UP OF SCREW COMPRESSORS

6.1.2. Under continuous Run-Load-Unload Regulation, the drive motor shall

run continuously while the compressor shall be loaded at pre-set
(adjustable) cut- in pressure as the receiver pressure falls and unloaded
at a higher pre-set (adjustable) cut-out pressure, as the receiver pressure
rises. With automatic Start-Stop Regulation, the drive motor shall
automatically start at pre-set (adjustable) cut-in pressure as the receiver
pressure falls and automatically stop at a pre-set (adjustable) higher cut-out
pressure as the receiver pressure rises.
6.1.3. With either system, the compressor shall always be unloaded when the
drive motor starts. The unloaders shall keep the compressor unloaded till
the drive motor comes to full speed.
6.1.4. Each compressor shall be provided with one selector switch having
three positions marked AUTO-OFF-ON for the following functions :
(a)

OFF

(b)

AUTO -

Stops the motor.

Keeps the compressor(s) in load / unload mode as
selected by master selector switch.
Starts the motor of the compressor in start-stop
regulation as selected by master selector switch.

(c)

ON

For manual start up by push buttons with load /

unload regulation.

6.1.5. When all the three (3) units are operating continuously, all the five (5)
compressors shall work on load/unload mode meeting the service and
instrument air requirement. This shall be controlled by load/unload
pressure switches mounted on the service and instrument air receiver.
When demand of either the instrument air or service air increases and the
pressure in any of the receivers is below the unloading pressure, the auto
stand by compressor shall cut in to make up the demand leaving the lost
compressor as maintenance stand by. Based on the above, it shall be
possible to control through a master control facility (connecting the
individual control systems of all the compressor) which shall select fan
among compressors A, B, C, D & E all F to operate either on load unload
control or on auto start / stop mode as follows:

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

VOLUME - II
SECTION: D1
SHEET 7 OF 10

SPECIFICATION FOR COMPRESSED AIR SYSTEM

WRITE-UP OF SCREW COMPRESSORS

Combination - I
ABCDE

On load/unload

On auto start / stop mode

On maintenance standby

Combination - II
ABCDF

On load / unload

On auto start / stop made

On maintenance standby

The combinations mentioned above are indicative and it should be possible

to have any combination. Thus it should be possible to operate any
compressor on any mode i.e., on load/unload or auto start / stop or leaving
compressor as maintenance standby.
6.2.

Two pressure switches shall be provided to monitor receiver pressure

for each compressor, one for load-unload control and the other for startstop control considering two (2) steps regulation for load-unload mode. In
case number of steps is more as indicated in data sheet A, number of
pressure switches provided shall be sufficient to meet the requirement.

6.3.

Pressure switches with alarm initiating contacts shall be provided for

the receiver high and low pressures.

6.4.

The dual control units shall be complete with pressure switches,

solenoid valves, control air tubing, air filter (if required) and other
accessories as required for the afore-mentioned operations.

6.5.

For centrifugal compressors anti-surge control shall also be provided to

protect compressor from surging.

6.6.

One potential free contact shall be made available for each compressor
for remote alarm under trip condition and a common contact for compressor
auto start.

6.7.

Green and red lamps shall be provided to indicate motor running and
stop conditions respectively.

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

VOLUME - II
SECTION: D1
SHEET 8 OF 10

SPECIFICATION FOR COMPRESSED AIR SYSTEM

WRITE-UP OF SCREW COMPRESSORS

6.8.

Motors shall be provided with motor winding over-heat sensors and

bearing temperature sensors for alarm indication and to trip the motor.

6.9.

For compressors driven with turbine, the required turbine control and
instrumentation shall be provided.

6.10.

For air / gas compressors, depending on the hazardous area

classification, motors and instrument enclosures shall be explosion-proof
certified for the specific area.

7.0

NOISE AND VIBRATIONS

7.1.

Noise level produced by any rotating equipment individually or

collectively shall not exceed 85 dB (A) measured at a distance of 1.0
metres from the sourcein any direction.

7.2.

The overall vibration level will be as per zones A and B of ISO 10816-1.
The values of vibration will be less than 3mm/s. Vibration dampening
pads if required will be provided.

8.0

PERFORMANCE GUARANTEES
Performance parameters to be guaranteed by the CONTRACTOR and
tolerances permitted shall be as indicated in section C and / or data sheet
A. BIDDER shall confirm acceptance of these by indicating values in data
sheet B. Compressor or any portion thereof is liable for rejection, if it fails
to give any of the guaranteed performance parameters.

VOLUME - II

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

SECTION: D1
SHEET 9 OF 10

SPECIFICATION FOR COMPRESSED AIR SYSTEM

WRITE-UP OF SCREW COMPRESSORS

DATA SHEET C
DATA TO BE FURNISHED BY THE CONTRACTOR AFTER THE AWARD OF
CONTRACT
1.

List of drawings and documents to be submitted for review, approval and

information with scheduled submission dates

2.

Quality Assurance Plan (QAP)

3.

Calculations for compressor capacity drive motor rating, selection of speed

reducers and couplings. Torsional vibration analysis for centrifugal and
screw compressors

4.

Thermal design calculations for inter-coolers, after-coolers and oil-coolers.

5.

Detailed P&l diagram showing clearly the scope of supply of equipment,

piping with line sizes and material specifications, valves, specialities,
instrumentation and control and all the accessories. All equipment, lines,
valves, specialities and instruments shall be tagged as per
the PURCHASER's procedure to be given to the successful BIDDER. All
terminal points shall be clearly identified. All design data and other
information furnished in data sheets A and B shall be covered either in
this drawing or other relevant drawings or documents mentioned below.

6.

Detailed equipment list and

the CONTRACTOR's scope

7.

Sub-vendor list for all bought-out items

8.

Mechanical design calculations for inter-coolers, after-coolers, oil-coolers,

moisture and oil separator and receivers

9.

Characteristic curves of compressors. For centrifugal compressors,

in addition to curves for operating conditions, characteristic curves shall
be submitted
considering
minimum
and
maximum
ambient
temperature, minimum and maximum humidity and minimum and
maximum
frequency
conditions Dimensioned to-scale equipment layout drawing showing all
equipment, accessories, relevant external dimensions, location and
elevation of terminal points, details of piping and electrical
connections to be made by the PURCHASER, clearances required for
erection, dismantling, operation and maintenance

bill

of

materials

of

all

items

in

VOLUME - II

CARBERY INFRASTRUCTURE PTE LTD

SECTION: D1

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

SHEET 10 OF 10

SPECIFICATION FOR COMPRESSED AIR SYSTEM

WRITE-UP OF SCREW COMPRESSORS

DATA SHEET C (CONTD.)

11.

Dimensioned cross-section drawings of compressors

proprietary items with part list and materials of construction.

12.

Detailed fabrication drawings of all fabricated equipment like intercoolers, after-coolers, air receivers etc.

13.

Line designation schedule for all lines in the CONTRACTOR'S scope.

14.

List of valves, specialities and instruments in the CONTRACTOR'S

scope with tag numbers, type, makes, pressure ratings, materials of
construction and ranges for instruments etc.

15.

Manufacturer's drawings, data sheets and catalogues for valves,

specialities and instruments etc.

16.

Dimensioned
to-scale piping
layout
drawing
for
piping
in
the CONTRACTOR'S scope with allowable forces and moments on the
piping nozzles and displacement of the nozzles

17.

Overall foundation plan, base frame drawing for each equipment, static
and dynamic loads on each of the anchor bolts and dimensional details of
pockets and anchor bolts.

18.

Motor drawings.

19.

Electrical control wiring diagrams with all interlocks.

20.

Control philosophy, interlock description and logic diagrams

21.

Dimensional to-scale general arrangement and section drawings of MCC

and instrument control panel with complete bill of materials.

22.

List of alarms and trip settings.

23.

Erection, start-up, operation

with lubrication schedule etc.

and

maintenance

manual

and

other

complete

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

VOLUME - II
SECTION: D1
SHEET 1 OF 6

DATA SHEET A
AIR COMPRESSORS
1. DESIGNATION: COMPRESSORS FOR
INSTRUMENT AIR AND SERVICE AIR

19.2 FOR INTER-COOLER, AFTER-COOLER

AND OIL-COOLER: WATER
20. COOLING WATER QUALITY:

2. NUMBER REQUIRED : 7(5W+2S)

-

4. LOCATION: INDOOR

21. COOLING WATER INLET

TEMPERATURE: 380 C

5. OPERATION: CONTINUOUS
Hrs/Day

22. MAXIMUM COOLING WATER OUTLET

TEMPERATURE: 46 0 C

6. TYPE OF DRIVE: ELECTRIC MOTOR

23. COOLING WATER PRESSURE

AT INLET: TO BE FURNISHED BY BIDDER
DESIGN DATA (CONTD.)

GENERAL

3. TAG NUMBERS:

PASSIVATED DM WATER

7. APPLICABLE STANDARDS:
IS 6206/IS13124/API 617/API 672/
IS 11780/ISO1217
8.
9.
10. TYPE : OIL FREE SCREW

24. MAXIMUM COOLING WATER

PRESSURE DROP IN THE COMPRESSOR,
INTER-COOLER, AFTER-COOLER AND
OIL- COOLER : 0.5 Kg/ cm 2
25. COMPRESSOR FRAME LUBRICATION :
PRESSURISED
26. TYPE OF CAPACITY CONTROL :
LOAD/UNLOAD

11. FLUID TO BE COMPRESSED : AIR

27. METHOD OF CAPACITY CONTROL AT
CONSTANT SPEED :
BASED ON THE PRESSURE AT THE AIR
RECEIVER / HEADER PRESSURE

13. MASS FLOW RATE : N.A

Kg/Hr

14. PROPERTIES OF GAS/ GAS COMPOSITION : ATMOSPHERIC AIR

28.

15. SUCTION PRESSURE : ATMOSPHERIC

Kg/ cm2 (g)
16. SUCTION TEMPERATURE - MINIMUM /
MAXIMUM : AMBIENT / 0 C
17. DISCHARGE PRESSURE : 8.6Kg/ cm 2 (g)
18. MAXIMUM COMPRESSOR SPEED :
By bidder RPM
19. COOLING MEDIUM :
19.1 FOR COMPRESSOR : WATER

29.
DUAL TYPE CONTROLS

DESIGN DATA

12. CAPACITY (FAD): 3850 M3/Hr

30. ADJUSTABLE RANGE FOR PRESSURE

SWITCHES :
BY BIDDER
Kg/ cm 2
31. EXPECTED SETTING OF PRESSURE
SWITCHES FOR : BY BIDDER
31.1 AUTO LOAD-UNLOAD REGULATION :
(a) LOAD: 8.2 Kg/ cm 2 (g)
(b) UNLOAD: 8.4 Kg/ cm 2 (g)

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

VOLUME - II
SECTION: D1
SHEET 2 OF 6

DATA SHEET A

31.2 AUTO START-STOP REGULATION:

(a) START: 8.0 Kg/ cm 2 (g)
(b) STOP: 8.4 Kg/ cm 2 (g)

31.4 HIGH RECEIVER PRESSURE

ALARM: 8.4 Kg/ cm 2 (g)
32. NUMBER OF STEPS FOR LOAD UNLOAD REGULATION: 2 / 3 / 4 /
33.

MATERIALS OF CONST.
FOR CENTRIFUGAL
COMPRESSORS

MATERIALS OF CONSTRUCTION FOR

RECIPROCATING COMPRESSORS

VOID

MATERIALS OF CONSTRUCTION
FOR CENTRIFUGAL COMPRESSORS (CONTD.)

31.3 VERY LOW RECEIVER PRESSURE

ALARM: 8.0 Kg/ cm 2 (g)

44. VOID

45. VOID

46. VOID

47. VOID

48. VOID

42. VOID

43. VOID

MATERIALS OF CONSTRUCTION
FOR SCREW COMPRESSORS

DUAL TYPE CONTROLS (CONTD.)

AIR COMPRESSORS

49. CASING: CI IS 210 OR ASTM A 278 CL

40/ FABRICATED STEEL ASTM A 353/
CAST STEEL ASTM A 216 GR WCB
NORMALIZED / CAST SS ASTM A 743
AND 744 CA6-NM

50. ROTOR BODY: CI ASTM A 395/

FORGED STEEL AISI 1030-1045/ CAST
ALUMINIUM ASTM B 26 ALLOY 355
OR C 355/ CAST STEEL GG 20

51. SHAFT: FORGED STEEL AISI 1030-1035/

FORGED SS ASTM A151 TYPE 410 SS / CAST STEEL
GG 20

VOLUME - II
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SHEET 3 OF 6

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh
DATA SHEET A
AIR COMPRESSORS
52. INTAKE FILTER TYPE : PAPER/
EFFICIENCY 99.99% DOWN TO 3 MICRON

69. DESIGNATION FOR INTER-COOLERS/

AFTER-COOLERS : NA

52.1 MATERIAL OF CONSTRUCTION:

CASING: MS/ ALUMINIUM

70. TAG NUMBERS FOR INTER-COOLERS:

-

52.2 TIMING GEAR : ALLOY STEEL

53. SILENCER REQUIRED :

71. AFTER-COOLERS REQUIRED: YES

NUMBER : 5

YES

72. TAG NUMBERS FOR AFTER-COOLERS :

54. DRIVE PULLEYS WITH V-BELT AND

BELT GUARDS REQUIRED :
NA

COMPRESSOR ACCESSORIES

55. COUPLINGS AND COUPLING GUARDS

REQUIRED :
YES
FOR DIRECT COUPLED COMPRESSORS
56. SLIDE RAILS FOR MOTOR REQUIRED:
YES
57. CONTROL CABINET REQUIRED :
YES(Microprocessor Controls)
58. IMPULSE TUBING : COPPER/
ADMIRALITY BRASS AS PER BS EN 1057
EXCEPT FOR EDDY CURRENT TEST/
STAINLESS STEEL/

59. MOTOR BY : BIDDER

60. STARTER BY : BIDDER
61. INLET THROTTLE VALVE & HOUSING:
ALUMINIUM
61. SAFETY VALVE : BRASS/ BRONZE/GUN
METAL/ SS

INTER-COOLERS / AFTER-COOLERS / OIL-COOLERS

DESIGN DATA

73. CAPACITY OF :
73.1 INTER-COOLERS : To suit Compressor capacity
M3 / Hr
73.2 AFTER-COOLERS : To suit Compressor capacity
M3 / Hr
74. TYPE : HORIZONTAL/ VERTICAL
SHELL AND TUBE TYPE WITH
REMOVABLE TUBE BUNDLES
75. TYPE OF FLOW : COUNTER-CURRENT
76. OPERATING PRESSURE FOR AFTERCOOLERS BY BIDDER
76.1 AIR/ GAS SIDE :BYBIDDER Kg/ cm 2 (g)
76.2 WATER SIDE : BYBIDDER Kg/ cm 2 (g)
77. DESIGN PRESSURE FOR AFTERCOOLERS 1.25 TIMES OPERATING PRESSURE
77.1 AIR/ GAS SIDE :

Kg/ cm 2(g)

77.2 WATER SIDE :

Kg/ cm 2(g)

78. MAXIMUM ACCEPTABLE OUTLET AIR/

GAS TEMPERATURE : 80 C ABOVE COOLING WATER

62. WATER SEPARATOR : CI

INLET TEMP OF AFTER COOLER

63. NRV : SS SPRING LOADED TYPE

79. ALLOWABLE PRESSURE DROP OF AIR/

GAS THROUGH AFTER-COOLER : 0.2 Kg/ cm 2

64. BLOW OFF VALVE : SS

65. UNLOADING CYLINDER HEADER :
ALUMINIUM
66. UNLOADING CYLINDER HEADER :
ALUMINIUM
67. GEAR BOX & GEARS : CI & ALLOY STEEL
68. OIL PIPING & VALVES : SS

80. DESIGN CODE : ASME SEC. VIII DIV. 1

AND TEMA
81. CORROSION ALLOWANCE :

1.5 mm (Min)

CARBERY INFRASTRUCTURE PTE LTD

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VOLUME - II
SECTION: D1
SHEET 4 OF 6

90. DESIGNATION : RECEIVERS FOR

IA AND SA

82. SHELL : CS SA 106 GR B/ IS 2002/

91. NUMBER REQUIRED :

TWO (4) FOR IA
TWO (4) FOR SA

83. TUBES : COPPER/ ADMIRALITY BRASS

AS PER BS EN 1057 EXCEPT FOR EDDY
CURRENT TEST / SS 316 / SS R 249(FOR
INTERCOOLER AND AFTER COOLER ONLY)

92. TAG NUMBERS :

84. TUBE SHEETS : CS SA 105/ IS 2002/
BRASS/ SS 316/CrNi

93. TYPE : HORIZONTAL/ VERTICAL/

CYLINDRICAL WITH WELDED DISHED
ENDS

86.ACOUSTIC ENCLOSURE : TO MEET NOICE

LEVEL

87. MOISTURE AND OIL SEPARATOR

WITH AUTO DRAIN TRAP TO BE
PROVIDED WITH EACH INTERCOOLER AND AFTER-COOLER TO
DISCHARGE MOISTURE AND OIL TO
DRAIN

RECEIVER DESIGN DATA

85. TUBE SUPPORT PLATES : IS 2062/CrMo

94. OPERATING PRESSURE :
8.5 Kg/ cm 2 (g)
95. DESIGN PRESSURE : 10.75 Kg/ cm 2 (g)
96. DESIGN TEMPERATURE : BIDDER C
97. NOMINAL VOLUME : 17 M 3
98. DIMENSIONS : BY BIDDER
98.1 HEIGHT TAN TO TAN : BY BIDDER
mm
98.2 DIAMETER :
BY BIDDER
mm
99. APPLICABLE CODE : IS 2825

87.1 TYPE OF MOISTURE AND OIL

SEPARATOR : CENTRIFUGAL/
DEMISTER PAD/ BAFFLE

100. CORROSION ALLOWANCE : 1.5 mm(Min)

101. SHELL AND DISHED END MATERIAL :
IS 2002/ IS 2062 / ASTM A 516 Gr 70

87.2 TYPE OF AUTO DRAIN TRAP :

INVERTED BUCKET / BALL FLOAT /
SOLENOID OPERATED / ELECTRONIC
LEVEL CONTROLLED

102. INTERNAL PAINTING : BLACK

BITUMINOUS /

88. MATERIAL OF CONSTRUCTION OF

MOISTURE AND OIL SEPARATOR

103. INSULATION :

88.1 BODY/ SHELL : CS SA 106 GR B/

IS 2002

105. SUPPORT LEGS/ LUGS/ SKIRT

REQUIRED :

YES

106. MANHOLE WITH COVER FOR

INSPECTION AND CLEANING
REQUIRED :

YES

88.2
89. MATERIAL OF CONSTRUCTION OF
AUTO DRAIN TRAP
89.1 BODY : CI IS 210/ SS / CAST ALUMINIUM
89.2 TRIM : BRONZE/SS

NO

104.

RECEIVER
ACCESSORIES

INTER-COOLERS / AFTER-COOLERS ACCESSORIES

INTER-COOLERS/AFTERCOOLERS/ OILCOOLERS M O C

DATA SHEET A
AIR COMPRESSORS

107.SAFETY VALVE
108.

YES

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

VOLUME - II
SECTION: D1
SHEET 5 OF 6

MISCELLANEOUS

109. ALL THE VALVES, SPECIALITIES

INSTRUMENTS AND ACCESSORIES
AS PER ENCLOSED P&I D
: REQUIRED

110. COUNTER FLANGES FOR ALL THE

CONNECTIONS AT BATTERY LIMITS
WITH NUTS, STUDS, BOLTS, GASKETS
AND WASHERS REQUIRED : YES

110.1 FLANGES : AS PER REQUIREMENT

111. FOUNDATION BOLTS FOR ALL THE

EQUIPMENT REQUIRED :
YES

SPARES AND MAINTENANCE TOOLS AND

TACKLES

DATA SHEET A
AIR COMPRESSORS

123. AS PER SECTION C11 OF THIS

SPECIFICATION

124. VOID

113. ERECTION SUPERVISION BY

BIDDER :
YES
114.
115. PRIMER : REFER NOTE 2

115.2 DRY FILM THICKNESS:REFER NOTE 2

116. FINISH PAINT : REFER NOTE 2

125. VOID

126. PERFORMANCE TEST AT SITE

REQUIRED :
YES
127. APPLICABLE STANDARDS : IS 5456 /
API 618 / API 617 / API 672 / API 619 /
IS 11780 /

116.1. NUMBER OF COATS : REFER NOTE 2

128. VOID

116.2 DRY FILM THICKNESS: REFER NOTE2

129. VOID

117. MOTORS : REFER SECTION C7

130. CAPACITY OF EACH COMPRESSOR :

3850
(+)
() 0 M3/Hr

118.
119. PIPING MATERIAL SPECIFICATIONS :
GI HEAVY CLASS (IS1239/IS3589) FOR
DETAIL REFER SECTION D3
120. INSTRUMENTATION AND CONTROL
REFER SECTION C-8
121. CONTROL CABINET : REFER SECTION
C-8
122. CABLES : REFER SECTION C7

PERFORMANCE GUARANTEES

COMPANION SPECIFICATIONS

PAINTING

115.1 NUMBER OF COATS : REFER NOTE 2

TESTS AND INSPECTION

112. ERECTION BY BIDDER :YES

131. DISCHARGE PRESSURE :

8.6 (+)
() 0 Kg/ cm2 (g)
132. POWER CONSUMPTION :
BY BIDDER (+) 0
() KW
133. TEMPERATURE OF AIR AT OUTLET
OF AFTER COOLER : BY BIDDER C
134. COOLING WATER FLOW RATE :
BY BIDDER
M3/Hr

CARBERY INFRASTRUCTURE PTE LTD

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Pradesh

VOLUME - II
SECTION: D1
SHEET 6 OF 6

135. COOLING WATER OUTLET

TEMPERARURE : BY BIDDER

136. COOLING WATER PRESSURE DROP :

BY BIDDER
Kg/ cm2 (g)
137.
138.

NOTES
1.

DELETED.

2.

PAINTING SHALL BE AS PER SECTION C-12

COST LOADING
AND PENALTY

PERFORMNCE
GUARANTEES (CONTD.)

DATA SHEET A
AIR COMPRESSORS
139. POWER CONSUMPTION :
Rs. 2,41,000 / KW
140. COOLING WATER CONSUMPTION :
Rs.
/ M3/Hr
141.
142.

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

VOLUME - II
SECTION: D1
SHEET 1 OF 7

DATA SHEET B
AIR COMPRESSORS

GENERAL

SL.
NO.
1.

BIDDER
ITEM
DESIGNATION

2.

NUMBER OFFERED

3.

TAG NUMBERS

4.

TYPE OF COMPRESSOR

5.

MAKE AND MODEL NUMBER

COMPRESSORS FOR
(W+S)

RECIPROCATING/CENTRIFUGAL/SCREW
LUBRICATED / NON-LUBRICATED

6.
7.
RECIP
8.

NUMBER OF STAGES

9.

NUMBER OF CYLINDERS PER

CENT

SCREW

NA

NA

VER / HOR

NA

NA

NA

NA

NA

NA

COMPRESSOR DATA

STAGE
10.

TYPE OF CYLINDER

11.

CYLINDER LINER PROVIDED

YES / NO

12.

SINGLE ACTING /DOUBLE

SINGLE/

ACTING

DOUBLE
3

13.

CAPACITY (FAD)

M / Hr

14.

MASS FLOW RATE

Kg/Hr

15.

TYPE OF SUCTION AND

DISCAHRGE VALVE

16

SUCTION PRESSURE

17.

DISCHARGE PRESSURE

NA
PLATE /
CHANNEL
TYPE

NA
IGV/
BUTTERFLY
VALVE (OP)
AT SUCTION

BUTTERFLY
/ PISTON
VALVE (OP)
AT SUCTION

Kg/
cm2(g)
Kg/
cm2(g)

LEGEND : RECIP = RECIPROCATING, CENT= CENTRIFUGAL, VER = VERTICAL,

HOR = HORIZONTAL,IGV = INLET GUIDE VANES, OP = OPTIONAL, NA = NOT
APPLICABLE
NOTES TO BIDDER
1.

ITEMS WHICH DEVIATE FROM THE SPECIFICATION SHOULD BE

MARKED WITHIN ASTERISK (*) AND DETAILS TO BE GIVEN IN
SCHEDULE OF DEVIATIONS.

2.

THIS DATA SHEET SHALL BE FILLED UP COMPLETELY AND A

COPY SHALL BE ENCLOSED WITH EACH COPY OF THE BID.

SIGNATURE OF BIDDER & DATE

CARBERY INFRASTRUCTURE PTE LTD

VOLUME - II

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

SECTION: D1
SHEET 2 OF 7

DATA SHEET B
AIR COMPRESSORS

COMPRESSORS DATA (CONTD.)

SL.
NO.

BIDDER
ITEM

18.

SUCTION TEMPERATURE EACH STAGE

19.

DISCHARGE TEMPERATURE EACH STAGE

20.

SELECTED COMPRESSOR SPEED

RPM

21.

BKW AT SELECTED COMPRESSOR

SPEED

KW

22.

RECOMMENDED MAXIMUM
SPEED

RPM

23.

BKW AT RECOMMENDED
MAXIMUM SPEED

KW

24.

VOLUMETRIC EFFICIENCY

25.

MECHANICAL EFFICIENCY

26.

MOTOR RATING AND SPEED

27.

LUBE OIL CONSUMPTION

FOR EACH COMPRESSOR

28.

LUBE OIL PUMP DRIVEN BY

COMPRESSOR MOTOR

29.

MOTOR RATING, IF LUBE OIL

PUMP IS DRIVEN BY SEPARATE
MOTOR

30.

AUXILIARY LUBE OIL PUMP

TO BE PROVIDED

31.

AUXILIARY LUBE OIL PUMP

MOTOR RATING AND SPEED

32.

TYPE AND MAKE OF BEARINGS

KW/RPM

RECIP

CENT

SCREW

YES/ NO

YES/ NO

YES/ NO

LPM

KW

WHETHER PROVIDED
YES/ NO
KW/RPM

NOTES TO BIDDER
1.

ITEMS WHICH DEVIATE FROM THE SPECIFICATION SHOULD BE

MARKED WITHIN ASTERISK (*) AND DETAILS TO BE GIVEN IN
SCHEDULE OF DEVIATIONS.

2.

THIS DATA SHEET SHALL BE FILLED UP COMPLETELY AND A

COPY SHALL BE ENCLOSED WITH EACH COPY OF THE BID.

SIGNATURE OF BIDDER & DATE

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3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

DATA SHEET B
AIR COMPRESSORS
SL.
NO.

BIDDER
ITEM

33.

COOLING WATER
REQUIREMENTS (NOTE 1)

33.1

FOR COMPRESSOR COOLING

33.1.1

FLOW RATE

33.1.2

INLET AND MINIMUM OUTLET

PRESSURE

33.1.3

INLET AND MAXIMUM OUTLET

TEMPERATURE

RECIP

CENT

SCREW

M3/ Hr
Kg/cm 2(g)
0

COMPRESSOR DATA (CONTD.)

33.1.4
33.1.5
33.1.6
33.2

FOR BEARING COOLING IF REQIRED

33.2.1

FLOW RATE

33.2.2

INLET AND MINIMUM OUTLET

PRESSURE

33.2.3

INLET AND MAXIMUM OUTLET

TEMPERATURE

M3/ Hr
Kg/cm2 (g)
0

33.2.4
33.2.5
34.

INTAKE FILTER TYPE

34.1

FILTER ELEMENT

34.2

RATED CAPACITY

34.3

EFFICIENCY

34.4

DESCRIPTIVE LITERATURE
TO BE ENCLOSED

M3/ Hr
%
WHETHER ENCLOSED
YES/ NO

34.5
NOTES TO BIDDER
1.

ITEMS WHICH DEVIATE FROM THE SPECIFICATION SHOULD BE

MARKED WITHIN ASTERISK (*) AND DETAILS TO BE GIVEN IN
SCHEDULE OF DEVIATIONS.

2.

THIS DATA SHEET SHALL BE FILLED UP COMPLETELY AND A

COPY SHALL BE ENCLOSED WITH EACH COPY OF THE BID.

SIGNATURE OF BIDDER & DATE

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3 X 660 MW Super Critical TPP at Lalitpur, Uttar

Pradesh
DATA SHEET B
AIR COMPRESSORS
SL.
NO.

BIDDER
ITEM

COMPRESSOR DATA (CONTD.)

RECIP

CENT

SCREW

35.

CAPACITY CONTROL

35.1

TYPE AND NUMBER OF STEPS

35.2

METHOD EMPLOYED IN CASE OF

CONSTANT SPEED TYPE

35.3

CONTROL SYSTEM WRITE-UP TO

BE ENCLOSED

WHETHER ENCLOSED
YES/ NO

35.4

WIRING AND TUBING DIAGRAM

WITH CONTROL SCHEME TO BE
ENCLOSED

WHETHER ENCLOSED
YES / NO

36.

EQUIPMENT AND ACCESSORIES

MOUNTED ON COMMON BASE
FRAME WITH THE COMPRESSOR

36.1

WEIGHT OF ENTIRE UNIT MOUNTED

ON COMMON BASE FRAME

Kg

36.2

OVERALL DIMENSIONS OF
COMMON BASE FRAME L X W

37.

EQUIPMENT AND ACCESSORIES

MOUNTED ON SEPARATE BASE
FRAME

37.1

WEIGHT OF EQUIPMENT AND

ACCESSORIES MOUNTED ON
SEPARATE BASE FRAME

Kg

37.2

OVERALL DIMENSIONS OF
SEPARATE BASE FRAME L X W

38.

39.

BY SPEED VARIATION / AT CONSTANT

SPEED

NAME AND OVERALL DIMENSIONS

OF SINGLE LARGEST COMPONENT
TO BE LIFTED
LXWXH

NAME AND WEIGHT OF HEAVIEST

SINGLE COMPONENT TO BE LIFTED

Kg

NOTES TO BIDDER
1.

ITEMS WHICH DEVIATE FROM THE SPECIFICATION SHOULD BE

MARKED WITHIN ASTERISK (*) AND DETAILS TO BE GIVEN IN
SCHEDULE OF DEVIATIONS.

2.

THIS DATA SHEET SHALL BE FILLED UP COMPLETELY AND A

COPY SHALL BE ENCLOSED WITH EACH COPY OF THE BID.

SIGNATURE OF BIDDER & DATE

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3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

DATA SHEET B
AIR COMPRESSORS

COMPRESSOR DATA (CONTD.)

SL.
NO.

BIDDER
ITEM

40.

SUCTION FLANGE - FIRST STAGE

SIZE/ STANDARD/ RATING

mm
NB/

41.

DISCHARGE FLANGE -FINAL

STAGE - SIZE/ STANDARD/
RATING

mm
NB/

42.

IF DRIVE MOTOR IS TO BE
FURNISHED BY THE PURCHASER

42.1

RATING/ SPEED

42.2

STARTING TORQUE
DIRECTION OF ROTATION OF
MOTOR AS VIEWED FROM
COUPLING END

42.3

43.

RECIP

CENT

SCREW

KW/RPM
Kg M

ALL THE ACCESSORIES AS

CALLED FOR IN DATA SHEET A
TO BE INCLUDED

WHETHER INCLUDED
YES / NO

44.

INTER-COOLERS / AFTER-COOLERS

I/C
1 STG
45.

DESIGNATION

46.

NUMBER OFFERED

47.

TAG NUMBERS

48.

TYPE

VER/ HOR

CAPACITY (FAD)

M /Hr

50.

COOLING WATER FLOW RATE

M3/ Hr

51.

AIR/ GAS INLET/OUTLET

52.

VER/HOR

COOLING WATER INLET/ MAXIMUM OUTLET TEMPERATURE

3 STG

49.

TEMPERATURE

2 STG

A/C

NOTES TO BIDDER
1.

ITEMS WHICH DEVIATE FROM THE SPECIFICATION SHOULD BE

MARKED WITHIN ASTERISK (*) AND DETAILS TO BE GIVEN IN
SCHEDULE OF DEVIATIONS.

2.

THIS DATA SHEET SHALL BE FILLED UP COMPLETELY AND A

COPY SHALL BE ENCLOSED WITH EACH COPY OF THE BID.

SIGNATURE OF BIDDER & DATE

VOLUME - II

CARBERY INFRASTRUCTURE PTE LTD

SECTION: D1
SHEET 6 OF 7

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

DATA SHEET B
AIR COMPRESSORS
SL.
NO.

BIDDER
ITEM

RECEIVERS

INTER-COOLERS / AFTER-COOLERS (CONTD.)

I/C

A/C

53.

AIR/ GAS INLET AND OUTLET

PRESSURE

Kg/cm2(g)

54.

COOLING WATER INLET/

MINIMUM OUTLET PRESSURE

Kg/cm2(g)

55.

COOLING SURFACE AREA

56.

DESIGN PRESSURE - AIR/ GAS SIDE

Kg/cm2(g)

57.

DESIGN PRESSURE - WATER SIDE

Kg/cm2(g)

58.

CODE OF CONSTRUCTION

59.

CORROSION ALLOWANCE

60.

NUMBER OF PASSES

61.

EMPTY WEIGHT

Kg

62.

OPERATING WEIGHT

Kg

63.

WATER FILLED WEIGHT

Kg

64.

ALL THE ACCESSORIES

AS CALLED FOR IN DATA SHEET A
TO BE INCLUDED

65.

DESIGNATION

66.

NUMBER OFFERED

67.

TAG NUMBERS

68.

TYPE

M2

mm

WHETHER INCLUDED
YES / NO

RECEIVERS FOR

VER/ HOR

69.

CAPACITY

70.

SIZE

70.1

DIAMETER

mm

70.2

HEIGHT TAN TO TAN

mm

71.

DESIGN PRESSURE

72.

CODE OF CONSTRUCTION

73.

CORROSION ALLOWANCE

VER/ HOR

VER/ HOR

Kg/cm2(g)
mm

NOTES TO BIDDER
1.

ITEMS WHICH DEVIATE FROM THE SPECIFICATION SHOULD BE

MARKED WITHIN ASTERISK (*) AND DETAILS TO BE GIVEN IN
SCHEDULE OF DEVIATIONS.

2.

THIS DATA SHEET SHALL BE FILLED UP COMPLETELY AND A

COPY SHALL BE ENCLOSED WITH EACH COPY OF THE BID.

SIGNATURE OF BIDDER & DATE

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

VOLUME - II
SECTION: D1
SHEET 7 OF 7

DATA SHEET B

PERFORMANCE GUARANTEES

MISCELLANEOUS

RECEIVERS (CONTD.)

AIR COMPRESSORS
SL.
NO.
74.

ITEM
THICKNESS

BIDDER

74.1

SHELL

mm

74.2

DISHED ENDS

mm

75.

WEIGHT

75.1

EMPTY

Kg

75.2

OPERATING

Kg

75.3

FILLED WITH WATER

Kg

76.

ALL THE ACCESSORIES AS CALLED

FOR IN DATA SHEET A TO BE
INCLUDED

WHETHER INCLUDED
YES / NO

77.

ALL THE VALVES, SPECIALITIES,

INSTRUMENTS, COUNTER FLANGES,
FOUNDATION BOLTS ETC. AS
CALLED FOR IN DATA SHEET A AND
AS PER ENCLOSED P & I D TO BE
INCLUDED

WHETHER INCLUDED
YES / NO

78.

CAPACITY OF COMPRESSOR

M3/ Hr
2

(+)

()

79.

DISCHARGE PRESSURE

Kg/cm (g)

(+)

()

80.

POWER CONSUMPTION

KW

(+)

()

81.

TEMPERATURE OF AIR AT OUTLET

OF AFTER-COOLER

(+)

()

82.

COOLING WATER FLOW RATE

M / Hr

(+)

()

83.

COOLING WATER OUTLET TEMP.

(+)

()

(+)

()

84.

COOLING WATER PRESSURE DROP

C
2

Kg/cm (g)

85.
NOTES
1. IF AIR COOLED COMPRESSOR IS OFFRERED, BIDDER TO FURNISH COOLING SYSTEM
DETAILS LIKE NATURAL OR FORCED COOLING, FAN CAPACITY, MOTOR RATING ETC.
LEGEND : I/C = INTER-COOLER, A/C = AFTER-COOLER, STG = STAGE

NOTES TO BIDDER
1.

ITEMS WHICH DEVIATE FROM THE SPECIFICATION SHOULD BE

MARKED WITHIN ASTERISK (*) AND DETAILS TO BE GIVEN IN
SCHEDULE OF DEVIATIONS.

2.

THIS DATA SHEET SHALL BE FILLED UP COMPLETELY AND A

COPY SHALL BE ENCLOSED WITH EACH COPY OF THE BID.

SIGNATURE OF BIDDER & DATE

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

VOLUME - II
SECTION: D2
SHEET 1 OF 4

SPECIFICATION FOR COMPRESSED AIR SYSTEM

WRITE-UP OF AIR DRYING PLANT

1.0

SCOPE
This specification covers the general design, materials, construction
features, manufacture, shop inspection and testing at manufacturer's works,
delivery at site, handling at site, erection, testing, commissioning,
performance testing and handing over of Desiccant Type Air Drying Plant.

2.0

CODES AND STANDARDS

The design, materials, construction, manufacture, inspection, testing and
performance of Air Drying Plant shall comply with all currently applicable
statutes, regulations and safety codes in the locality where the plant is to be
installed. The equipment shall also conform to the latest applicable Indian or
equivalent standards. Other international standards are also acceptable, if these
are established to be equal or superior to the listed standards. Nothing in this
specification shall be construed to relieve the CONTRACTOR of this
responsibility.

3.0

DESIGN AND CONSTRUCTION FEATURES

3.1

GENERAL
The air drying plant shall be an integrai unit consisting of filters, desiccant
Chambers, interconnecting piping, valves, specialities, instrumentation and
controi cabinet all assembled on a floor mounted common supporting frame.
Desiccant chamber shall be filled with desiccant. Chamber construction shall be
such that desiccant can be conveniently removed and recharged. Flow rate
through desiccant bed shall be Iow enough to avoid dispiacement of bed.
Chamber shall be insulated except for heatless type air drying plant. All the
piping, valves and specialities carrying hot air shall be insulated. Two-way and
four-way plug valves shall be teflon coated. Diaphragm operated controi valve
shall preferably have teflon seat. The air drying plant shall be one of the following
types as specified in Data Sheet A :

3.2

(a)

No Purge Loss Split Flow

(b)

Blower Reactivated

(c)

Heatless

(d)

Heat of Compression

CONTROL SYSTEM

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

VOLUME - II
SECTION: D2
SHEET 2 OF 4

SPECIFICATION FOR COMPRESSED AIR SYSTEM

WRITE-UP OF AIR DRYING PLANT

3.2.1 The controi system shall be fully automatic, designed to suit the required
drying and reactivation cycle. Provision for switch-over to manual operation
shall also be made except for heatless type air drying plant. The controi
system shall be so designed that the air drying process is continuous. The air
stream shall be automaticaiiy switched over from one chamber which is
saturated with moisture to the other chamber and the reactivation cycle of the
first chamber shall start automaticaiiy. Controi cabinet shall be an integrai part of
the air drying plant. The controi cabinet shall be skid mounted on air dryer skid.
Potential free contacts shall be provided in the control cabinet for all the alarms,
potential free contacts shall be wired upto the terminals in the cabinet for use by
purchaser. The control cabinet shall be constructed from CRCA sheet metal
of minimum 1.6 mm thickness for all sides and door and 3 mm thick for
mounting plate & gland plate. The control cabinet shall have weather protection
class of minimum IP 52. The control cabinet shall be powder coated with
minimum paint thickness of 60 microns and paint shade RAL 7034.
3.2.2

For no purge loss split flow and blower reactivated type of air drying plant,
electric heater shall be automatically switched 'on' and 'off' during heating and
cooling cycle respectively. During heating cycle, provision shall be made to
start and stop heater depending on air temperature at heater outlet. Provision
shall be made for auto start and stop for blower in blower reactivated type air
drying plant. Temperature switch and suitable logic shall be included to
ensure that outlet air temperature from electric heater does not go beyond the
temperature required for reactivation.

3.2.3 For heatless type of air drying plant, an adjustable purge rate valve shall be
provided to conserve dry air when air drying plant is not operated at its full
capacity. Venting of wet air from the chamber under reactivation shall be
automatic and at constant intervals.
3.2.4

For heat of compression type of air drying plant, electric heater shall be
automatically switched on when the temperature of the air from compressor is
less than the temperature for reactivation. Temperature switch and suitable
logic shall be included to ensure that outlet air temperature from electric
heater does not go beyond the temperature required for reactivation

4.0

PERFORMANCE GUARANTEES
Performance parameters to be guaranteed by the CONTRACTOR and
tolerances permitted shall be as indicated in section C and / or data sheet A.
BIDDER shall confirm acceptance of these by indicating values in data sheet B.
Air drying plant or any portion thereof is liable for rejection, if it fails to give any
of the guaranteed performance parameters.

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

VOLUME - II
SECTION: D2
SHEET 3 OF 4

SPECIFICATION FOR COMPRESSED AIR SYSTEM

WRITE-UP OF AIR DRYING PLANT

DATA SHEET C
DATA TO BE FURNISHED BY THE CONTRACTOR AFTER THE AWARD OF
CONTRACT

1.

List of drawings and documents to be submitted for review, approval and

information with scheduled submission dates.

2.

Quality Assurance Plan (QAP)

3.

Design calculations for quantity of desiccant per chamber, sizing of desiccant

Chambers, heat exchangers and other major equipment.

4.

Mechanical design calculations for all the pressure vessels and heat
exchangers.

5.

Detailed P&l diagram showing clearly the scope of supply of equipment,

piping with line sizes and material specifications, valves, specialities,
instrumentation and control and all the accessories. All equipment, lines,
valves, specialities and instruments shall be tagged as per the
PURCHASER's procedure to be given to the successful BIDDER. All terminal
points shall be clearly identified. All design data and other information
furnished in data sheets A and B shall be covered either in this drawing or
other relevant drawings or documents mentioned below.

6.

Detailed equipment list

CONTRACTOR's scope.

7.

Sub-vendor list for all bought-out items.

8.

Dimensioned to-scale equipment layout drawing showing all equipment,

accessories, relevant external dimensions, location and elevation of terminal
points, details of piping and electrical connections to be made by the
PURCHASER, clearances required for erection, dismantling, operation and
maintenance.

9.

Dimensioned cross-section drawings of all proprietary equipment like

blowers, heating elements etc. with part list and materials of construction.

10.

Detailed fabrication drawings of all fabricated equipment including all

internals.

11.

Line designation schedule for all lines in the CONTRACTOR'S scope

12.

List of valves, specialities and instruments in the CONTRACTOR'S scope

with tag numbers, type, makes, pressure ratings, materials of construction

and

bill

of

materials

of

all

items

in

the

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

VOLUME - II
SECTION: D2
SHEET 4 OF 4

SPECIFICATION FOR COMPRESSED AIR SYSTEM

WRITE-UP OF AIR DRYING PLANT

and ranges for instruments etc.

13.

Manufacturer's drawings, data sheets and catalogues for valves, specialities

and instruments etc.

14.

Dimensioned to-scale piping layout drawing for piping in the

CONTRACTOR's scope with allowable forces and moments on the piping
nozzles and displacement of the nozzles

15.

Overall foundation plan, base frame drawing for each equipment, static and
dynamic loads on each of the anchor boits and dimensional details of pockets
and anchor boits

16.

Motor drawings

17.

Electrical control wiring diagrams with all interlocks

18.

Control philosophy, interlock description and logic diagrams

19.

Dimensioned to-scale general arrangement and section drawings of

instrument control panel with compete bill of materials, wiring diagram,
terminal details, weight of panel, colour shade, weather protection class,
sheet thickness, front facia drawing and internal general arrangement

20.

List of alarms and trip settings

21.

Erection, start-up, operation and maintenance manual complete with

lubrication schedule etc.

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

VOLUME - II
SECTION: D2
SHEET 1 OF 3

DATA SHEET A
AIR DRYING PLANT HOC TYPE
23. PRESSURE AT THE OUTLET OF THE
LAST INTERCOOLER OF THE MULTISTAGE COMPRESSOR (FOR HOC TYPE
ONLY) : BIDDER Kg/cm(g)

1. DESIGNATION : AIR DRYING PLANT

FOR INSTRUMENT AIR

3. TAG NUMBERS :

4. OPERATION : CONTINUOUS /
INTERMITTENT
Hrs/DAY
5. LOCATION :

INDOOR / OUTDOOR

6. INLET AIR QUALITY : OIL AND DUST

FREE COMPRESSED AIR
7. APPLICABLE CODE : IS 11989/ISO 8573-1
8.

DESIGN DATA (CONTD.)

GENERAL

2. NUMBER REQUIRED : 4 (3W+1S)

9.

25. CW INLET TEMPERATURE : 38 C

26. MAXIMUM ALLOWABLE CW OUTLET
TEMPERATURE : 46 C
27. CW INLET PRESURE :

BY BIDDER Kg/cm(g)

28. MAXIMUM ALLOWABLE CW

PRESSURE DROP :
0.5
Kg/cm

10. TYPE : HOC TYPE

29. CONTROL POWER SUPPLY :

SECTION C7

11. TYPE OF DESICCANT : SILICA GEL/

ACTIVATED ALUMINA/ MOLECULAR
SIEVE

30.

REFER

31.
32. DESIGN CODES FOR ALL PRESSURE
VESSELS : ASME SEC VIII DIV 1/IS 2825

13. OPERATING PRESSURE : 8.6 Kg/cm(g)

33. CORROSION ALLOWANCE :

15. MAXIMUM ALLOWABLE PRESSURE

DROP ACROSS AIR DRYING PLANT :
0.3 Kg/cm
16. AIR INLET TEMPERATURE : BIDDER C
17. AIR OUTLET TEMPERATURE: BIDDER C
18. OUTLET AIR DEW POINT (NOTE 1) :
18.1 AT ATMOSPHERIC PRESSURE : (-)40C
18.2 AT OPERATING PRESSURE : (-)20C
19. MAXIMUM DIFFERENTIAL MOISTURE
LOADING (% BY WEIGHT) :

10 %

20. TEMPERATURE AT THE OUTLET OF

THE LAST INTER COOLER OF THE
MULTI-STAGE COMPRESSOR (FOR
HOC TYPE ONLY) : BIDDER C

MATERIALS AND CODES OF CONSTRUCTION

12. DESIGN CAPACITY (FAD) : 2,900 M3/Hr

14. DESIGN PRESSURE : 10.75 Kg/cm(g)
DESIGN DATA

24. QUALITY OF COOLING WATER (CW) :

PASSIVATED DM Water

3 mm

34. DESSICANT CHAMBER : IS 2062 GR B /

IS 2002 GR 2
35. FILTERS SHELL : SA 106 GR B /
IS 2062 GR B / IS 2002 GR 2
36. MOISTURE SEPARATOR SHELL :
SA 106 GR B/IS 2062 GR B/IS 2002 GR 2
37. DISTRIBUTOR SHELL : SA 106 GR B /
IS 2062 GR B / IS 2002 GR 2
38. ELECTRIC HEATER CHAMBER :
SA 106 GR B / IS 2002 GR 2
39. HEAT EXCHANGER
39.1 DESIGN CODES : ASME SEC VIII DIV 1
AND TEMA C
39.2 SHELL : SA 106 GR B / IS 2002 GR 2

21.

39.3 TUBES : COPPER/ADMIRALITY BRASS

AS PER BS EN 1057

22.

39.4 TUBE SHEET : IS 2002 GR 2 / SA 105

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

VOLUME - II
SECTION: D2
SHEET 2 OF 3

DATA SHEET A

52. BY PASS ARRANGEMENT FOR THE

PLANT REQUIRED :
YES / NO

40. PIPING : REFER SECTION D3

53. ALL THE VALVES, SPECIALITIES

INSTRUMENTS AND ACCESSORIES
: AS REQUIRED

41.
42.
43. CONTROL SIGNAL LAMPS FOR
43.1 HEATER ON
43.2 POWER, CONTROL SUPPLY ON
43.3 CHAMBER A ON ADSORPTION
43.4 CHAMBER B ON ADSORPTION
44 SWITCHES/PUSH BUTTONS FOR
44.1 ACKNOWLEDGE/RESET/TEST
44.2 START/STOP OF HEATER

54. COUNTER FLANGES FOR ALL THE

CONNECTIONS AT BATTERY LIMITS
WITH NUTS, STUDS, BOLTS, GASKETS
AND WASHERS REQUIRED : YES / NO
55. FLANGES : AS PER REQUIREMENT
56. FOUNDATION BOLTS FOR ALL THE
EQUIPMENT REQUIRED:
YES / NO
57. ERECTION BY CONTRACTOR: YES/NO

44.3 AUTO / MANUAL CHANGE-OVER

SELECTOR SWITCH

58. ERECTION SUPERVISION BY

CONTRACTOR:
YES/ NO

45. ANNUNCIATION SYSTEM

VOID

59.
60.
61.
62. PRIMER : REFER NOTE 2
62.1 NUMBER OF COATS : REFER NOTE 2

PAINTING

62.2 DRY FILM THICKNESS PER COAT :

REFER NOTE 2

VOID

COMPANION
SPECIFICATIONS

CONTROLS FOR HEATLESS

TYPE

MISCELLANEOUS

39.5 BAFFLE PLATES : IS 2062 GR B /

IS 2002 GR 2

CONTROLS FOR BLOWER

REACTIVATED TYPE

CONTROLS FOR NO PURGE LOSS MATERIALS AND CODES

OF CONST. (CONTD.)
AND HOC TYPE

AIR DRYING PLANT HOC TYPE

63. FINISH PAINT : REFER NOTE 2

63.1 NUMBER OF COATS : REFER NOTE 2
63.2 DRY FILM THICKNESS PER COAT :
REFER NOTE - 2
64.
65.
66.
67.
68. VOID
69.
70.
71.
72.
73.
74.

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

VOLUME - II
SECTION: D2
SHEET 3 OF 3

DATA SHEET A

LIST OF SUB-VENDORS FOR

BOUGHT-OUT ITEMS

PERFORMANCE GUARANTEES (CONTD.)

74. AS PER SECTION C11

75.
75.1
75.2
75.3
75.4
75.5
75.6
76.

77.
78.
79. DESIGN CAPACITY (FAD) :

81. PRESSURE DEW POINT AT OUTLET :

(+)
C
()
C
82. AIR PRESSURE DROP ACROSS THE
PLANT :
(+)
Kg/cm
()
Kg/cm
83. AIR OUTLET TEMPERATURE :
(+)
()

2,900 (+) M /Hr

() 0 M3/Hr
80. OUTLET AIR DEW POINT AT
ATMOSPHERIC PRESSURE :

(-)40C
(+) C
() 0 C

C
C

84. TOTAL POWER CONSUMPTION PER

CYCLE :
(+)
KW
()
KW
85. PURGE AIR QUANTITY :
(+)
()

COST LOADING
AND PENALTY

PERFORMANCE
GUARANTEES

TESTS AND
INSPECTION

SPARES AND MAINTENANCE

TOOLS AND TACKLES

AIR DRYING PLANT HOC TYPE

M3/Hr
M3/Hr

86. TOTAL POWER CONSUMPTION/CYCLE:

Rs.
/ KW
87.
88.
89.

90. SUMMMIT
91. DELAIR
92. GEM
93. MELLCON
94. ABACUS ENGINEERING
95. INDCON
90.
97.
98.

NOTES
1. THE FLOW THROUGH THE AIR DRYING PLANT MAY VARY. HOWEVER, THE SPECIFIED AIR DEW POINT
TEMPERATURE SHALL BE ACHIEVED FOR ANY FLOW UPTO DESIGN CAPACITY.
2. PAINTING SHALL BE AS PER SECTION C-12
3. QUALITY OF AIR SHALL BE AS PER ISO 8573 1, FOR DETAIL REFER SECTION C9, CLAUSE NO 9.2.2 (d)
4. CAPACITY INDICATED IS TENTATIVE ONLY.

VOLUME - II

CARBERY INFRASTRUCTURE PTE LTD

SECTION: D2
SHEET 1 OF 2

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

DATA SHEET B
AIR DRYING PLANT HOC TYPE
SL.
NO.
1.

BIDDER
ITEM
DESIGNATION

2.

NUMBER OFFERED

TAG NUMBERS

4.

MAKE / MODEL NUMBER

5.

TYPE OF AIR DRYING PLANT

6.

MAXIMUM CAPACITY AT OPERATING

CONDITION (FAD)

7.

TYPE OF DESSICANT

8.

QUANTITY OF DESICCANT PER

AIR DRYING PLANT FOR

M /Hr

CHAMBER

Kg

9.

EXPECTED LIFE OF DESICCANT

YR

10.

AIR PRESSURE DROP ACROSS AIR

DRYING PLANT AT MAXIMUM FLOW

11.

OUTLET AIR TEMPERATURE

12

OUTLET AIR DEW POINT

Kg/cm
C

12.1

AT ATMOSPHERIC PRESSURE

12.2

AT OPERATING PRESSURE

13.

COOLING WATER (CW) FLOW RATE

13.1

CW OUTLET TEMPERATURE

13.2

CW PRESSURE DROP

14.

ADSORPTION CYCLE TIME

Hr

15.

REACTIVATION CYCLE TIME

Hr

15.1

HEATING

Hr

15.2

COOLING

Hr

15.3

PURGING

MIN.

16.

WEIGHT OF WATER REMOVED PER

17.

M /Hr
C
Kg/cm

CYCLE

Kg

REGENERATION AIR TEMPERATURE

NOTES TO BIDDER
1.

ITEMS WHICH DEVIATE FROM THE SPECIFICATION SHOULD BE

MARKED WITHIN ASTERISK (*) AND DETAILS TO BE GIVEN IN
SCHEDULE OF DEVIATIONS.

2.

THIS DATA SHEET SHALL BE FILLED UP COMPLETELY AND A COPY

SHALL BE ENCLOSED WITH EACH COPY OF THE BID.

SIGNATURE OF BIDDER & DATE

VOLUME - II

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

SECTION: D2
SHEET 2 OF 2

DATA SHEET B
AIR DRYING PLANT HOC TYPE
SL.
NO.
18.

DESIGN DATA (CONTD.)

19.
20.
21.
22.
23.
24.
25.

26.

BIDDER
ITEM
NUMBER / RATING OF EACH HEATING
ELEMENT
HEATER POWER CONSUMTPION PER
CYCLE
BLOWER CAPACITY
BLOWER POWER CONSUMPTION PER
CYCLE / MOTOR RATING
PURGE AIR QUANTITY
OVERALL DIMENSIONS
LxWxH
TOTAL WEIGHT
DETAILED DESCRIPTION OF
OPERATING SEQUENCE, CONTROLS,
INTERLOCKS TO BE ENCLOSED
WHETHER SUPPLY OF VALVES,
SPECIALITIES AND INSTRUMENTS AS
PER DATA SHEET A AND P & I
DIAGRAM IS INCLUDED?

KW

KWHr
M3/Hr
KW
M3/Hr
M
Kg

/
x

WHETHER ENCLOSED
YES / NO
WHETHER INCLUDED
YES / NO

PERFORMANCE GUARANTEES

27.
M3/ Hr

(+)

()

ATMOSPHERIC PRESSURE

(+)

()

30.

PRESSURE DEW POINT AT OUTLET

(+)

()

31.

AIR PRESSURE DROP ACROSS THE

Kg/cm

(+)

()

28.

DESIGN CAPACITY (FAD)

29.

OUTLET AIR DEW POINT AT

PLANT
32.

AIR OUTLET TEMPERATURE

(+)

()

33.

TOTAL POWER CONSUMPTION/CYCLE

KW

(+)

()

34.

PURGE AIR QUANTITY

(+)

()

M / Hr

35.
36.

NOTES TO BIDDER
1.

ITEMS WHICH DEVIATE FROM THE SPECIFICATION SHOULD BE

MARKED WITHIN ASTERISK (*) AND DETAILS TO BE GIVEN IN
SCHEDULE OF DEVIATIONS.

2.

THIS DATA SHEET SHALL BE FILLED UP COMPLETELY AND A COPY

SHALL BE ENCLOSED WITH EACH COPY OF THE BID.

SIGNATURE OF BIDDER & DATE

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

VOLUME - II
SECTION: D3
SHEET 1 OF 3

PIPING AND VALVE SCHEDULE

PIPING AND VALVE SCHEDULE

GATE / GLOBE / CHECK VALVES
Sl.No
.

Description

Water service
(Passivated DM water)

Air service ( Globe &

Check valves only)

15 TO 50 NB

65 NB&
ABOVE

15 TO 50
NB

65 NB&
ABOVE

1.0

BODY / BONNET

Bronze as per
ASTM B62 /
IS 318 LTB2

CI as per IS
210 FG200

Bronze as
per ASTM
B62 / IS 318
LTB2

Cast steel,
as per ASTM
A216
Gr.WCB

2.0

DISC

-----do----

-----do----

-----do----

-----do----

3.0

STEM

Manganese
bronze IS320
Gr.HT-2

Manganese
bronze IS320
Gr.HT-2

Manganese
bronze
IS320
Gr.HT-2

Alloy Steel
as per
ASTM A 479
Type 410-2

Bronze as per
ASTM B62 /
IS 318 LTB2

Bronze as
per IS 318
Gr. LTB2

Bronze as
per ASTM
B62 / IS 318
LTB2

( not applicable for check

valves)
4.0

BODY SEAT / DISC SEAT

-----do----

5.0

END CONNECTION

Screwed as
per IS554
tapered

Flat faced
flanged to
ANSI B16.1

Screwed as
per IS554
tapered

Raised
flange as
per
ANSIB16.5

6.0

VALVE RATING

150 lb

125lb

150 lb

150lb

VOLUME - II

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

SECTION: D3
SHEET 2 OF 3

PIPING AND VALVE SCHEDULE

BALL VALVE (In case the bidder offers these kind of valves)
Sl.No.

Description

Air service
15 TO 50 NB

65NB & ABOVE

1.0

BODY / BONNET

A 105

ASTM A216 GR
WCB

2.0

BALL

13% Cr Steel

13% Cr Steel

3.0

STEM

4.0

BODY SEAT / DISC

SEAT

13% Cr Steel

13% Cr Steel

5.0

END CONNECTION

Screwed as per IS554

tapered

FLANGED RAISED
FACE ENDS
DRILLED TO ASME
B.16.5

6.0

VALVE RATING

600 lb

150 lb

A 479

Type 410-2

A 479

Type 410-2

General
1.0

For carbon steel valves Bolts and Nuts:

ASTM A 193 Gr. B7, ASTM A

194 Gr.2H

2.0

Hand wheel / Lever ( for all valves) :

Malleable Iron ASTM A 47

Gr.3251

3.0

For Bolts & nuts (for CI & bronze valves):

ASTM A 307 Gr. B

VOLUME - II

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

SECTION: D3
SHEET 3 OF 3

PIPING AND VALVE SCHEDULE

PIPES AND FITTINGS

SL.NO

1.0

Description

LINE JOINTS

Water line

Air line

15 50NB

65NB &
above

Plain end as per

ANSI B 16.11.
Flanged
connection for
eqpt.

Butt-welded
ends. Flanged
joints for
equpt.

15 50NB

65NB & above

Screwed

Flanged

2.0

Pipes to confirm

IS1239 / IS 3589 (Heavy class)

IS1239 / IS 3589 (Heavy

class),Gr 410

3.0

Flanges

ANSI 150lb forged steel ASTM

105 to B16.5 flat face.

ANSI 150lb forged steel ASTM

105 to B16.5 flat face.

4.0

Fittings

3000lb- forged
carbon steel to
ASTM105 as per
ANSI B16.11

A234 Gr.WPB
with Butt
welded to
ANSI B16.9

5.0

MOC of piping

CS, ERW

CS, ERW

3000lb- forged
carbon steel to
ASTM105 as
per ANSI
B16.11

A234 Gr.WPB
with Butt
welded to ANSI
B16.9

CS, ERW (GALVANISED)

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar
Pradesh

VOLUME - II
SECTION: D4
SHEET 1 OF 4

MOTORS AND VALVE ACTUATORS

DATASHEET - A
Sl. No.
1.0

DESCRIPTION

UNIT

REQUIREMENT

GENERAL
Application

Drive Motors For CA System

Numbers Required

As required

1.3

Type Of Motor

Squirrel Cage

1.4

Supply System Fault Level

1.5

Type Of Earthing Of Supply System

Neutral

2.0

RATING

2.1

Rated Output

1.1
1.2

MVA

11 kV - 40 kA, 415 V 50 kA
11 kV - Non Effectively Earthed,
415 V - Effectively Earthed

kW

As required
11 kV- For Motors Above 200kW

2.2
2.3
2.4

Rated Voltage
NUMBER OF PHASES &
FREQUENCY
Supply condition (Ref.
cl.no.2.0 of CIPL.6071A-c-604-004,
Volume-II, sec-c7.

2.5

Synchronous Speed

3.0

DUTY

3.1

Type Of Duty (Clause 9.2 of Is:325 or

Equivalent)

3.2

Power Required By Load

3.3
4.0
5.0
5.1

415 V- For Motors of 200 kW &

Below
3 Ph, 50Hz

*
RPM

S1 (Continuous)
kW

Energy Efficiency Class as per Is-12615

*
EFF1

METHOD OF STARTING

D.O.L.

Insulation
Class F With Temp. Rise Limited To
Class B

Class Of Insulation

5.2

Ref. Ambient Temperature

Deg.C

50

5.3

Temperature Rise Of Winding

By Winding Resistance Method

Deg.C

Corresponding To Class B
Insulation

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar
Pradesh

VOLUME - II
SECTION: D4
SHEET 2 OF 4

MOTORS AND VALVE ACTUATORS

DATASHEET - A
Sl. No.

DESCRIPTION

UNIT

REQUIREMENT

6.0

INSTALLATION

6.1

Location

6.2

Hazardous Area Division

(IS: 5572 or Equivalent)

6.3

Atmosphere

7.0

ENCLOSURE

7.1

Type Of Cooling (IS 6362)

IC4A1A1 (TEFC)

7.2

Designation For Degree Of

Protection (IS 4691)

IP55-Outdoor and Indoor application

8.0

MAIN TERMINAL BOX

8.1

8.2

Location As Seen From NonDrive End:

Ratings
(A) Short Time
I. Current :
Ii. Duration :
(B) Dynamic :

8.3

Indoor /
Outdoor

Dusty

TOP/RIGHT/LEFT *
kArms
Secs.

11 KV 40 KA, 415 V 50 KA
0.25

kApeak

11 KV 105 KA, 415 V -130 KA

External Cable Details

8.3.1

Type

XLPE Insulated, FRLS PVC

Sheathed

8.3.2

Size & No Of Cores

3C X *

8.4

Earthing Conductors

8.4.1

Material

GS FLAT

8.4.2

Size

75X10 Sq.mm.

9.0

MISCELLANEOUS REQUIREMENTS

9.1

Shaft Orientation

9.2

Mounting Symbol (IS:2253 or Equivalent)

9.3

Rotation As Seen From Non-Drive End

9.4

Type Of Bearing

9.4.1

Drive End

To be filled if motors are bought

separately
Horizontal / Vertical /
Hollow Vertical

Clockwise / Anti-Clockwise *

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar
Pradesh

VOLUME - II
SECTION: D4
SHEET 3 OF 4

MOTORS AND VALVE ACTUATORS

DATASHEET - A
Sl. No.
9.4.2
9.5

DESCRIPTION

UNIT

REQUIREMENT

Non Drive End

Whether Bed Plate Required

Yes

A)
B)
C)
D)

Motor shall match the following torque

requirements of the driven equipment
Starting Torue
Full Load (Rated) Torque
Pull Out Torque
Pull Up Torque

9.7

Coupling By Motor Supplier

Yes

9.8

If Yes, Type of Coupling

9.9

GD2 of Load

10.0

COLOUR SHADES OF PAINT

Flint grey: RAL-7032

A) whether vibration pads required

For Motors > 200 kW Vibration Pads

For Mounting Detectors In X
Direction To Be Provided (Vibration
Monitoring Equipment Shall Be
Provided by Bidder)

B) if required size of the pad

9.6

11

12
12.1
12.2
12.3
13

TEMPERATURE DETECTORS/
INDICATORS
Embedded temperature Detectors for
winding Required
Embedded temperature Detectors for
bearings Required
Bearing thermometers For driving end &
non Driving ends required
SPACE HEATERS FOR MOTORS
REQUIRED

As Required

HT

LT

YES

NO

YES

NO

YES

NO

YES

NO

Required for motors above 30 kW

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar
Pradesh

VOLUME - II
SECTION: D4
SHEET 4 OF 4

MOTORS AND VALVE ACTUATORS

DATASHEET - A
Sl. No.

DESCRIPTION

UNIT

REQUIREMENT

NOTES
Drawings should be submitted for review as follows:
1)

General arrangement within 8 weeks after award of contract.

2)

Details marked thus (*) will be decided and intimated by the bidder based on
driven equipment characteristics. However, this data furnished by the bidder is
subject to purchasers approval.

3)

Data marked thus

will be decided and intimated by the bidder.

4)

All instruments and accessories as called for in I & C design requirements of this
specification shall also be supplied.

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar
Pradesh

VOLUME - II
SECTION: D4
SHEET 1 OF 2

MOTOR AND VALVE ACTUATOR

DATASHEET - B
ENQUIRY / SPECIFICATION NO.

Sl. No.

DESCRIPTION

1.

Application

2.

Manufacturer

3.

Country of Origin

4.

Applicable Standards

5.

Efficiency Category( For Energy

Efficient Motors only)
Rated

6.

(a) Output
(b) Speed
(c) Frame size

7.

Type of Duty (IS 325 or equivalent)

8.

Supply Conditions
a) Voltage
b) No. Of phases
c) Frequency

9.

Allowable variation in supply condition

a) Voltage
b) Frequency
c) Combined

10.

Current
a) Full Load
b) Starting

11.

Method of Starting

12.

Insulation
a) Class of Insulation
b) Whether Tropicalised

13.
14.

Reference Ambient Temperature

Temp. rise of windings by Resistance
Method
a) Stator
b) Rotor

NOTES TO BIDDER
1.

ITEMS WHICH DEVIATE FROM THE SPECIFICATION SHOULD BE

MARKED WITHIN ASTERISK (*) AND DETAILS TO BE GIVEN IN
SCHEDULE OF DEVIATIONS.

2.

THIS DATA SHEET SHALL BE FILLED UP COMPLETELY AND A

COPY SHALL BE ENCLOSED WITH EACH COPY OF THE BID.

BIDDER

UNIT

REQUIREMENT

kW
RPM

Volt
Hz

Amp.
% of FLC

Yes / No
o

SIGNATURE OF BIDDER & DATE

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar
Pradesh

VOLUME - II
SECTION: D4
SHEET 2 OF 2

MOTOR AND VALVE ACTUATOR

DATASHEET - B
ENQUIRY / SPECIFICATION NO.

Sl. No.
15.
16.
17.

18.

DESCRIPTION
Temp. rise of bearings
Degree of Protection
(IS 4691 or equivalent)
Suitable for Outdoor
Operation
Normal winding connection
a) Stator
b) Rotor

BIDDER

UNIT

REQUIREMENT

Yes / No

Star / Delta
Star / Delta

Terminal box
(i) Type & No. of Terminals brought Out
19.

(ii) Fault withstand capacity at rated

voltage & duration
(iii) Maximum size of Aluminium armoured
cable that can be terminated

20.

Space heater Rating

21.

Dimensional Drawing Enclosed

Torque
a. Full load torque

22.

kA
Cores X
Sqmm.
Watt
Yes / No
Kg. m

b. Starting torque

% of FLT

c.

Pull out Torque

% of FLT

d.

Pull up Torque

NOTES TO BIDDER
1.

ITEMS WHICH DEVIATE FROM THE SPECIFICATION SHOULD BE

MARKED WITHIN ASTERISK (*) AND DETAILS TO BE GIVEN IN
SCHEDULE OF DEVIATIONS.

2.

THIS DATA SHEET SHALL BE FILLED UP COMPLETELY AND A

COPY SHALL BE ENCLOSED WITH EACH COPY OF THE BID.

% of FLT

SIGNATURE OF BIDDER & DATE

CARBERY INFRASTRUCTURE PTE LTD

VOLUME - II
SECTION: D5
SHEET 1 OF 6

3 X 660 MW Super Critical TPP at Lalitpur, Uttar

Pradesh
415 VOLT SWITCHGEAR / PMCC
DATASHEET A
Sl. No.

DESCRIPTION

1.0

Switchgear and Bus Bar Rating

1.1

Rated voltage, phases & frequency

1.2

System neutral earthing

1.3

Maximum system voltage

1.4

One minute power frequency

Voltage

(a)

UNIT

REQUIREMENT

Volt
Phase
Hz

415
3
50
Solidly earthed

Volt

433

Power circuits

Volt

2500

(b)

Control circuits

Volt

1500

(c)

Aux. Circuits connected to sec of CTs

Volt

2000

1.5

Material of bus bar

1.6

Reference ambient temperature

1.7

Maximum temperature of bus bars and

droppers/connectors under site conditions
specified

1.8

Short circuit current withstand for busbars

and droppers

(a)

Short time (1 sec.)

kArms

50

(b)

Dynamic rating

kApeak

105

1.9

Whether busbars have been insulated

Yes / No

Required

1.10

Whether suitable for operation in seismic

zone 3 (As per IS) and vibration test report
enclosed

1.11

Type of insulation

1.12

Standard applicable

2.0

Switchgear & Bus Bar Particulars:

2.1

Bus bar details

(a)

Amps

(b)

Cu/Al

Al

(c)

TP/TPN

TP

2.3

Fully draw out (FD)/ Fixed (F)

Aluminium / Copper
C

50
85 deg C

Required
Heat shrinkable PVC sleeves
Refer section D2.17

FD For PMCC/MCC

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar
Pradesh

VOLUME - II
SECTION: D5
SHEET 2 OF 6

415 VOLT SWITCHGEAR / PMCC

DATASHEET A
Sl. No.
2.4

3.0

3.1

DESCRIPTION

UNIT

REQUIREMENT

Entry Top (T)/Bottom (B)

A). Power

Busducts (T), Cables (B)

B). Control

Bottom for cables

Switchgear constructional
requirements

Thickness of sheet steel (in mm)

Cold
rolled

Frame

2.0

Doors

Covers

Gland plate

1.6

1.6

3.0

IP-52 for rating up to 1600A

IP-42 for rating above 1600A

3.2

Degree of protection

3.3

Colour finish shade

Interior
exterior

Glossy white:RAL-9010
Flint grey:RAL-7032

3.4

Earthing bus

Material
Size

GS
65 x 10 Sq.mm

3.5

Minimum clearances in air of live parts

A)

Phase to phase

mm

25.4

B)

Phase to earth

mm

19.4

Top/
Bottom,
Indoor/
Outdoor

Top, indoor Bus duct required for switchgear

with transformer incomers.

3.6

Metal enclosed busduct/bustrunking entry

to cubicles if required

4.0

Starters
DOL
Rev /
StarDelta

4.1

Type

4.2

Contactor rated duty

4.3

Single phasing preventor reqd.

Yes / no

Yes

4.4

Thermal overload relay reset

Manual /
Auto

Settable for either to Manual or Auto

5.0

Circuit Breakers

5.1

Voltage, frequency & no. of phases

DOL
AC3 for DOL

415 V, 50 Hz, 3 Ph

CARBERY INFRASTRUCTURE PTE LTD

VOLUME - II
SECTION: D5
SHEET 3 OF 6

3 X 660 MW Super Critical TPP at Lalitpur, Uttar

Pradesh
415 VOLT SWITCHGEAR / PMCC
DATASHEET A
Sl. No.

DESCRIPTION

UNIT

REQUIREMENT

5.2

Rated operating duty

O-3 Min-CO-3 Min-CO

5.3

Applicable standards

Refer section on standards

5.4

Circuit breakers type

ACB

5.5

Rated ultimate breaking capacity (Icu) at 41

V, 0.25 PF

kArms

50

5.6

Rated service breaking capacity (Ics) at

415 V, 0.25 PF

kArms

50

5.7

Short circuit withstand current for 1 sec.

Duration

kA

50

5.8

Rated making current

kAPeak

105

5.9

Type of operating mechanism manual,

spring assisted manual, spring charged
motor, wound spring charged.

5.10

Key interlocking required

Yes/no

Yes, wherever specified

5.11

Shunt trip required

Yes/no

Yes

5.12

Minimum no. of auxiliary

Contacts for purchasers use

5.13

Control voltage

Spring charged motor and also

spring assisted manual

6 NC, 6 NO

A)

For Spring charging motor

V
AC/DC

230V AC

B)

For closing/tripping

V
AC/DC

220V DC

5.14

Emergency manual operation required in

addition to electrical operating devices

A)

For spring charging & closing

Yes /No

Yes

B)

For tripping

Yes /No

Yes

5.15

Limits of voltage for satisfactory operation

of the following devices as a % of normal
voltage

I)

Operating mechanism

As per IS

II)

Closing at normal voltage

As per IS

III)

Trip coil

As per IS

Yes/No

Required

5.16

Have electrical and mechanical anti-

CARBERY INFRASTRUCTURE PTE LTD

VOLUME - II
SECTION: D5
SHEET 4 OF 6

3 X 660 MW Super Critical TPP at Lalitpur, Uttar

Pradesh
415 VOLT SWITCHGEAR / PMCC
DATASHEET A
Sl. No.

DESCRIPTION

UNIT

REQUIREMENT

pumping features been provided

6.0
6.1

MCCB / MPCB
Moulded case circuit breakers to be
provided

For motor control circuits with shunt trip for

motor rated 110kW and above

Yes/No

As per write up

ii

For other circuits

Yes/No

As per write-up

6.2

Voltage, frequency & no. Of phases

6.3

Rated operating duty

6.4

Rated ultimate breaking capacity

(Icu) at 415 V, 0.25 PF

kArms

50

6.5

Rated service breaking capacity (Ics) at

415 V, 0.25 PF

kArms

50

6.6

Rated making current

kApeak

105

6.7

415 V, 50 Hz & 3 PH
P2

On/off operation

Manual

Yes/No

Yes.

ii

Remote

Yes/No

Yes. (for Motorised MCCBs)

6.8

Releases required
Yes/No

Yes

6.8.1

Over-load inverse time, short circuit and

earth fault

7.0

Instrumentation Transformers

7.1

Measuring CTs

7.2

Protection CTs

Cl 5P20

7.3

Measuring VTs

Cl. 0.5 (For transformer incomer

feeder)

7.4

Protection VTs

Cl 1.0

7.5

Class of insulation

8.0

Contactors

8.1

Rated duty

Cl - 0.5S (For transformer incomer

feeder) and others 1.0
Instrument safety factor 5.0

Class F with temp rise limited to

class B

AC3 /

AC3 for DOL

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar
Pradesh

VOLUME - II
SECTION: D5
SHEET 5 OF 6

415 VOLT SWITCHGEAR / PMCC

DATASHEET A
Sl. No.

DESCRIPTION

UNIT

REQUIREMENT

AC4

AC4 for RDOL

8.2

Limits of operation

9.0

Control transformers

9.1

Type

9.2

Applicable standards

Refer Section D2.17

9.3

Class of insulation

Class-B or Better

10.0

Meters

10.1

General

10.2

Applicable Standards

10.3

Accuracy Class

11.0

Voltmeter

11.1

Type

11.2

Applicable standards

11.3

Accuracy class

12.0

Ammeter

12.1

Type

12.2

Applicable standards

12.3

Accuracy class

13.0

Indicating lamps

13.1

Type

14.0

Wiring and terminal blocks

14.1

Voltage grade

14.2

Minimum size of conductor for:

14.3

As per IS/IEC

Dry Type

Refer Codes and Standards Section

Class 1.0 & 0.5S (multifunction
meter with communication facility)
Digital
Refer Section D2.17
Class 1.0

Digital
Refer Section C7.9
Class 1.0

Clustered Led

1.1 kV

I) Power wiring

Sq.mm

2.5 or higher for CT & PT

As per sizing calculation for power
circuits

Ii) Control wiring

Sq.mm

1.5 for others

Type of terminal blocks:

I) For Withdrawable Type
II) For Fixed Type

Sliding type
Stud & nut type

CARBERY INFRASTRUCTURE PTE LTD

VOLUME - II
SECTION: D5
SHEET 6 OF 6

3 X 660 MW Super Critical TPP at Lalitpur, Uttar

Pradesh
415 VOLT SWITCHGEAR / PMCC
DATASHEET A
Sl. No.

DESCRIPTION

14.4

Minimum current rating of terminal blocks

14.5

Whether terminals for CTs have been

provided with short circuiting facilities
Note:
* Information will be furnished by Bidder.

UNIT

REQUIREMENT

10

YES/NO

Required

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar
Pradesh

VOLUME - II
SECTION D5
SHEET 1 OF 12

415 VOLT SWITCHGEAR / PMCC

DATASHEET - B
ENQUIRY / SPECIFICATION NO.

Sl. No.
1.0

DESCRIPTION

UNIT

REQUIREMENT

PMCC

1.1.0

Assembly

1.1.1

Make

1.1.2

Type

1.1.3

Reference Standard

1.1.4

Short Circuit Rating

1.1.5

Interrupting Symmetrical

1.1.6

Short time for 1 sec.

1.1.7

Insulation Level

1.1.8

1-min., 50 Hz Voltage withstand

1.1.9

Metal clad, air insulated,

floor mounting

1.1.10

Enclosure

1.1.11

Degree of Protection

1.1.12

Minimum thickness of sheet metal mm

1.2.0

Construction

1.2.1

Design

1.2.2

Completely compartmentalized

1.2.3

Working height limits from

floor level

1.2.4

Colour finish shade

1.2.5

Dimension(LXBXH)

1.2.6

Weight

1.2.7

Horizontal wire way for inter panel

Wiring provided
All meter, switch and relays flush
mounted type

1.2.8

BIDDER

NOTES TO BIDDER
1.

ITEMS WHICH DEVIATE FROM THE SPECIFICATION SHOULD BE

MARKED WITHIN ASTERISK (*) AND DETAILS TO BE GIVEN IN
SCHEDULE OF DEVIATIONS.

2.

THIS DATA SHEET SHALL BE FILLED UP COMPLETELY AND A

COPY SHALL BE ENCLOSED WITH EACH COPY OF THE BID.

kA
kArms

kVrms
Yes/No

mm

mm
kg

Yes/No

SIGNATURE OF BIDDER & DATE

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar
Pradesh

VOLUME - II
SECTION D5
SHEET 2 OF 12

415 VOLT SWITCHGEAR / PMCC

DATASHEET - B
ENQUIRY / SPECIFICATION NO.

Sl. No.

DESCRIPTION

1.3.0

Busbar

1.3.1

Make

1.3.2

Material & Grade

1.3.3

Reference, Standard

1.3.4

Cross Sectional area

1.3.5.

1.3.6

a)

Main Busbar

b)

Vertical Busbar

UNIT

REQUIREMENT

sq.mm

Type of Insulation
a)

Main Busbar

b)

Vertical Busbar

Continuous current (at site Condition 50

deg.C ambient & within cubicle)
a)

Main bus bar

b)

Vertical bus bar

1.3.7

Maximum temperature rise over 50 DegC

for bus bar
& bus
connection

1.3.8

Short-time current for 1 Sec.

1.3.9

Separate enclosure/phase barriers

Sleeving / shrouding provided for

1.3.10

BIDDER

a)

Main busbar

b)

Vertical droppers

Amp

DegC:
kArms

Circuit Breaker connections

1.3.10.1

Bus Connections

1.3.10.2

Silver plated

1.3.10.3

Provided with anti-oxide grease

1.3.10.4

Bimetallic connectors between

dissimilar metals

NOTES TO BIDDER
1.

ITEMS WHICH DEVIATE FROM THE SPECIFICATION SHOULD BE

MARKED WITHIN ASTERISK (*) AND DETAILS TO BE GIVEN IN
SCHEDULE OF DEVIATIONS.

2.

THIS DATA SHEET SHALL BE FILLED UP COMPLETELY AND A

COPY SHALL BE ENCLOSED WITH EACH COPY OF THE BID.

SIGNATURE OF BIDDER & DATE

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar
Pradesh

VOLUME - II
SECTION D5
SHEET 3 OF 12

415 VOLT SWITCHGEAR / PMCC

DATASHEET - B
ENQUIRY / SPECIFICATION NO.

Sl. No.
1.3.10.5

DESCRIPTION

BIDDER

UNIT

Minimum clearance of bare busbar and

connection
a)

Phase to phase

mm

b)

Phase to ground

mm

1.3.10.6

Busbar support spacing

1.3.10.7

Busbar colour coded

1.3.11

Bus Support Insulator

mm
Yes/No

1.3.11.1

Make

1.3.11.2

Voltage class

KV

1.3.11.3

Minimum Creepage Distance

mm

1.4

REQUIREMENT

Circuit breaker

1.4.1

Make

1.4.2

Type

1.4.3

Reference Standard

1.4.4

Rated Voltage

KV

1.4.5

Rated Frequency

Hz

1.4.6

No. of Poles No.

1.4.7

Rated Currents :

1.4.8

Continuous (at site condition,

50 DegC ambient & within cubicle)

Amp.

1.4.9

Short-time Current for 1 second

kArms

1.4.10

Maximum temperature rise over

50 DegC ambient

Deg .C

1.4.11

Rated Operating Duty

1.4.12

Interrupting Capacity at rated

Voltage and Operating duty
a)

Symmetrical

NOTES TO BIDDER
1.

ITEMS WHICH DEVIATE FROM THE SPECIFICATION SHOULD BE

MARKED WITHIN ASTERISK (*) AND DETAILS TO BE GIVEN IN
SCHEDULE OF DEVIATIONS.

2.

THIS DATA SHEET SHALL BE FILLED UP COMPLETELY AND A

COPY SHALL BE ENCLOSED WITH EACH COPY OF THE BID.

kArms

SIGNATURE OF BIDDER & DATE

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar
Pradesh

VOLUME - II
SECTION D5
SHEET 4 OF 12

415 VOLT SWITCHGEAR / PMCC

DATASHEET - B
ENQUIRY / SPECIFICATION NO.

Sl. No.

BIDDER

DESCRIPTION
b)

UNIT

REQUIREMENT

kArms

Asymmetrical

1.4.13

Rated Making Current

kApeak

1.4.14

1-minute 50 Hz voltage
withstand

kVrms

1.4.15

At 100% interrupting capacity

1.4.15.1

Opening time

ms.

1.4.15.2

Arcing time

ms.

1.4.15.3

Total tripping time

ms.

1.4.15.4

Total closing time

1.4.16

Number of breaks per pole

1.4.17

No. of breaker operations permissible,

without requiring inspection,replacement of
contacts and other main parts

1.4.18

Operating Mechanism

1.4.18.1

Type

1.4.18.2

Anti-pumping features provided?

1.4.18.3

Spring Charging Motor

1.4.18.4

Rating

kW

1.4.18.5

Voltage

1.4.18.6

Permissible Voltage

1.4.18.7

Closing Coil

1.4.18.8

Voltage

1.4.18.9

Permissible Voltage variation

1.4.18.10

Closing current at rated voltage

1.4.18.11

Tripping Coil

1.4.18.12

Voltage

variation

NOTES TO BIDDER
1.

ITEMS WHICH DEVIATE FROM THE SPECIFICATION SHOULD BE

MARKED WITHIN ASTERISK (*) AND DETAILS TO BE GIVEN IN
SCHEDULE OF DEVIATIONS.

2.

THIS DATA SHEET SHALL BE FILLED UP COMPLETELY AND A

COPY SHALL BE ENCLOSED WITH EACH COPY OF THE BID.

SIGNATURE OF BIDDER & DATE

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar
Pradesh

VOLUME - II
SECTION D5
SHEET 5 OF 12

415 VOLT SWITCHGEAR / PMCC

DATASHEET - B
ENQUIRY / SPECIFICATION NO.

Sl. No.

DESCRIPTION

BIDDER

UNIT

1.4.18.13

Permissible Voltage variation

1.4.18.14

Trip current at rated voltage

1.4.19

Breaker/Cubicle Accessories

1.4.19.1
1.4.20

Accessories such as control switch,

indication lamps, relays furnished
as specified
Breaker/Breaker Cubicle
provided with following

1.4.20.1

Mechanical safety interlock

1.4.20.2

Automatic safety shutter

1.4.20.3

Emergency manual trip

1.4.21

Mechanical ON-OFF indicator

1.4.22

Manual spring charging device

1.4.23

Manual operating handle

1.4.24

Operation counter

1.4.25

Charge/Discharge indication

1.4.26

Spare auxiliary switch with

6 NO+6 NC contacts for interlock

1.5

REQUIREMENT

MCCBS

1.5.1

Make

1.5.2

Type

1.5.3

Voltage, frequency & no. Of phases

1.5.4

Rated operating duty

1.5.5

Rated ultimate breaking capacity

(Icu) at 415 V, 0.25 PF

kArms

1.5.6

Rated service breaking capacity (Ics) at

415 V, 0.25 PF

kArms

1.5.7

Rated making current

kApeak

NOTES TO BIDDER
1.

ITEMS WHICH DEVIATE FROM THE SPECIFICATION SHOULD BE

MARKED WITHIN ASTERISK (*) AND DETAILS TO BE GIVEN IN
SCHEDULE OF DEVIATIONS.

2.

THIS DATA SHEET SHALL BE FILLED UP COMPLETELY AND A

COPY SHALL BE ENCLOSED WITH EACH COPY OF THE BID.

SIGNATURE OF BIDDER & DATE

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar
Pradesh

VOLUME - II
SECTION D5
SHEET 6 OF 12

415 VOLT SWITCHGEAR / PMCC

DATASHEET - B
ENQUIRY / SPECIFICATION NO.

Sl. No.

DESCRIPTION

BIDDER

UNIT

1.5.8

On/off operation

1.5.9

Manual

Yes/No

1.5.10

Remote

Yes/No

1.5.11

Releases required

1.5.12

Over-load inverse time, short circuit and

earth fault

1.6

Yes/No

Contactors

1.6.1

Make

1.6.2

Type

1.6.3

Reference standard

1.6.4

Duty class

1.6.5

Utilization category

1.6.6

Operating Coil Voltage

1.6.7

Rated
a)

Pick up

b)

Drop out

1.6.8

Continuous Current rating at

50 Deg.C & within cubicle

1.6.9

Power Consumption

1.7

REQUIREMENT

a)

During closing

VA

b)

After closing

VA

Push Buttons

1.7.1

Make

1.7.2

Type & Cat. No.

1.7.3

Contact rating

NOTES TO BIDDER
1.

ITEMS WHICH DEVIATE FROM THE SPECIFICATION SHOULD BE

MARKED WITHIN ASTERISK (*) AND DETAILS TO BE GIVEN IN
SCHEDULE OF DEVIATIONS.

2.

THIS DATA SHEET SHALL BE FILLED UP COMPLETELY AND A

COPY SHALL BE ENCLOSED WITH EACH COPY OF THE BID.

SIGNATURE OF BIDDER & DATE

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar
Pradesh

VOLUME - II
SECTION D5
SHEET 7 OF 12

415 VOLT SWITCHGEAR / PMCC

DATASHEET - B
ENQUIRY / SPECIFICATION NO.

Sl. No.
1.8

DESCRIPTION

UNIT

Make

1.8.2

Type & Cat. No.

1.8.3

Watts/Voltage
Current Transformer

1.9.1

Make

1.9.2

Type

1.9.3

Class/ALF or ISF/VA burden furnished for

1.9.4

Relaying C.T

1.9.5

Metering C.T.

1.9.6

Short-Circuit Withstand

1.9.6.1

Short-time current for 1 sec.

KArms

1.9.6.2

Dynamic current

KApeak

1.9.7

Class of Insulation

1.9.8

Temperature rise over

50 Deg C ambient

1.9.9

Basic Insulation level

1.10

Control Transformer

1.10.1

Make

1.10.2

Ratio

1.10.3

VA rating

1.11

REQUIREMENT

Indication

1.8.1

1.9

BIDDER

KVrms

Voltage Transformer

1.11.1

Make

1.11.2

Type

1.11.3

Voltage ratio

NOTES TO BIDDER
1.

ITEMS WHICH DEVIATE FROM THE SPECIFICATION SHOULD BE

MARKED WITHIN ASTERISK (*) AND DETAILS TO BE GIVEN IN
SCHEDULE OF DEVIATIONS.

2.

THIS DATA SHEET SHALL BE FILLED UP COMPLETELY AND A

COPY SHALL BE ENCLOSED WITH EACH COPY OF THE BID.

SIGNATURE OF BIDDER & DATE

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar
Pradesh

VOLUME - II
SECTION D5
SHEET 8 OF 12

415 VOLT SWITCHGEAR / PMCC

DATASHEET - B
ENQUIRY / SPECIFICATION NO.

Sl. No.

DESCRIPTION

1.11.4

Accuracy class

1.11.5

VA burden

1.11.6

Over Voltage factor

a)

Continuous

b)

30 seconds

1.11.7

Class of Insulation

1.11.8

Temperature rise over 50 Deg.C ambient

1.11.9

Basic Insulation level

1.11.10

Winding Connection

1.12

a)

Primary

b)

Secondary

BIDDER

UNIT

REQUIREMENT

kVrms

Numerical Relays

1.12.1

Make

1.12.2

Type

1.12.3

Model

1.13

Meters

1.13.1

Make

1.13.2

Type

1.13.3

Reference Standard

1.13.4

Accuracy class

1.13.5

Meter Switch

1.13.5.1

Make

1.13.5.2

Type

1.13.5.3

Cat . No

NOTES TO BIDDER
1.

ITEMS WHICH DEVIATE FROM THE SPECIFICATION SHOULD BE

MARKED WITHIN ASTERISK (*) AND DETAILS TO BE GIVEN IN
SCHEDULE OF DEVIATIONS.

2.

THIS DATA SHEET SHALL BE FILLED UP COMPLETELY AND A

COPY SHALL BE ENCLOSED WITH EACH COPY OF THE BID.

SIGNATURE OF BIDDER & DATE

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar
Pradesh

VOLUME - II
SECTION D5
SHEET 9 OF 12

415 VOLT SWITCHGEAR / PMCC

DATASHEET - B
ENQUIRY / SPECIFICATION NO.

Sl. No.
1.14

DESCRIPTION

Type of Insulation

1.14.2

Voltage grade

1.14.3

Conductor material

1.14.4

Conductor Size (Minimum)

1.14.4.1

Potential & Control Circuit

1.14.4.2

Current Circuit

1.14.4.3

Wires identified at both ends with markers

Make

1.15.2

Type

1.15.3

Cat. No

1.15.4

Voltage grade

1.15.5

20% spare terminals furnished

1.16.1
1.16.2

Cable Termination
Cable termination/connection
furnished as specified
Cable entry provision from top
and bottom

1.16.3

Re-movable Gland Plate

1.16.4

Material for multi-core cable

1.16.5

Material for I/C cable

1.16.6

Thickness of the plate

1.17

REQUIREMENT

Terminal Block

1.15.1

1.16

UNIT

Secondary Wiring

1.14.1

1.15

BIDDER

Yes/No

Earth Bus

1.17.1

Earth bus furnished

1.17.2

Material

NOTES TO BIDDER
1.

ITEMS WHICH DEVIATE FROM THE SPECIFICATION SHOULD BE

MARKED WITHIN ASTERISK (*) AND DETAILS TO BE GIVEN IN
SCHEDULE OF DEVIATIONS.

2.

THIS DATA SHEET SHALL BE FILLED UP COMPLETELY AND A

COPY SHALL BE ENCLOSED WITH EACH COPY OF THE BID.

SIGNATURE OF BIDDER & DATE

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar
Pradesh

VOLUME - II
SECTION D5
SHEET 10 OF 12

415 VOLT SWITCHGEAR / PMCC

DATASHEET - B
ENQUIRY / SPECIFICATION NO.

Sl. No.
1.17.3
1.18

DESCRIPTION

1.18.2

Thickness

1.18.3

Size for
a)

Panel

b)

Equipment / Device

Space Heater/Plug Socket

Cubicle Heater

1.19.1.1

Thermostat controlled?

1.19.1.2

Wattage

1.19.1.3.

Voltage

1.19.2

Motor Heater

1.19.3

Provision made for motor heater supply

1.19.4

Separate contactor furnished If so,

contactor rating
Cubicle heater, motor heater plug
socket circuit provided with individual
MCB?
Any special treatment for
tropical protection
Screens are of corrosion resistant
materials

1.19.5
1.20
1.21
1.22

REQUIREMENT

Name plate
Material

1.19.1

UNIT

Size

1.18.1

1.19

BIDDER

Yes / No

Painting
a)

Finish

b)

Inside

c)

Outside

d)

Whether powder coated?

NOTES TO BIDDER
1.

ITEMS WHICH DEVIATE FROM THE SPECIFICATION SHOULD BE

MARKED WITHIN ASTERISK (*) AND DETAILS TO BE GIVEN IN
SCHEDULE OF DEVIATIONS.

2.

THIS DATA SHEET SHALL BE FILLED UP COMPLETELY AND A

COPY SHALL BE ENCLOSED WITH EACH COPY OF THE BID.

SIGNATURE OF BIDDER & DATE

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar
Pradesh

VOLUME - II
SECTION D5
SHEET 11 OF 12

415 VOLT SWITCHGEAR / PMCC

DATASHEET - B
ENQUIRY / SPECIFICATION NO.

Sl. No.
2.0
2.1
2.2

DESCRIPTION

BIDDER

UNIT

REQUIREMENT

BUS DUCT
Manufacturer/ Country
Bus Conductor
(a) Busbar grade
(b) Shape of busbar
(c) Size of busbar

2.3

Phase to phase spacing

2.4

Size of enclosure W x H or Diameter if

circular

2.5

Resistance/metre/Phase at 20C of
conductor

2.6

Inductive reactance/metre/phase at 20C

2.7

Capacitive reactance/metre/phase at 20C

2.8

Heat loss in the bus duct at full rated

current

2.9

Weight of 3-phase duct

2.10

Standard section length

2.11

Minimum required clearances from the

periphery of the bus duct
i) To structural steel work parallel to the
duct
ii) To structural steel work perpendicular
to the duct

NOTES TO BIDDER
1.

ITEMS WHICH DEVIATE FROM THE SPECIFICATION SHOULD BE

MARKED WITHIN ASTERISK (*) AND DETAILS TO BE GIVEN IN
SCHEDULE OF DEVIATIONS.

2.

THIS DATA SHEET SHALL BE FILLED UP COMPLETELY AND A

COPY SHALL BE ENCLOSED WITH EACH COPY OF THE BID.

mm2
mm
Mmxmm/
mm
Ohm
Ohm
Ohm
Watts/ ph/
m
Kg/metre
m

mm

mm
SIGNATURE OF BIDDER & DATE

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar
Pradesh

VOLUME - II
SECTION D5
SHEET 12 OF 12

415 VOLT SWITCHGEAR / PMCC

DATASHEET - B
ENQUIRY / SPECIFICATION NO.

Sl. No.

DESCRIPTION

2.12.0

INSULATORS

2.12.1

Manufacturer/ Country

2.12.2

Type

2.12.3

Cantilever strength
i) Upright
ii) Underhung

2.12.4

Weight of each insulator

NOTES TO BIDDER
1.

ITEMS WHICH DEVIATE FROM THE SPECIFICATION SHOULD BE

MARKED WITHIN ASTERISK (*) AND DETAILS TO BE GIVEN IN
SCHEDULE OF DEVIATIONS.

2.

THIS DATA SHEET SHALL BE FILLED UP COMPLETELY AND A

COPY SHALL BE ENCLOSED WITH EACH COPY OF THE BID.

BIDDER

UNIT

REQUIREMENT

Kg.
Kg.
Kg.

SIGNATURE OF BIDDER & DATE

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar
Pradesh

VOLUME - II
SECTION: D6
SHEET 1 OF 2

CABLE AND CABLE CARRIER SYSTEM

DATASHEET - B
ENQUIRY / SPECIFICATION NO.

SL. NO.

DESCRIPTION

Name of manufacturer

Conductor :
a) No. core x Size
b) Form- circular/segmented
c) Effective cross sectional area sq. mm

Whether cores identification numbers for

cables with 5 cores and above to be
provided

Whether incremental running lengths are

marked on cable

Finished cable
a)
Diameter under armour in
b)
Diameter over armour in
c)
Overall diameter in

BIDDER

UNIT

BIDDERS DATA

mm

Cable drums
a)
b)
6
c)
d)
e)

Whether cable drums confirm

to IS : 10417
Length of cables in drum &
tolerance
Weight of cable drum without
cables
Weight of cable drum with
cables
Type of end sealing

FRLS cables
a)

Critical oxygen index value at

250 deg C when tested for
temperature index test as per
ASTM- D-2863-77.

b)

Total acid gas as determined by

titration method will be less than
20% by weight when tested as per
IEC-754-1 (1994).

NOTES TO BIDDER
1.

ITEMS WHICH DEVIATE FROM THE SPECIFICATION SHOULD BE

MARKED WITHIN ASTERISK (*) AND DETAILS TO BE GIVEN IN
SCHEDULE OF DEVIATIONS.

2.

THIS DATA SHEET SHALL BE FILLED UP COMPLETELY AND A

COPY SHALL BE ENCLOSED WITH EACH COPY OF THE BID.

SIGNATURE OF BIDDER & DATE

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar
Pradesh

VOLUME - II
SECTION: D6
SHEET 2 OF 2

CABLE AND CABLE CARRIER SYSTEM

DATASHEET - B
ENQUIRY / SPECIFICATION NO.

SL. NO.

DESCRIPTION
c)

BIDDER

UNIT

BIDDERS DATA

KA

Minimum 40kA and 50 kA for

HT and LT respectively and
shall
be
in
line
with
requirements of the switchgear
and protection.

Percentage of light
transmission under fire for
assessment of smoke
generation when tested as
per ASTM D 2843-7

d)

Will the cables offered against

this specification pass the
flammability tests as per
1) Class F3 Swedish standard
SS-424- 1475
2) IEC 60332 1C
3) IEC 60331 1
Maximum dielectric loss of cable per KM at
normal voltage and frequency

Short circuit capability for 1 Sec (HT & LT

Power Cable)

10

Maximum dielectric stress at core screen

11

Max. overall diameter of cables

NOTES TO BIDDER
1.

ITEMS WHICH DEVIATE FROM THE SPECIFICATION SHOULD BE

MARKED WITHIN ASTERISK (*) AND DETAILS TO BE GIVEN IN
SCHEDULE OF DEVIATIONS.

2.

THIS DATA SHEET SHALL BE FILLED UP COMPLETELY AND A

COPY SHALL BE ENCLOSED WITH EACH COPY OF THE BID.

SIGNATURE OF BIDDER & DATE

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar
Pradesh

VOLUME - II
SECTION: D7
SHEET 1 OF 1

LOCAL CONTROL PANEL, DCDB & OTHERS

DATASHEET - B
ENQUIRY / SPECIFICATION NO.

SL. NO.

DESCRIPTION

1.0

Manufacturer's name

2.0

Indoor / Outdoor application

3.0

Thickness of sheet steel

4.0

Degree of protection provided (as per

IS:2147 or equivalent)

5.0

Bill of Material for the various equipment

giving make, type, ratings etc. enclosed

6.0

Colour of finish paint

BIDDER

UNIT

BIDDERS DATA

mm

Yes / No

a) Outside
b) Inside
7.0

Bus Bars for power devices (when

applicable)
a) Material (Insulated/Bare)
b) Continuous current rating

8.0

Amp.

Control Wiring/Power Wiring

a) Material of conductor and size

Cu / Al mm2

b) Conductor - solid/Stranded

NOTES TO BIDDER
1.

ITEMS WHICH DEVIATE FROM THE SPECIFICATION SHOULD BE

MARKED WITHIN ASTERISK (*) AND DETAILS TO BE GIVEN IN
SCHEDULE OF DEVIATIONS.

2.

THIS DATA SHEET SHALL BE FILLED UP COMPLETELY AND A

COPY SHALL BE ENCLOSED WITH EACH COPY OF THE BID.

SIGNATURE OF BIDDER & DATE

SECTION - F

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

VOLUME - II
SECTION: F1
SHEET 1 OF 7

SCHEDULE OF PRICES

SCHEDULE OF PRICES
The contract for the Compressed air System (CAS) Package shall be in
accordance with the specification - for supply and for erection, testing and
commissioning.
The Bidder shall indicate the quoted price against each contract separately.
1.0

SUPPLY PRICE

1.1

Lump sum ex-works price for manufacture , shop inspection

&testing , packing &forwarding

1.1.1

Seven (7) Nos. of air compressors with associated inter

coolers (with safety valves, oil and moisture separators, auto
drain traps, auto drain traps drive equipment, bolts, etc.,) in
accordance with the specification.
Rs--------------------------

1.1.2

Seven (7) Nos. of after coolers, one required for each

compressor complete with supporting stands, safety valves,
oil and moisture separators, auto drain traps, fusible plugs, Rs------------------------foundation bolts, etc.

1.1.3

Eight (8) Nos. of air receivers with supporting stands, safety

valves, auto drain traps, pressure gauges, foundation bolts
Rs------------------------in accordance with the specification.

1.1.4

Four (4) Nos. of air driers with accessories.

Rs-------------------------

1.1.5

Painting of all equipment as per specification.

Rs-------------------------

1.1.6

One (1) lot of cooling water, instrument air & impulse piping,
fittings, supports, valves & specialities and instruments in
Rs------------------------accordance with the specification.

1.1.7

Control system with all accessories.

1.1.8

One set of spares as specified, Special maintenance tools &

tackles

Rs-------------------------

Rs-------------------------

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

VOLUME - II
SECTION: F1
SHEET 2 OF 7

SCHEDULE OF PRICES

1.2
1.2.1

EXCISE DUTY FOR ITEMS LISTED UNDER ITEM 1.1.

Seven (7) Nos. of air compressors with associated inter
coolers (with safety valves, oil and moisture separators, auto
drain traps, auto drain traps drive equipment, bolts, etc.,) in Rs-------------------------accordance with the specification.

1.2.2

Seven (7) Nos of after coolers, one required for each

compressor complete with supporting stands, safety valves,
oil and moisture separators, auto drain traps, fusible plugs, Rs-------------------------foundation bolts, etc.

1.2.3

Eight (8) Nos of air receivers with supporting stands, safety Rs-------------------------valves, auto drain traps, pressure gauges, foundation bolts
in accordance with the specification.

1.2.4

Four (4) Nos of air dryers with accessories.

Rs--------------------------

1.2.5

Painting of all equipment as per specification.

Rs--------------------------

1.2.6

One (1) lot of cooling water, instrument air & impulse piping, Rs-------------------------fittings, supports, valves & specialities and instruments in
accordance with the specification.

1.2.7

Control system with all accessories.

1.2.8

One set of spares as specified, Special maintenance tools & Rs-------------------------tackles

1.2.9

Any other items required for system completeness

Rs--------------------------

a)

Rs--------------------------

b)

Rs--------------------------

c)

Rs--------------------------

d)

Rs--------------------------

1.3

CST /ST FOR ITEMS LISTED UNDER ITEM 1.1.

1.3.1

Seven (7) Nos. of air compressors with associated inter Rs-------------------------coolers (with safety valves, oil and moisture separators, auto

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

VOLUME - II
SECTION: F1
SHEET 3 OF 7

SCHEDULE OF PRICES

drain traps, auto drain traps drive equipment, bolts, etc.,) in

accordance with the specification.
1.3.2

Seven (7) Nos of after coolers, one required for each

compressor complete with supporting stands, safety valves,
oil and moisture separators, auto drain traps, fusible plugs, Rs------------------------foundation bolts, etc.

1.3.3

Eight (8)) Nos of air receivers with supporting stands, safety

valves, auto drain traps, pressure gauges, foundation bolts
Rs------------------------in accordance with the specification.

1.3.4

Four (4) Nos of air dryers with accessories.

Rs-------------------------

1.3.5

Painting of all equipment as per specification.

Rs-------------------------

1.3.6

One (1) lot of cooling water, instrument air & impulse piping,
fittings, supports, valves & specialities and instruments in
Rs-----------------------accordance with the specification.

1.3.7

Control system with all accessories.

1.3.8

One set of spares as specified, Special maintenance tools & Rs-------------------------tackles

1.3.9

Any other items required for system completeness

Rs------------------------

a)

Rs--------------------------

b)

Rs--------------------------

c)

Rs--------------------------

d)

Rs--------------------------

1.4

ENTRY TAX FOR ITEMS LISTED UNDER ITEM 1.1.

1.4.1

Seven (7) Nos of air compressors with associated inter

coolers (with safety valves, oil and moisture separators, auto
drain traps, auto drain traps drive equipment, bolts, etc.,) in Rs-------------------------accordance with the specification.

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

VOLUME - II
SECTION: F1
SHEET 4 OF 7

SCHEDULE OF PRICES

1.4.2

Seven (7) Nos of after coolers, one required for each

compressor complete with supporting stands, safety valves,
oil and moisture separators, auto drain traps, fusible plugs, Rs-------------------------foundation bolts, etc.

1.4.3

Eight (8) Nos of air receivers with supporting stands, safety

valves, auto drain traps, pressure gauges, foundation bolts
Rs-------------------------in accordance with the specification.

1.4.4

Four (4) Nos of air dryers with accessories.

Rs--------------------------

1.4.5

Painting of all equipment as per specification.

Rs--------------------------

1.4.6

One (1) lot of cooling water, instrument air & impulse piping,
fittings, supports, valves & specialities and instruments in
Rs-------------------------accordance with the specification.

1.4.7

Control system with all accessories.

1.4.8

One set of spares as specified, Special maintenance tools & Rs-------------------------tackles

1.4.9

Any other items required for system completeness

Rs--------------------------

a)

Rs--------------------------

b)

Rs--------------------------

c)

Rs--------------------------

d)

Rs--------------------------

1.5

ANY OTHER TAXES, DUTIES &LEVIES (PLEASE

SPECIFY SUCH TAXES, DUTIES AND LEVIES) FOR
ITEMS LISTED UNDER ITEM 1.1.

1.5.1

Seven (7) Nos of air compressors with associated inter

coolers (with safety valves, oil and moisture separators, auto
drain traps, auto drain traps drive equipment, bolts, etc.,) in Rs-------------------------accordance with the specification.

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

VOLUME - II
SECTION: F1
SHEET 5 OF 7

SCHEDULE OF PRICES

1.5.2

Seven (7) Nos of after coolers, one required for each

compressor complete with supporting stands, safety valves,
oil and moisture separators, auto drain traps, fusible plugs, Rs-------------------------foundation bolts, etc.

1.5.3

Eight (8) Nos of air receivers with supporting stands, safety

valves, auto drain traps, pressure gauges, foundation bolts
Rs-------------------------in accordance with the specification.

1.5.4

Four (4) Nos of air dryers with accessories.

Rs--------------------------

1.5.5

Painting of all equipment as per specification .

Rs--------------------------

1.5.6

One (1) lot of cooling water, instrument air & impulse piping,
fittings, supports, valves & specialities and instruments in
Rs-------------------------accordance with the specification.

1.5.7

Control system with all accessories.

1.5.8

One set of spares as specified, Special maintenance tools & Rs-------------------------tackles

1.5.9

Any other items required for system completeness

Rs--------------------------

a)

Rs--------------------------

b)

Rs--------------------------

c)

Rs--------------------------

d)

Rs--------------------------

1.6

Inland transportation to site for all the items listed under item
1.1
Rs--------------------------

1.7

Inland transit insurance for all the items listed in clause 1.1
above
Rs--------------------------

1.8

TOTAL QUOTED LUMP SUM PRICE FOR SUPPLY

1.1+1.2+1.3+1.4+1.5+ 1.6+1.7)
Rs--------------------------

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

VOLUME - II
SECTION: F1
SHEET 6 OF 7

SCHEDULE OF PRICES

2.0

Receipt and unloading at site ,verifying packing list and

filing insurance claims in case of damage, storing at
site,transportation, to place of erection, testing and Rs-------------------------commissioning and training owner's personnel.

2.1

Seven (7) Nos of air compressors with associated inter

coolers (with safety valves, oil and moisture separators, auto
drain traps, auto drain traps drive equipment, bolts, etc.,) in Rs-------------------------accordance with the specification.

2.2

Seven (7) Nos of after coolers, one required for each

compressor complete with supporting stands, safety valves,
oil and moisture separators, auto drain traps, fusible plugs, Rs-------------------------foundation bolts, etc.

2.3

Eight (8) Nos. of air receivers with supporting stands, safety Rs-------------------------valves, auto drain traps, pressure gauges, foundation bolts
in accordance with the specification.

2.4

Four (4) Nos. of air dryers with accessories.

Rs--------------------------

2.5

Painting of all equipment as per specification.

Rs--------------------------

2.6

One (1) lot of cooling water, instrument air & impulse piping,
fittings, supports, valves & specialities and instruments in
Rs-------------------------accordance with the specification.

2.7

Control system with all accessories.

2.8

One set of spares as specified, Special maintenance tools & Rs-------------------------tackles

2.9

Any other items required for system completeness

Rs--------------------------

a)

Rs--------------------------

b)

Rs--------------------------

c)

Rs--------------------------

d)

Rs--------------------------

2.10

Spares as specified

Rs--------------------------

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

VOLUME - II
SECTION: F1
SHEET 7 OF 7

SCHEDULE OF PRICES

2.11

Special maintenance tools and tackles

Rs--------------------------

2.12

Erection insurance for all the items listed in clause 2.0 Rs-------------------------above

2.13

Service tax /work contract tax for all items listed in clause Rs-------------------------2.o above.

2.14

Any other taxes , duties and levies (Please specify such

taxes, duties and levies )

a)

Rs--------------------------

b)

Rs--------------------------

c)

Rs--------------------------

d)

Rs--------------------------

2 .15

Charges for obtaining statutory clearances if any

2.16

Total quoted lump sum price for erection , testing and Rs-------------------------commissioning.

COMPANY SEAL

SIGNATURE
NAME
DESIGNATION
DATE

Rs--------------------------

CARBERY INFRASTRUCTURE PTE LTD

SCHEDULE OF DEVIATIONS FROM
TECHNICAL SPECIFICATIONS

SECTION: F2

SHEET 1 OF 1

The BIDDER shall indicate below all deviations from the Technical Specifications.
SL.
NO.

SECTION

SPECIFICATION
NO.

PARA
NO.

DEVIATION

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
The BIDDER hereby certifies that the above mentioned are the only deviations from the
PURCHASERs Technical Specifications for this Enquiry Document. The BIDDER further confirms
that in the event any other data and information presented in the BIDDERs proposal and
accompanying documents including drawings and catalogues etc. are at variance with the specific
requirements laid out in the PURCHASERs Technical Specifications, the latter shall govern and shall
be binding on the BIDDER without any price implication.
COMPANY SEAL

SIGNATURE
NAME
DESIGNATION
COMPANY
DATE

CARBERY INFRASTRUCTURE PTE LTD

SCHEDULE OF DEVIATIONS FROM
GENERAL CONDITIONS

SECTION: F 3

SHEET 1 OF 1

The BIDDER shall indicate below all deviations from the General Conditions.
SL.
NO.

SECTION

SPECIFICATION
NO.

PARA
NO.

DEVIATION

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
The BIDDER hereby certifies that the above mentioned are the only deviations from the
PURCHASERs General Conditions for this Enquiry Document. The BIDDER further confirms that in
the event any other data and information presented in the BIDDERs proposal and accompanying
documents including drawings and catalogues etc. are at variance with the specific requirements laid
out in the PURCHASERs General Conditions, the latter shall govern and shall be binding on the
BIDDER without any price implication.
COMPANY SEAL

SIGNATURE
NAME
DESIGNATION
COMPANY
DATE

SECTION: F4

CARBERY INFRASTRUCTURE PTE LTD

SCHEDULE OF ESSENTIAL AND RECOMMENDED SPARES

SHEET 1 OF 1

REMARKS

DELIVERY
PERIOD (WEEKS)
FROM DATE OF
LOI

TOTAL PRICE
Rs.

UNIT PRICE
Rs.

QUANTITY/SET
RECOMMENDED
PER UNIT
EQUIPMENT

MANUFACTURER
AND PART
NUMBER

MATERIAL OF
CONSTRUCTION

DESCRIPTION OF
SPARE

EQUIPMENT TAG
NUMBER

SL. NO.

The BIDDER shall indicate below Essential and Recommended Spares for three (3) years of trouble
free operation of the equipment, plant or system offered by him.

A. ESSENTIAL SPARES AS INDICATED BY THE PURCHASER

1.
2.
3.
4.
5.
6.
7.
8.
9.
B. RECOMMENDED SPARES AS INDICATED BY THE BIDDER IN ADDITION TO ESSENTIAL
SPARES AS INDICATED BY THE PURCHASER
1.
2.
3.
4.
5.
6.
7.
8.
9.
COMPANY SEAL

SIGNATURE
NAME
DESIGNATION
COMPANY
DATE

CARBERY INFRASTRUCTURE PTE LTD

SECTION: F5

SCHEDULE OF MAINTENANCE TOOLS AND TACKLES

SHEET 1 OF 1

The BIDDER shall indicate below Special Maintenance Tools and Tackles for the equipment, plant or
system offered by him.

SL.
NO.

QUANTITY
OR
NUMBER
OF SETS

DESCRIPTION

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
COMPANY SEAL

SIGNATURE
NAME
DESIGNATION
COMPANY
DATE

UNIT
PRICE
Rs.

TOTAL
PRICE
Rs.

REMARKS

CARBERY INFRASTRUCTURE PTE LTD

SCHEDULE OF WEIGHTS AND DIMENSIONS

SECTION: F6

SHEET 1 OF 1

The BIDDER shall state below the weights and dimensions of various packages for shipment
comprising the complete scope.
SL.
NO.

PACKAGE
DESCRIPTION

WEIGHT IN TONNES

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
COMPANY SEAL

SIGNATURE
NAME
DESIGNATION
COMPANY
DATE

DIMENSIONS IN METRES
LxBxH

SECTION: F7

CARBERY INFRASTRUCTURE PTE LTD

SCHEDULE OF BIDDERS EXPERIENCE

SHEET 1 OF 1

REMARKS

REASON FOR
DELAY IN
COMPLETION, IF
APPLICABLE

ACTUAL DATE OF
COMPLETION

SCHEDULED DATE
OF COMPLETION

CONTRACT PRICE
IN Rs.

SCOPE OF
SERVICES
(SEE
LEGEND)

BRIEF DETAILS OF
EQUIPMENT/
SYSTEM SUPPLIED

PURCHASER
ORDER/
CONTRACT NO.
AND DATE

NAME, ADDRESS,
TEL. NO., FAX NO.
AND E-MAIL ID OF
CLIENT AND
PROJECT NAME

SL. NO.

The BIDDER shall indicate below a list of similar jobs executed by him, to whom a reference may be
made by the PURCHASER.

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
LEGEND: E - ERECTION, S - SUPPLY, SUP - SUPERVISION OF ERECTION, TC - TESTING AND
COMMISSIONING
COMPANY SEAL

SIGNATURE
NAME
DESIGNATION
COMPANY
DATE

VOLUME - II

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

SECTION: F 8
SHEET 1 OF 1

DOCUMENTS DISTRIBUTION SCHEDULE

DOCUMENTS DISTRIBUTION SCHEDULE

SL.
PARTICULARS
NO
CORRESPNDENCE
1.

Office

Site

Vendor

SC or 1P

2P

SC+4P

SC or 1P

SC or 1P

SC + 6P

2P

O+4

PURCHASER TO VENDOR

2.
VENDOR TO PURCHASER
VENDOR DRAWINGS FOR APPROVAL
1.

FIRST ISSUE
SC+6P
COMMENTS ON
SC or 1P
2.
DRAWINGS
3.
FINAL APPROVED
SC + 6P
VENDOR DRAWINGS FOR INFORMATION
1.
2.
3.

FIRST ISSUE
COMMENTS ON
DRAWINGS, IF ANY
FINAL DRAWING

MANUFACTURING
1.

TEST REPORTS

INSTRUCTION MANUALS
1.

PRELIMINARY

2.

FINAL

LEGEND
1.

O : ORIGINAL

2.

S : SOURCE

3.

P : PRINT

4.

SC : SOFT COPY

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

VOLUME - II
SECTION: F 9
SHEET 1 OF 2

SCHEDULE OF GENERAL PARTICULARS

9.0

SCHEDULE OF GENERAL PARTICULARS

1.0

Name of the Bidder / Manufacturer

2.0

Address of the Bidder / Manufacturer

3.0

Telegraphic, Fax &

addresses
of
the
Manufacturer

4.0

Name and designation of the officer

of the Bidder / Manufacturers
representative to whom all reference
shall be made for expeditious
technical co-ordination

5.0

Place of Manufacture

6.0

Current registration
DGS & D

7.0

Service facilities available

8.0

Availability of spare parts

9.0

Bidders proposal number and date

10.0

Penalty for delay in delivery

acceptable as per general conditions
of contract

Yes/No

11.0

All particulars called for in Data

Sheet-B Section-F of specification
furnished

Yes/No.

12.0

All deviations pointed out in Schedule

of Deviation

Yes/No.

Telephone
Bidder
/

number

with

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

VOLUME - II
SECTION: F 9
SHEET 2 OF 2

SCHEDULE OF GENERAL PARTICULARS

13.0

Is the Bidder agreeable to supply the

equipment in case the deviations
stipulated by him are not acceptable
to Purchaser

Yes/No.

14.0

Validity of tender (shall not be less

than 180 days)

Yes/No.

SEAL OF THE COMPANY

SIGNATURE

NAME

DESIGNATION

COMPANY

DATE

VOLUME - II

CARBERY INFRASTRUCTURE PTE LTD

SECTION: F 10

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

SHEET 1 OF 1

OVERALL TIME SCHEDULE

OVERALL TIME SCHEDULE

Weeks from date of Notice To Proceed
Sl.
No.

Work
Description

UNIT NO. 1
Start

1.0

Design and
Engineering

2.0

Manufacture

3.0

Delivery FOB
Portion

4.0

Erection,
commissioning
and testing

Finish

UNIT NO. 2
Start

Finish

UNIT NO. 3
Start

Finish

Note: The shipment schedule with details of equipment covered in each shipment
shall be furnished.
SIGNATURE
NAME
COMPANY SEAL

DESIGNATION
DATE
COMPANY

H - HOLD POINT.

G.
H.

E.
F.

C.
D.

ACCEPTANCE NORM
7

RECORD

FORMAT OF

S M T C

AGENCY

Q.P.DATE

Q.P. NO.

S SIGN.
NAME
FOR STAGES WITNESSED / DOCUMENTS REVIEWED BY PURCHASER, COPIES OF RELEVANT DOCUMENTS SHALL BE FURNISHED TO PURCHASER.
M SIGN.
PURCHASERS IDENTIFICATION STAMP ON MATERIALS SHALL BE PRESERVED / GOT TRANSFERRED BY PURCHASER AT APPROPRIATE STAGES.
NAME
THE EXTENT INDICATED IN COLUMN 5 IS IN VENDORS SCOPE. PURCHASER / CLIENT MAY INSPECT AS PER THIS COLUMN OR RANDOM SAMPLES.
T SIGN.
COLUMN 6 SHALL BE AS PER PURCHASER / CLIENT APPROVED DRAWINGS / DATA SHEETS / SPECIFICATIONS WHEREVER APPLICABLE.
NAME
INSTRUMENTS FOR LEAK TESTS AND PERFORMANCE TESTS SHALL HAVE VALID CALIBRATION CERTIFICATE WITH TRACEABILITY TO NATIONAL C SIGN.
LEGENDS :
S - SUB - VENDOR,
M - MAIN VENDOR,
T- PURCHASER,
C - PURCHASERS CLIENT,
1 - WITNESS,
2 - DOCUMENTS REVIEW,
NAME

Note: This is typical schedule of quality plan. Bidder may incorporate more details.

N
O
T
E

OF CHECK

P.O.NO. & DT.

SUB - ITEM

MAIN ITEM

REF. DOCUMENT /

A. STATUTORY REQUIREMENTS SHALL BE COMPLIED WITH BY THE VENDOR.

B. MATERIAL TESTS OF SAMPLES DRAWN BY PURCHASER SHALL BE WITNESSED BY PURCHASER.

Uttar

TYPE / METHOD EXTENT

Pradesh.

3 x 660 MW Lalitpur,

CHARACTERISTICS
CHECKED

COMPONENT / OPERATION

PROJECT

LPGCL

NO.

SR.

OWNER

SUB - VENDOR

MAIN VENDOR

SCHEDULE OF
QUALITY PLAN

SECTION F11

HOLD POINTS (H )

REMARKS /

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

VOLUME - II
SECTION: F 12
SHEET 1 OF 1

SCHEDULE OF PERFORMANCE GUARANTEE

12.0

SCHEDULE OF PERFORMANCE GUARANTEE

Sl. No.

(A)

Value Inclusive
of design,
manufacture
and all other
Tolerances
(Refer Note-1)

Particulars

Applicable
Test Codes

Remarks

Performance Guarantee Under Liquidated Damages

1.0 Total Auxiliary power consumption
for the Compressed Air System
Package
running

with
at

all

equipments

maximum

design

capacities.

Note
1. For tolerance refer section - C9, clause 9.2.2

SEAL OF THE COMPANY

SIGNATURE

__________________

NAME

__________________

DESIGNATION

__________________

COMPANY

__________________

DATE

__________________

CARBERY INFRASTRUCTURE PTE LTD

3 X 660 MW Super Critical TPP at Lalitpur, Uttar Pradesh

VOLUME - II
SECTION: F 13
SHEET 1 OF 1

SCHEDULE OF PLACES OF TEST AND INSPECTION

14.0

SCHEDULE OF PLACES OF TEST AND INSPECTION

The Bidder shall indicate the item of Equipment supplied, name of the
MANUFACTURER or SUBCONTRACTOR and place of test and inspection
as shown below.

ITEM OF
EQUIPMENT

MANUFACTURER /
SUBCONTRACTOR

SIGNATURE
NAME
COMPANY SEAL

DESIGNATION
DATE

PLACE OF TESTING &

INSPECTION